E Ab412 PT6T 2

E-AB412-PT6T-2
E-AB412-PT6T-2
AB412
HELICOPTER
MODEL
THIS PUBLICATION IS ISSUED BY AGUSTAWESTLAND S.P.A.

E-AB412-PT6T-2
FRONTISPIECE
AB412
HELICOPTER
MODEL
THIS PUBLICATION IS ISSUED BY AGUSTAWESTLAND S.P.A.
NOTICE:
This manual replaces manual E-AB412-PT6T-2 dated 27 June 1997 updated with Revision 2 dated 15 November 2013.
ISSUE: 6 DECEMBER 2011

REVISION: No. 3 - 20 JUNE 2014
E-AB412-PT6T-2
LIST OF EFFECTIVE MODULES
Insert latest revision pages and dispose of superseded ones.
On a revised page, the text and/or illustration affected by the latest revision is shown by a vertical line. A revised page with
only a vertical line next to the page number indicates that text has shifted or that non-technical correction(s) were made on
that page.
Issue - 27 June 1997

Revision 1 28 November 2003
Issue - 6 December 2011
Revision 1 27 September 2012
Revision 2 15 November 2013
Revision 3 20 June 2014
LOG OF MODULES
Module No. Rev No. Module No. Rev No. Module No. Rev No.
Frontispiece ...................................3 CHAPTER 11 CHAPTER 25

LOEM ............................................3 11-Index (1 and 2) .........................0 25-Index (1 thru 14) ...................... 3
ROR ...............................................1 11-01-01 (1 and 2) .........................0 25-00-00 (1 and 2)......................... 0
ROTR.............................................3 25-11-01 (1 thru 12) ...................... 1
LOC ...............................................1 CHAPTER 12 25-11-02 (1 thru 8) ........................ 0
LOA ...............................................1 12-Index (1 thru 4).........................3 25-21-01 (1 thru 4) ........................ 0
12-00-00 (1 thru 4) ........................3 25-23-01 (1 thru 4) ........................ 0
CHAPTER 00 12-11-01 (1 thru 6) ........................3 25-31-01 (1 and 2)......................... 0
00-Index (1 thru 4).........................3 12-12-01 (1 and 2) .........................3 25-33-01 (1 thru 8) ........................ 1
00-00-00 (1 and 2) .........................3 12-13-01 (1 thru 8) ........................3 25-33-11 (1 thru 4) ........................ 0
00-00-40 (1 thru 22).......................3 12-14-01 (1 and 2) .........................0 25-51-01 (1 thru 4) ........................ 0
12-15-01 (1 and 2) .........................3 25-60-01 (1 thru 4) ........................ 0
CHAPTER 06 12-16-01 (1 and 2) .........................0 25-60-02 (1 thru 4) ........................ 0
06-Index (1 and 2) .........................0 12-17-01 (1 and 2) .........................0 25-61-01 (1 and 2)......................... 0
06-00-01 (1 thru 4).........................0 12-18-01 (1 and 2) .........................0 25-61-02 (1 and 2)......................... 0
06-00-02 (1 thru 4).........................0 12-21-01 (1 thru 10) ......................3 25-61-03 (1 and 2)......................... 0
25-61-04 (1 thru 16) ...................... 0
CHAPTER 07 CHAPTER 18 25-66-01 (1 thru 4) ........................ 2
07-Index (1 and 2) .........................0 18-Index (1 thru 6).........................3 25-71-01 (1 thru 8) ........................ 0
07-00-00 (1 and 2) .........................0 18-00-00 (1 and 2) .........................0 25-71-02 (1 thru 6) ........................ 0
07-11-01 (1 and 2) .........................0 18-11-01 (1 thru 4) ........................0 25-91-00 (1 thru 10) ...................... 3
18-12-01 (1 thru 32) ......................2 25-91-01 (1 thru 6) ........................ 2
CHAPTER 08 18-12-02 (1 thru 12) ......................2 25-91-02 (1 thru 14) ...................... 2
08-Index (1 and 2) .........................2 18-12-03 (1 thru 10) ......................3 25-92-00 (1 thru 10) ...................... 1
08-00-00 (1 and 2) .........................0 18-12-04 (1 and 2) .........................0 25-92-01 (1 and 2)......................... 1
08-21-01 (1 and 2) .........................0 18-12-05 (1 thru 14) ......................0 25-92-02 (1 thru 6) ........................ 1
08-41-01 (1 thru 10).......................3 18-13-01 (1 thru 28) ......................0 25-92-03 (1 thru 4) ........................ 1
18-13-02 (1 thru 10) ......................0 25-92-04 (1 and 2)......................... 0
CHAPTER 09 18-13-03 (1 thru 10) ......................0 25-92-05 (1 thru 4) ........................ 3
09-Index (1 thru 4).........................2
25-92-06 (1 thru 4) ........................ 0
09-11-01 (1 thru 6).........................2 CHAPTER 21 25-92-07 (1 thru 4) ........................ 0
21-Index (1 thru 4).........................0 25-92-08 (1 and 2)......................... 0
CHAPTER 10 21-00-00 (1 thru 6) ........................0 25-92-09 (1 thru 4) ........................ 0
10-Index (1 and 2) .........................0 21-21-01 (1 thru 14) ......................0 25-92-10 (1 and 2)......................... 0
10-11-01 (1 thru 4).........................0 21-41-01 (1 thru 8) ........................0 25-92-11 (1 and 2) ......................... 0
10-21-01 (1 thru 10).......................0 21-42-01 (1 and 2) .........................0 25-92-12 (1 and 2)......................... 0
10-31-01 (1 thru 12).......................0 21-61-01 (1 thru 6) ........................0 25-92-13 (1 thru 4) ........................ 3
Rev. 3 LOEM-1
E-AB412-PT6T-2
LOG OF MODULES (CONT.D)
25-92-14 (1 thru 4) ........................ 0 28-10-18 (1 thru 10)...................... 1 28-20-37 (1 thru 4).........................1
25-92-15 (1 thru 4) ........................ 0 28-10-19 (1 thru 4)........................ 0 28-20-38 (1 thru 4).........................0
25-92-16 (1 and 2)......................... 0 28-10-20 (1 thru 4)........................ 0 28-20-39 (1 thru 4).........................0
25-92-17 (1 and 2)......................... 0 28-10-21 (1 thru 4)........................ 0 28-20-40 (1 thru 4).........................0
25-92-18 (1 and 2)......................... 0 28-10-22 (1 thru 6)........................ 2 28-20-41 (1 thru 4).........................0
25-92-19 (1 and 2)......................... 0 28-10-23 (1 thru 6)........................ 2 28-40-01 (1 and 2) .........................0
25-92-20 (1 and 2)......................... 0 28-10-24 (1 thru 4)........................ 0 28-40-02 (1 thru 6).........................0
25-92-21 (1 and 2)......................... 0 28-10-25 (1 thru 4)........................ 0 28-40-03 (1 and 2) .........................0
25-92-22 (1 and 2)......................... 1 28-10-26 (1 thru 4)........................ 2 28-40-04 (1 thru 4).........................0
25-92-23 (1 and 2)......................... 0 28-10-27 (1 thru 4)........................ 0 28-40-05 (1 and 2) .........................0
25-92-24 (1 and 2)......................... 0 28-10-28 (1 thru 4)........................ 2 28-40-06 (1 and 2) .........................2
25-92-25 (1 and 2)......................... 0 28-10-29 (1 thru 4)........................ 0 28-40-07 (1 and 2) .........................0
25-92-26 (1 and 2)......................... 0 28-10-30 (1 and 2) ........................ 0 28-40-08 (1 thru 12).......................0
25-92-27 (1 and 2)......................... 0 28-10-31 (1 thru 4)........................ 0
25-92-28 (1 and 2)......................... 0 28-10-32 (1 thru 6)........................ 2 CHAPTER 29
25-92-29 (1 thru 4) ........................ 0 28-10-33 (1 thru 4)........................ 0 29-Index (1 thru 6).........................3
25-92-30 (1 and 2)......................... 0 28-10-34 (1 thru 4)........................ 0 29-00-00 (1 thru 6).........................3
25-92-31 (1 and 2)......................... 0 28-20-01 (1 thru 6)........................ 0 29-01-01 (1 thru 12).......................3
25-93-00 (1 thru 8) ........................ 3 28-20-02 (1 thru 6)........................ 0 29-11-01 (1 and 2) .........................0
25-94-00 (1 thru 4) ........................ 0 28-20-03 (1 thru 6)........................ 0 29-11-02 (1 thru 4).........................3
25-94-01 (1 thru 4) ........................ 0 28-20-04 (1 and 2) ........................ 0 29-11-03 (1 thru 4).........................3
25-94-02 (1 and 2)......................... 0 28-20-05 (1 and 2) ........................ 0 29-11-04 (1 thru 6).........................3
25-94-03 (1 and 2)......................... 0 28-20-06 (1 thru 4)........................ 3 29-11-05 (1 thru 10).......................3
28-20-07 (1 thru 4)........................ 0 29-11-06 (1 and 2) .........................3
CHAPTER 26 28-20-08 (1 and 2) ........................ 0 29-11-07 (1 and 2) .........................3
26-Index (1 and 2)......................... 3 28-20-09 (1 thru 4)........................ 0 29-11-08 (1 thru 4).........................3
26-00-00 (1 and 2)......................... 0 28-20-10 (1 thru 6)........................ 0 29-11-09 (1 thru 4).........................3
26-11-01 (1 thru 6) ........................ 0 28-20-11 (1 and 2)......................... 0 29-11-10 (1 and 2) .........................3
26-12-01 (1 thru 4) ........................ 3 28-20-12 (1 thru 4)........................ 0 29-11-11 (1 thru 6).........................3
26-21-01 (1 thru 14) ...................... 3 28-20-13 (1 thru 6)........................ 0 29-11-12 (1 thru 6).........................3
26-22-01 (1 thru 4) ........................ 3 28-20-14 (1 thru 6)........................ 0
28-20-15 (1 and 2) ........................ 0 CHAPTER 30
CHAPTER 28 28-20-16 (1 thru 4)........................ 0 30-Index (1 and 2) .........................0
28-Index (1 thru 24) ...................... 3 28-20-17 (1 and 2) ........................ 0 30-00-00 (1 and 2) .........................0
28-00-00 (1 and 2)......................... 0 28-20-18 (1 thru 8)........................ 0 30-41-01 (1 thru 8).........................0
28-00-01 (1 thru 6) ........................ 0 28-20-19 (1 thru 4)........................ 0 30-42-01 (1 and 2) .........................0
28-00-02 (1 thru 10) ...................... 0 28-20-20 (1 thru 4)........................ 0 30-42-02 (1 thru 4).........................0
28-10-01 (1 thru 4) ........................ 0 28-20-21 (1 thru 4)........................ 1
28-10-02 (1 thru 6) ........................ 0 28-20-22 (1 thru 4)........................ 0 CHAPTER 32
28-10-03 (1 thru 4) ........................ 0 28-20-23 (1 thru 4)........................ 0 32-Index (1 thru 6).........................3
28-10-04 (1 thru 6) ........................ 0 28-20-24 (1 thru 4)........................ 0 32-00-00 (1 and 2) .........................0
28-10-05 (1 thru 4) ........................ 0 28-20-25 (1 thru 4)........................ 0 32-11-01 (1 thru 6).........................3
28-10-06 (1 thru 8) ........................ 0 28-20-26 (1 thru 4)........................ 0 32-11-02 (1 thru 10).......................3
28-10-07 (1 and 2)......................... 0 28-20-27 (1 thru 4)........................ 0 32-11-03 (1 thru 6).........................3
28-10-08 (1 thru 6) ........................ 0 28-20-28 (1 thru 6)........................ 0 32-11-04 (1 and 2) .........................3
28-10-09 (1 thru 4) ........................ 0 28-20-29 (1 thru 4)........................ 0 32-11-05 (1 thru 4).........................3
28-10-10 (1 thru 4) ........................ 0 28-20-30 (1 thru 4)........................ 3 32-11-06 (1 thru 10).......................3
28-10-11 (1 thru 6) ........................ 0 28-20-31 (1 thru 6)........................ 3 32-11-07 (1 thru 6).........................3
28-10-12 (1 thru 6) ........................ 0 28-20-32 (1 thru 4)........................ 1 32-11-08 (1 thru 12).......................3
28-10-13 (1 thru 6) ........................ 0 28-20-33 (1 thru 4)........................ 0 32-11-09 (1 thru 10).......................3
28-10-14 (1 thru 4) ........................ 0 28-20-34 (1 thru 4)........................ 0 32-11-10 (1 and 2) .........................0
28-10-15 (1 thru 4) ........................ 0 28-20-35 (1 and 2) ........................ 0 32-21-01 (1 thru 6).........................3
28-10-16 (1 thru 8) ........................ 0 28-20-36 (1 and 2) ........................ 0 32-31-01 (1 thru 4).........................3
28-10-17 (1 thru 6) ........................ 0 32-41-01 (1 thru 12).......................3
LOEM-2 Rev. 3
E-AB412-PT6T-2
CHAPTER 52 63-00-01 (1 and 2) .........................0 64-Index (1 thru 4) ........................ 3
52-Index (1 thru 4).........................0 63-11-01 (1 thru 12) ......................3 64-00-00 (1 and 2)......................... 0
52-00-00 (1 thru 14).......................0 63-11-02 (1 thru 4) ........................0 64-11-01 (1 thru 16) ...................... 3
52-11-01 (1 thru 6).........................0 63-21-01 (1 thru 10) ......................3 64-21-01 (1 thru 14) ...................... 3
52-11-02 (1 thru 4).........................0 63-22-01 (1 thru 12) ......................0 64-31-01 (1 and 2)......................... 3
52-11-03 (1 thru 4).........................0 63-22-02 (1 thru 6) ........................0 64-31-02 (1 thru 4) ........................ 3
52-11-04 (1 thru 6).........................0 63-22-03 (1 and 2) .........................0 64-31-03 (1 thru 4) ........................ 3
52-31-01 (1 thru 6).........................0 63-23-01 (1 thru 4) ........................0 64-31-04 (1 and 2)......................... 3
52-31-02 (1 and 2) .........................0 63-23-02 (1 and 2) .........................0 64-31-05 (1 and 2)......................... 3
52-31-03 (1 thru 4).........................0 63-23-03 (1 and 2) .........................0 64-31-06 (1 and 2)......................... 3
52-31-04 (1 thru 4).........................0 63-23-04 (1 and 2) .........................0 64-31-07 (1 and 2)......................... 3
52-31-05 (1 thru 4).........................0 63-23-05 (1 and 2) .........................0 64-31-08 (1 and 2)......................... 3
52-41-01 (1 thru 4).........................0 63-23-06 (1 and 2) .........................0
52-41-02 (1 and 2) .........................0 63-23-07 (1 and 2) .........................0 CHAPTER 65
52-41-03 (1 and 2) .........................0 63-23-08 (1 and 2) .........................0 65-Index (1 thru 6) ........................ 3
63-23-09 (1 and 2) .........................0 65-00-00 (1 and 2)......................... 0
CHAPTER 53 63-23-10 (1 thru 4) ........................0 65-11-01 (1 thru 12) ...................... 2
53-Index (1 and 2) .........................2 63-23-11 (1 and 2) .........................0 65-11-02 (1 thru 8) ........................ 3
53-00-00 (1 and 2) .........................0 63-23-12 (1 and 2) .........................0 65-12-01 (1 thru 20) ...................... 2
53-10-01 (1 thru 4).........................2 63-23-13 (1 and 2) .........................0 65-13-01 (1 thru 10) ...................... 2
53-10-02 (1 thru 4).........................0 63-23-14 (1 thru 4) ........................0 65-21-01 (1 thru 8) ........................ 3
53-20-01 (1 thru 16).......................2 63-23-15 (1 thru 4) ........................0 65-21-02 (1 and 2)......................... 2
53-31-01 (1 thru 4).........................0 63-23-16 (1 thru 4) ........................3 65-21-03 (1 thru 4) ........................ 0
63-23-17 (1 thru 6) ........................0 65-21-04 (1 and 2)......................... 0
56-Index (1 thru 4).........................2 63-23-19 (1 and 2) .........................0 65-21-06 (1 thru 4) ........................ 3
56-00-00 (1 and 2) .........................0 63-24-01 (1 thru 6) ........................0 65-22-01 (1 thru 10) ...................... 3
56-11-01 (1 thru 4).........................0 63-24-02 (1 and 2) .........................0 65-22-02 (1 thru 10) ...................... 3
56-11-02 (1 thru 4).........................0 63-24-03 (1 thru 4) ........................0 65-22-03 (1 and 2)......................... 0
56-11-03 (1 thru 4).........................0 63-24-04 (1 and 2) .........................0 65-22-04 (1 thru 4) ........................ 0
56-11-04 (1 and 2) .........................0 63-25-01 (1 thru 8) ........................3 65-22-05 (1 thru 4) ........................ 0
56-11-05 (1 thru 4).........................0 63-25-02 (1 thru 14) ......................3 65-22-06 (1 thru 4) ........................ 2
56-11-06 (1 thru 4).........................1 63-25-03 (1 thru 6) ........................0
56-21-01 (1 and 2) .........................0 63-25-04 (1 thru 6) ........................2 CHAPTER 67
56-21-02 (1 thru 8).........................2 63-25-05 (1 thru 4) ........................0 67-Index (1 thru 16) ...................... 3
63-25-06 (1 thru 4) ........................0 67-00-00 (1 and 2)......................... 0
62-Index (1 thru 4).........................2 63-25-08 (1 thru 4) ........................3 67-11-02 (1 thru 36) ...................... 3
62-00-00 (1 and 2) .........................0 63-25-09 (1 thru 4) ........................0 67-11-03 (1 thru 8) ........................ 2
62-11-01 (1 thru 12).......................2 63-26-01 (1 and 2) .........................2 67-11-04 (1 thru 6) ........................ 0
62-21-01 (1 thru 14).......................2 63-27-01 (1 thru 6) ........................3 67-12-01 (1 and 2)......................... 0
62-31-01 (1 and 2) .........................0 63-27-02 (1 and 4) .........................3 67-12-02 (1 and 2)......................... 1
62-31-02 (1 thru 4).........................0 63-27-03 (1 thru 14) ......................3 67-12-03 (1 thru 4) ........................ 1
62-31-03 (1 thru 10).......................1 63-27-04 (1 and 6) .........................3 67-12-04 (1 thru 4) ........................ 1
62-31-04 (1 thru 14).......................2 63-27-05 (1 and 2) .........................3 67-12-05 (1 thru 4) ........................ 1
62-31-05 (1 thru 4).........................0 63-31-01 (1 thru 4) ........................2 67-12-06 (1 and 2)......................... 2
62-31-06 (1 thru 4).........................2 63-31-02 (1 and 2) .........................2 67-12-07 (1 thru 8) ........................ 3
62-31-07 (1 thru 8).........................2 63-31-03 (1 thru 4) ........................0 67-12-08 (1 and 2)......................... 0
62-31-08 (1 thru 4).........................2 63-31-04 (1 and 2) .........................0 67-12-09 (1 and 2)......................... 0
62-31-09 (1 thru 8).........................2 63-41-01 (1 thru 4) ........................3 67-12-10 (1 and 2)......................... 0
63-41-02 (1 thru 4) ........................0 67-12-11 (1 thru 4) ........................ 0
CHAPTER 63 63-41-03 (1 thru 4) ........................0 67-12-12 (1 and 2)......................... 0
63-Index (1 thru 14).......................3 67-12-13 (1 and 2)......................... 0
63-00-00 (1 thru 6).........................2 CHAPTER 64 67-12-14 (1 and 2)......................... 0
Rev. 3 LOEM-3
E-AB412-PT6T-2
67-12-15 (1 and 2)......................... 0 71-01-02 (1 and 2) ........................ 0 76-11-03 (1 thru 4).........................0
67-12-16 (1 and 2)......................... 0 71-02-01 (1 thru 18)...................... 0 76-11-04 (1 and 2) .........................0
67-12-17 (1 and 2)......................... 0 71-02-02 (1 thru 4)........................ 0 76-11-05 (1 thru 6).........................0
67-12-18 (1 thru 8) ........................ 2 71-02-03 (1 thru 6)........................ 0 76-12-01 (1 thru 4).........................0
67-12-19 (1 thru 4) ........................ 0 71-11-01 (1 thru 4) ........................ 1 76-12-02 (1 thru 6).........................0
67-13-01 (1 and 2)......................... 0 71-11-02 (1 and 2)......................... 1 76-12-03 (1 thru 6).........................0
67-13-02 (1 and 2)......................... 0 71-11-03 (1 thru 4) ........................ 1
67-13-03 (1 and 2)......................... 0 71-11-04 (1 thru 4) ........................ 1 CHAPTER 79
67-13-04 (1 and 2)......................... 0 71-11-05 (1 thru 4) ........................ 1 79-Index (1 thru 4).........................2
67-13-05 (1 thru 4) ........................ 0 71-21-01 (1 thru 4)........................ 0 79-00-00 (1 thru 6).........................2
67-13-06 (1 thru 4) ........................ 0 71-21-02 (1 and 2) ........................ 0 79-21-01 (1 thru 12).......................0
67-13-07 (1 thru 6) ........................ 3 71-21-03 (1 and 2) ........................ 0 79-22-01 (1 and 2) .........................0
67-13-08 (1 thru 8) ........................ 3 71-21-04 (1 and 2) ........................ 0
67-13-09 (1 thru 4) ........................ 0 71-21-05 (1 and 2) ........................ 0 CHAPTER 95
67-13-10 (1 thru 4) ........................ 2 71-21-06 (1 and 2) ........................ 0 95-Index (1 thru 6).........................2
67-13-11 (1 and 2)......................... 0 71-21-07 (1 and 2) ........................ 0 95-29-30 (1 and 2) .........................0
67-13-12 (1 and 2)......................... 0 71-21-08 (1 and 2) ........................ 0 95-31-10 (1 thru 6).........................0
67-13-13 (1 and 2)......................... 0 71-31-01 (1 thru 4)........................ 0 95-31-20 (1 thru 8).........................0
67-13-14 (1 thru 4) ........................ 2 71-31-02 (1 thru 8)........................ 0 95-34-10 (1 thru 10).......................2
67-13-15 (1 thru 4) ........................ 2 71-31-03 (1 thru 4)........................ 0 95-34-11 (1 and 2) .........................0
67-13-16 (1 and 2)......................... 0 71-31-04 (1 thru 4)........................ 0 95-34-12 (1 thru 4).........................0
67-13-17 (1 thru 4) ........................ 2 71-61-01 (1 thru 22)...................... 2 95-34-13 (1 thru 4).........................0
67-13-18 (1 thru 6) ........................ 0 71-61-02 (1 thru 6)........................ 1 95-34-14 (1 and 2) .........................2
67-13-19 (1 thru 4) ........................ 0 71-61-03 (1 thru 6)........................ 1
67-13-20 (1 thru 4) ........................ 0 71-61-04 (1 thru 6)........................ 1 CHAPTER 96
67-13-21 (1 thru 6) ........................ 0 71-61-05 (1 and 2) ........................ 0 96-Index (1 thru 20).......................3
67-13-22 (1 thru 6) ........................ 0 71-61-06 (1 thru 6)........................ 0 96-21-01 (1 thru 8).........................0
67-13-23 (1 and 2)......................... 0 71-81-01 (1 and 2) ........................ 0 96-24-00 (1 thru 44).......................0
67-13-24 (1 thru 4) ........................ 0 71-81-02 (1 and 2) ........................ 0 96-24-01 (1 thru 20).......................0
67-13-25 (1 and 2)......................... 0 71-81-03 (1 and 2) ........................ 0 96-24-02 (1 thru 24).......................0
67-13-26 (1 and 2)......................... 0 71-81-04 (1 thru 4)........................ 0 96-24-03 (1 and 2) .........................0
67-13-27 (1 and 2)......................... 0 71-81-05 (1 and 2) ........................ 0 96-24-04 (1 and 2) .........................0
67-21-01 (1 and 2)......................... 2 71-81-06 (1 and 2) ........................ 0 96-24-05 (1 and 2) .........................0
67-21-02 (1 and 2)......................... 0 71-81-07 (1 and 2) ........................ 0 96-24-06 (1 and 2) .........................0
67-21-03 (1 and 2)......................... 0 71-81-08 (1 and 2) ........................ 0 96-24-07 (1 and 2) .........................1
67-21-04 (1 and 2)......................... 0 71-81-09 (1 thru 4)........................ 0 96-24-08 (1 and 2) .........................1
67-21-05 (1 and 2)......................... 0 71-81-10 (1 and 2) ........................ 0 96-24-09 (1 thru 4).........................1
67-21-06 (1 thru 4) ........................ 0 71-81-11 (1 thru 8) ........................ 0 96-24-10 (1 thru 6).........................1
67-21-07 (1 thru 4) ........................ 2 96-24-11 (1 and 2) .........................1
67-21-08 (1 thru 4) ........................ 2 CHAPTER 76 96-24-12 (1 thru 4).........................1
67-21-09 (1 thru 4) ........................ 0 76-Index (1 thru 6) ........................ 0 96-24-13 (1 and 2) .........................1
67-21-10 (1 and 2)......................... 0 76-00-00 (1 thru 4)........................ 0 96-24-14 (1 and 2) .........................1
67-21-11 (1 thru 4) ........................ 0 76-10-01 (1 and 2) ........................ 0 96-24-20 (1 thru 4).........................0
67-21-12 (1 thru 4) ........................ 0 76-10-02 (1 thru 10)...................... 0 96-24-21 (1 thru 8).........................0
67-21-13 (1 and 2)......................... 0 76-10-03 (1 and 2) ........................ 0 96-24-22 (1 thru 18).......................0
67-26-01 (1 and 2)......................... 0 76-10-04 (1 thru 10)...................... 0 96-24-30 (1 and 2) .........................0
67-26-02 (1 thru 8) ........................ 0 76-10-05 (1 thru 14)...................... 0 96-24-31 (1 thru 8).........................3
67-26-03 (1 thru 4) ........................ 0 76-10-06 (1 thru 6)........................ 0 96-24-32 (1 thru 4).........................0
76-10-07 (1 thru 4)........................ 0 96-24-33 (1 thru 10).......................0
76-10-08 (1 thru 4)........................ 0 96-24-34 (1 thru 6).........................0
CHAPTER 71 76-10-09 (1 and 2) ........................ 0 96-24-35 (1 thru 8).........................3
71-Index (1 thru 12) ...................... 2 76-10-10 (1 and 2) ........................ 0 96-24-36 (1 thru 24).......................2
71-00-00 (1 and 2)......................... 0 76-11-01 (1 thru 4) ........................ 0 96-24-51 (1 thru 4).........................0
71-01-01 (1 thru 20) ...................... 2 76-11-02 (1 thru 4) ........................ 0 96-24-52 (1 and 2) .........................0
LOEM-4 Rev. 3
E-AB412-PT6T-2
96-24-53 (1 and 2) .........................0 97-20-05 (1 thru 8) ........................0 98-24-08 (1 thru 4) ........................ 0
96-24-54 (1 and 2) .........................0 97-20-06 (1 thru 10) ......................0 98-25-01 (1 and 2)......................... 2
96-24-55 (1 and 2) .........................0 97-20-07 (1 thru 8) ........................0 98-25-02 (1 and 2)......................... 2
96-24-56 (1 and 2) .........................0 97-20-08 (1 thru 12) ......................0 98-25-03 (1 and 2)......................... 0
96-24-57 (1 and 2) .........................0 97-20-09 (1 thru 10) ......................0 98-25-04 (1 and 2)......................... 0
96-24-58 (1 and 2) .........................0 97-20-10 (1 thru 8) ........................0 98-25-05 (1 and 2)......................... 0
96-24-59 (1 and 2) .........................0 97-20-11 (1 thru 6) ........................0 98-25-06 (1 and 2)......................... 0
96-24-60 (1 and 2) .........................0 97-20-12 (1 thru 8) ........................0 98-25-07 (1 and 2)......................... 0
96-24-61 (1 and 2) .........................0 97-20-13 (1 thru 14) ......................0 98-25-08 (1 and 2)......................... 0
96-24-62 (1 and 2) .........................0 97-20-14 (1 thru 6) ........................0 98-25-09 (1 and 2)......................... 2
96-24-63 (1 and 2) .........................0 97-20-15 (1 thru 8) ........................2 98-26-01 (1 and 2)......................... 0
96-24-64 (1 and 2) .........................0 97-21-01 (1 thru 8) ........................1 98-26-02 (1 and 2)......................... 0
96-24-65 (1 and 2) .........................0 97-22-01 (1 and 2) .........................0 98-26-03 (1 and 2)......................... 0
96-25-01 (1 and 2) .........................0 97-23-01 (1 and 2) .........................0 98-26-04 (1 and 2)......................... 0
96-25-02 (1 thru 4).........................0 97-23-02 (1 and 2) .........................0 98-26-05 (1 and 2)......................... 0
96-25-03 (1 and 2) .........................0 97-30-00 (1 and 2) .........................2 98-26-06 (1 and 2)......................... 0
96-26-01 (1 thru 4).........................1 97-30-01 (1 and 2) .........................0 98-28-01 (1 and 2)......................... 3
96-30-01 (1 and 2) .........................0 97-30-02 (1 and 2) .........................0 98-28-02 (1 thru 6) ........................ 0
96-31-30 (1 thru 20).......................3 97-30-03 (1 and 2) .........................0 98-28-03 (1 thru 4) ........................ 0
96-31-50 (1 thru 4).........................0 97-30-04 (1 and 2) .........................0 98-28-04 (1 thru 8) ........................ 0
96-31-51 (1 thru 8).........................0 97-30-05 (1 and 2) .........................0 98-28-05 (1 thru 4) ........................ 0
96-31-52 (1 thru 14).......................2 97-30-06 (1 and 2) .........................0 98-28-06 (1 thru 8) ........................ 0
96-31-53 (1 and 2) .........................0 97-30-07 (1 and 2) .........................0 98-28-07 (1 and 2)......................... 0
96-31-54 (1 thru 6).........................1 97-30-08 (1 and 2) .........................0 98-28-08 (1 and 2)......................... 0
96-31-55 (1 thru 4).........................0 97-30-09 (1 and 2) .........................0 98-28-09 (1 thru 4) ........................ 0
96-31-56 (1 and 2) .........................0 97-30-10 (1 and 2) .........................0 98-29-01 (1 thru 4) ........................ 0
96-32-00 (1 and 2) .........................0 97-30-11 (1 and 2) .........................0 98-29-02 (1 thru 4) ........................ 0
96-33-00 (1 and 2) .........................0 97-30-12 (1 and 2) .........................0 98-29-03 (1 and 2)......................... 0
96-33-10 (1 and 2) .........................0 97-30-13 (1 and 2) .........................0 98-29-04 (1 thru 4) ........................ 0
96-33-11 (1 and 2) .........................0 97-30-14 (1 thru 4) ........................0 98-29-05 (1 and 2)......................... 0
96-33-12 (1 and 2) .........................0 97-30-15 (1 thru 8) ........................0 98-29-06 (1 thru 4) ........................ 2
96-33-13 (1 thru 4).........................0 97-30-16 (1 and 2) .........................0 98-30-01 (1 and 2)......................... 0
96-33-14 (1 and 2) .........................0 97-30-17 (1 and 2) .........................2 98-30-02 (1 and 2)......................... 0
96-33-15 (1 and 2) .........................0 97-30-18 (1 and 2) .........................2 98-30-03 (1 and 2)......................... 0
96-33-16 (1 and 2) .........................0 98-30-04 (1 and 2)......................... 0
96-33-17 (1 and 2) .........................0 CHAPTER 98 98-31-01 (1 and 2)......................... 0
96-33-18 (1 and 2) .........................0 98-Index (1 thru 10).......................3 98-31-02 (1 and 2)......................... 0
96-33-19 (1 and 2) .........................0 98-00-00 (1 thru 14) ......................0 98-31-03 (1 thru 10) ...................... 0
96-33-30 (1 and 2) .........................0 98-21-01 (1 and 2) .........................0 98-31-04 (1 thru 4) ........................ 0
96-33-40 (1 and 2) .........................0 98-21-02 (1 and 2) .........................0 98-31-05 (1 and 2)......................... 2
96-33-41 (1 and 2) .........................0 98-21-03 (1 thru 4) ........................0 98-31-06 (1 and 2)......................... 2
96-33-42 (1 and 2) .........................0 98-21-04 (1 and 2) .........................0 98-33-01 (1 and 2)......................... 0
96-33-43 (1 thru 4).........................0 98-22-01 (1 thru 14) ......................0 98-33-02 (1 thru 4) ........................ 0
96-33-44 (1 thru 4).........................0 98-22-02 (1 thru 16) ......................3 98-33-03 (1 and 2)......................... 0
96-67-01 (1 thru 6).........................0 98-22-03 (1 thru 10) ......................3 98-33-04 (1 and 2)......................... 0
96-73-01 (1 thru 22).......................0 98-22-04 (1 and 2) .........................3 98-33-05 (1 and 2)......................... 0
98-23-01 (1 and 2) .........................0 98-33-06 (1 thru 4) ........................ 0
CHAPTER 97 98-24-01 (1 thru 6) ........................0 98-33-07 (1 and 2)......................... 0
97-Index (1 thru 14).......................2 98-24-02 (1 thru 8) ........................0 98-33-08 (1 thru 4) ........................ 0
97-00-00 (1 thru 4).........................0 98-24-03 (1 thru 6) ........................0 98-33-09 (1 and 2)......................... 0
97-20-01 (1 thru 10).......................0 98-24-04 (1 thru 8) ........................3 98-33-10 (1 and 2)......................... 0
97-20-02 (1 thru 8).........................0 98-24-05 (1 and 2) .........................2 98-33-11 (1 and 2) ......................... 0
97-20-03 (1 thru 12).......................0 98-24-06 (1 and 4) .........................3 98-33-12 (1 and 2)......................... 2
97-20-04 (1 thru 6).........................0 98-24-07 (1 thru 4) ........................0
Rev. 3 LOEM-5
E-AB412-PT6T-2
98-33-13 (1 and 2)......................... 0 A1-10-01 (1 thru 10) ..................... 0
98-33-14 (1 and 2)......................... 0 A1-10-02 (1 thru 8) ....................... 0
98-33-15 (1 and 2)......................... 0 A1-11-01 (1 thru 6) ....................... 0
98-33-16 (1 and 2)......................... 0 A1-12-01 (1 and 2)........................ 0
98-33-17 (1 and 2)......................... 0 A1-13-01 (1 thru 4) ....................... 0
98-33-18 (1 and 2)......................... 0 A1-14-01 (1 thru 6) ....................... 0
98-33-19 (1 and 2)......................... 0 A1-15-01 (1 thru 4) ....................... 2
98-33-20 (1 and 2)......................... 0 A1-16-01 (1 thru 6) ....................... 0
98-33-21 (1 and 2)......................... 0 A1-17-01 (1 thru 4) ....................... 0
98-33-22 (1 and 2)......................... 0 A1-18-01 (1 and 2)........................ 0
98-33-23 (1 and 2)......................... 0 A1-19-01 (1 and 2)........................ 0
98-33-24 (1 and 2)......................... 0 A1-20-01 (1 and 2)........................ 0
98-33-25 (1 and 2)......................... 0 A1-21-01 (1 and 2)........................ 0
98-33-26 (1 and 2)......................... 0 A1-22-01 (1 and 2)........................ 0
98-33-27 (1 and 2)......................... 0
98-33-28 (1 and 2)......................... 0 APPENDIX II
98-33-29 (1 and 2)......................... 0 A2-Index (1 and 2)........................ 0
98-33-30 (1 and 2)......................... 0 A2-10-01 (1 thru 18) ..................... 0
98-33-31 (1 and 2)......................... 0
98-34-01 (1 and 2)......................... 0 APPENDIX III
98-34-02 (1 and 2)......................... 0 A3-Index (1 thru 4) ....................... 2
98-34-03 (1 and 2)......................... 0 A3-10-01 (1 thru 8) ....................... 2
98-34-04 (1 and 2)......................... 0 A3-11-01 (1 thru 8) ....................... 0
98-34-05 (1 and 2)......................... 2 A3-12-01 (1 thru 4) ....................... 0
98-34-06 (1 and 2)......................... 2 A3-13-01 (1 thru 6) ....................... 2
98-34-07 (1 and 2)......................... 2 A3-14-01 (1 and 2)........................ 2
98-52-01 (1 and 2)......................... 0 A3-20-01 (1 thru 12) ..................... 0
98-52-02 (1 and 2)......................... 0
98-63-01 (1 and 2)......................... 0 APPENDIX IV
98-65-01 (1 and 2)......................... 0 A4-Index (1 thru 4) ....................... 0
98-65-02 (1 thru 4) ........................ 0 A4-00-01 (1 and 2)........................ 0
98-71-01 (1 thru 4) ........................ 0 A4-10-01 (1 thru 22) ..................... 0
98-71-02 (1 thru 4) ........................ 0 A4-11-01 (1 thru 8) ....................... 0
98-71-03 (1 thru 4) ........................ 0 A4-11-02 (1 thru 6) ....................... 0
98-71-04 (1 and 2)......................... 0 A4-12-01 (1 and 2)........................ 0
98-71-05 (1 and 2)......................... 0 A4-13-01 (1 thru 6) ....................... 0
98-71-06 (1 and 2)......................... 0 A4-14-01 (1 thru 4) ....................... 0
98-71-07 (1 and 2)......................... 0
98-72-01 (1 and 2)......................... 0
98-72-02 (1 and 2)......................... 0
98-74-01 (1 thru 4) ........................ 0
98-74-02 (1 and 2)......................... 0
98-74-03 (1 and 2)......................... 0
98-74-04 (1 and 2)......................... 0
98-77-01 (1 and 2)......................... 0
98-77-02 (1 thru 4) ........................ 0
98-77-03 (1 thru 4) ........................ 0
98-77-04 (1 thru 4) ........................ 0
98-96-01 (1 and 2)......................... 0
98-96-02 (1 and 2)......................... 0
APPENDIX I
A1-Index (1 thru 4) ....................... 2
A1-00-00 (1 and 2)........................ 0
LOEM-6 Rev. 3
E-AB412-PT6T-2
RECORD OF REVISION
REVISION NUMBER ISSUE DATE DATE INSERTED BY
Rev. 1 ROR-1
E-AB412-PT6T-2
PAGE INTENTIONALLY LEFT BLANK
ROR-2 Rev. 1
E-AB412-PT6T-2
RECORD OF TEMPORARY REVISION
Temporary Revision Interested Pages Incorporated

Date Inserted
No. Date Chapter/Module Page Rev. No. Date
TR-001 07-02-2012 25-33-01 6 1 27/09/2012
TR-002 15-02-2013 08-41-01 5 2 15/11/2013
TR-002 15-02-2013 08-41-01 6 2 15/11/2013
TR-002 15-02-2013 08-41-01 9 2 15/11/2013
TR-002 15-02-2013 62-21-01 10 2 15/11/2013
TR-002 15-02-2013 62-21-01 11 2 15/11/2013
TR-003 28-04-2014 25-93-00 4 3 20/06/2014
TR-003 28-04-2014 25-93-00 5 3 20/06/2014
TR-003 28-04-2014 25-93-00 6 3 20/06/2014
TR-003 28-04-2014 25-93-00 7 3 20/06/2014
Rev. 3 ROTR-1
E-AB412-PT6T-2
ROTR-2 Rev. 3
E-AB412-PT6T-2
LIST OF CHAPTERS
CHAPTER CHAPTER NO.
AIR VEHICLE GENERAL 00
DIMENSIONS AND CHARTS 06
LIFTING, SHORING, RECOVERING AND TRANSPORTING 07
LEVELING AND WEIGHING 08
HANDLING AND TAXIING 09
PARKING, MOORING AND STORING 10
PLACARDS AND MARKINGS 11
SERVICING 12
VIBRATION AND NOISE ANALYSIS AND ATTENUATION 18
ENVIRONMENTAL CONTROL 21
EQUIPMENT/FURNISHINGS 25
FIRE PROTECTION 26
FUEL SYSTEM 28
HYDRAULIC POWER 29
ICE AND RAIN PROTECTION 30
LANDING GEAR 32
DOORS 52
FUSELAGE 53
WINDOWS 56
MAIN ROTOR 62
MAIN ROTOR DRIVE 63
TAIL ROTOR 64
TAIL ROTOR DRIVE 65
ROTORS FLIGHT CONTROL 67
POWER PLANT 71
ENGINE CONTROLS 76
Rev. 1 LOC-1
E-AB412-PT6T-2
(Cont.d)
CHAPTER CHAPTER NO.
ENGINE OIL SYSTEM 79
INSTRUMENT SYSTEM 95
ELECTRICAL SYSTEM 96
AVIONICS 97
WIRING DIAGRAM 98
LOC-2 Rev. 1
E-AB412-PT6T-2
LIST OF APPENDICES
APPENDIX APPENDIX NO.
GENERAL RULES I
POWER PLANT BUILD-UP II
CORROSION CONTROL GUIDE III
WIRING HARNESSES AND CABLE IV
Rev. 1 LOA-1
E-AB412-PT6T-2
LOA-2 Rev. 1
E-AB412-PT6T-2
CHAPTER 00 - INTRODUCTION
CONTENTS — MAINTENANCE PROCEDURES

Module Page
Number Title Number
00-00-00 INTRODUCTION
1. Introduction - general .............................................................................................................................. 1
00-00-40 THE MANUAL
1. The manual - use of the manual .............................................................................................................. 1

2. The manual - numbering system ............................................................................................................. 1
3. The manual - applicability code .............................................................................................................. 2
4. The manual - list of helicopter serial numbers ....................................................................................... 2
5. The manual - consumable materials ....................................................................................................... 2
6. The manual - special tools and test equipment ....................................................................................... 8
6-1. Special tools - maintenance hoist ................................................................................................ 17
7. The manual - revision symbols ............................................................................................................. 19
8. The manual - temporary revision .......................................................................................................... 19
9. The manual - torques ............................................................................................................................ 19
10. The manual - terminology ..................................................................................................................... 19
10-1. Terminology - warning, cautions, and notes ............................................................................... 19
10-2. Terminology - use of procedural words ....................................................................................... 20
11. The manual - wear limits ...................................................................................................................... 20
12. The manual - replacement parts and assemblies ................................................................................... 20
00-Index
Rev. 3 Page 1
E-AB412-PT6T-2
FIGURES
Figure Page
Number Title Number
00-00-40 THE MANUAL
Figure 1. Maintenance hoist .........................................................................................................................................21
00-Index
Page 2 Rev. 3
E-AB412-PT6T-2
TABLES
Table Page
Number Title Number
00-00-40 THE MANUAL
Table 1. Consumable materials list............................................................................................................................... 2

Table 2. Special tools and test equipment list............................................................................................................... 8
00-Index
Rev. 3 Page 3
E-AB412-PT6T-2
00-Index
Page 4 Rev. 3
E-AB412-PT6T-2
0 -0 -0 INTRODUCTION
00-00-00
INTRODUCTION
1. INTRODUCTION - GENERAL
This Chapter provides a general description of the Model 412 SERIES Helicopter and the contents and use of this
maintenance manual.
The AB412 helicopter model, manufactured by AgustaWestland under license from Bell Helicopter Textron is a
fifteen-place utility helicopter which can also be employed for rescue operations. The AB412 is equipped with single main
rotor and powered by twin-turbine engine. The helicopter can be equipped with various types of armament and auxiliary
installations to permit various types of mission to be performed.
This maintenance manual contains the necessary field maintenance procedures for Model 412 SERIES helicopters S/N
25501 through 25519; S/N 25520 thru 25599; S/N 25600 thru 25669 and S/N 25670 and subsequent (Model HP). Generally,
maintenance procedures for components or assemblies which have been removed from the helicopter are contained in
E-AB412-PT6T-3 Overhaul Manual.
This manual is one of a set of publications relating to the above-mentioned helicopter model. For further information
concerning other relevant publications refer to manual E-AB412-PT6T-01 “List of Applicable Publications”.
The content of this manual cover maintenance of all helicopter systems and components. As far as the engine system is
concerned, the manual only provides information regarding AgustaWestland-built components; for other engine data
operator should consult the manufacturer’s maintenance manual.
The content of this manual is subject to updating.
Variations and modifications will be introduced as the result of increase of information available, modification of aircraft
and progressive extension of maintenance operations.
Every effort is made to keep this manual current, review conference with maintenance personnel and a constant review of
maintenance and discrepancy reports assure inclusion of the latest date in the manual. However, we cannot correct an error
unless we know of its existence. In this regard it is essential that you do your part by forwarding the attached discrepancy
form giving details of the discrepancy.
Discrepancies and/or suggestions for improvement of publication content, must be reported to:
AgustaWestland S.p.A.
CUSTOMER SUPPORT & SERVICES - ITALY
Product Support Engineering Department
Via del Gregge, 100
21015 Lonate Pozzolo (VA) - Italia
Fax: 0039-0331664680
e-mail: [email protected]
00-00-00
Rev. 3 Page 1
E-AB412-PT6T-2
TECHNICAL PUBLICATIONS DISCREPANCY FORM
SUBMITTED TO: SUBMITTED BY:
AgustaWestland S.p.A. Customer name and address:

Customer Support & Services - Italy ____________________________________________________________
Product Support Engineering ____________________________________________________________
Via Del Gregge, 100 ____________________________________________________________
21015 Lonate Pozzolo (VA) - Italy
____________________________________________________________
Fax: +39-0331664680
E-mail: [email protected] Phone ___________________________________________________
Fax _______________________________________________________
E-mail ___________________________________________________
IF YOU BELIEVE THAT YOU HAVE DISCOVERED A DISCREPANCY IN THE TECHNICAL PUBLICA-
TION, PLEASE IDENTIFY THE PUBLICATION, DESCRIBE THE DISCREPANCY OR DEFICIENCY IN
DETAIL AND FORWARD TO AGUSTAWESTLAND AT THE ABOVE ADDRESS.
NUMBER: DATE:
PUBLICATION AFFECTED: PUBLICATION TITLE:
ISSUE DATE: CHANGE/REVISION DATE:
AFFECTED PAGE N.: AFFECTED FIGURE:
DISCREPANCY OR DEFICIENCY (DESCRIBE DISCREPANCY WITH TEXT AND/OR SKETCH).
00-00-00
Page 2 Rev. 3
E-AB412-PT6T-2
0 -0 -40 THE MANUAL
00-00-40
THE MANUAL
1. THE MANUAL - USE OF THE MANUAL
This manual is divided in chapters which are divided in modules. To find a desired subject, refer to the List of Chapters
located within this Chapter. Refer to the Table of Contents at the beginning of the desired Chapter to locate the specific
module containing the desired information.
WARNING
ALL MAINTENANCE PROCEDURES LISTED IN THE MANUAL ARE

APPLICABLE TO THE AB 412 HELICOPTER UNLESS OTHERWISE
SPECIFIED IN THIS SUPPLEMENTARY PAGES. THE RETIREMENT AND
OVERHAUL CRITERIA ARE DETAILED IN DEDICATED MANUAL
E-AB412-PT6T-6, DEVELOPED BY AGUSTAWESTLAND. FOR THE
OPTIONAL EQUIPMENT (KITS), THE APPLICABLE RETIREMENT LIVES
ARE INCLUDED IN MANUAL E-AB412-PT6T-6; THE OVERHAUL AND
INSPECTION CRITERIA ARE DETAILED IN THE RELEVANT SERVICE
I N S T R U C T I O N . I N S P E C T I O N S , M A I N T E N A N C E , A N D PA RT
REQUIREMENTS FOR SUPPLEMENTAL TYPE CERTIFICATE (STC/COTS)
INSTALLATIONS ARE NOT INCLUDED IN THIS MANUAL. WHEN A STC/
COTS INSTALLATION IS INCORPORATED ON THE HELICOPTER, THOSE
PORTIONS AFFECTED BY THE INSTALLATION MUST BE INSPECTED IN
ACCORDANCE WITH THE MAINTENANCE PROGRAM SUPPLIED BY THE
OWNER OF THE STC/COTS. SINCE STC/COTS INSTALLATIONS MAY
CHANGE SYSTEMS INTERFACE, OPERATING CHARACTERISTICS AND
FATIGUE LIVES, AGUSTAWESTLAND-BELL HELICOPTER PROVIDED
MAINTENANCE CRITERIA MAY BE INVALID FOR THE MODIFIED
HELICOPTER.
2. THE MANUAL - NUMBERING SYSTEM
The numbering of the modules is in accordance with SPEC 1000D criteria.
The page numbering system used in this publication consists of three numbered elements separated by a dash, under which
the page number is printed.
For example:
28-20-00
Page 1
28- Chapter number
-20- Number of the corresponding chapter in SPEC 1000D
-00 Sub-system of the corresponding chapter in SPEC 1000D.
00-00-40
Rev. 3 Page 1
E-AB412-PT6T-2
3. THE MANUAL - APPLICABILITY CODE
The applicability code indicates the helicopters (by Serial Number) to which the information is applicable. Where no code
is shown, the information is applicable to all helicopters covered by this manual. The code used in this manual are shown in
the list of helicopter Serial Numbers.
4. THE MANUAL - LIST OF HELICOPTER SERIAL NUMBERS
Serial No. Applicability Code
25501 thru 25517 A or [A]
25518 thru 25599 B or [B]
25600 thru 25669 C or [C]
25670 and subsequent (Model HP) D or [D]
NOTE
Personalized configurations produced by AgustaWestland are treated in appropriate
supplements.
5. THE MANUAL - CONSUMABLE MATERIALS
WARNING
HANDLING AND STORAGE OF CONSUMABLE MATERIALS SHALL BE IN

ACCORDANCE WITH MANUFACTURERS INSTRUCTIONS UNLESS
OTHERWISE NOTED IN APPLICABLE MAINTENANCE TASKS.
Consumable materials required while performing maintenance are listed in the text by name and an item number such as
"solvent (C-304)". A list of all consumable materials (by item number and full nomenclature) required for each Chapter is
provided in table 1.
Table 1. Consumable materials list
ITEM NO. NOMENCLATURE
C-001 Grease, aircraft general purpose, MIL-PRF-81322 (aeroshell No. 22 or mobil No. 28).
C-002 Hydraulic fluid, MIL-PRF-5606.
C-003 Turbine fuel, grades JP-4 AND JP-5, MIL-T-5624.
C-005 Lubricant, solid film, air cured, AS5272, TIO LUBE 460.
C-007 Grease, MIL-PRF-25537.
00-00-40
Page 2 Rev. 3
E-AB412-PT6T-2
(Cont.d)
C-008 Petrolatum, VV-P-236.
C-009 Lubricating oil, grade 1010, MIL-L-6081.
C-010 Lubricating oil, turbine engine, MIL-L-7808.
C-011 Lubricating oil, turbine engine, MIL-L-23699.
C-012 Lubricant, Plastilube #3.
C-015 Lubricant (tube pack) 204-040-755-5.
C-021 Lubricant, solid film, air cured, MIL-L-23398, Type II, TIO LUBE 70.
C-024 Ultrachem assembly fluid No. 1.
C-028 Lubricant, dry film, Permalon 327.
C-030 Lubricating oil, DOD-PRF-85734.
C-041 Heatsink compound, silicone base, thermalcote 250.
C-063 Primer, class 5.
C-072 Hydraulic fluid, MIL-PRF-87257 (Aeroshell fluid 51, Brayco Micronic 881 or Royco
777)
C-100 "Chemical film material (Alodine 1200 or 1201) MIL-C-81706, class 1A, form II (dip
tank) or III (brush-on). Apply per MIL-C-5541".
C-101 Corrosion preventive compound, MIL-PRF-16173, grade 1.
C-105 Corrosion preventive compound, MIL-C-15074.
C-107 Hydraulic fluid, petroleum base, MIL-PRF-6083.
C-108 Cadmium plating solution (for brush cadmium plating), MIL-STD-865, LDC 4803.
C-114 Dichromate treatment, AMS-M-3171, type III.
C-116 Chromic trioxide (chromic acid), A-A-55827.
C-120 Calcium sulfate dihydrate, TS 567.
C-124 Corrosion preventive compound, BRAYCO 599.
C-126 Corrosion preventive compound, MIL-PRF-8188.
C-127 Corrosion preventive compound, MIL-C-11796, grade 3.
00-00-40
Rev. 3 Page 3
E-AB412-PT6T-2
(Cont.d)
C-136 Caps and plugs, protective, electrical connector, 3M 4270.
C-137 Cooling agent, Quik-Freeze MS-242N.
C-149 Edge sealer, erosion protective tape, DP190.
C-156 Caps and plugs, protective, electrical connector, NAS 820.
C-201 Zinc chromate primer, TT-P-1757.
C-202 Primer, catalyzed epoxy, 299-947-060, type I, Super Koropon K5635
C-202A Epoxy polyamide primer MIL-PRF-23377, type I or II, class C2.
C-204 Epoxy polyamide primer, MIL-PRF-23377, type I or II, class C2. Alternate with C-202
or C-246. C-246 not for wet installations.
C-205 Dope thinner, cellulose nitrate, MIL-T-6095.
C-206 Thinner, nitrate cellulose lacquer, MIL-T-19544.
C-210 Epoxy coating paint, MIL-PRF-22750.
C-216 Lacquer, gloss, clear, A-A-3165.
C-222 Catalyzed epoxy primer (tree part kit).
C-223 Nonslip compound, walkway, MIL-W-5044, A-A-59166, type II.
C-233 Enamel imron polyurethane, 299-947-117, type I.
C-237 Varnish, alkaline resistant, A-A-1800, type I or II.
C-243 Sodium thiosulphate (NA2S203), anhydrous, technical grade.
C-245 Coating, epoxy primer, waterborne, MIL-PRF-85285, type I.

Refer to text for color. Use with primer C-246.
C-246 Coating, epoxy primer, waterborne, MIL-PRF-85582, type I, class C2. Use C-204 for
wet installations.
C-251 Sealant, MIL-PRF-81733, type II-2, AC-665B-1/2, or PS-870B-1/2, or P/S 870A-2.
C-252 Adhesive, 299-947-320 type I, 3M No. AF163-2K.
C-253 Adhesive, primer, 299-947-320, class 1, 3M No. EC3924B.
C-300 Adhesive, 299-947-152. Type I, class 1 (Dapcotac 3300).
C-301 Adhesive, urethane base, 299-947-066 type I.
C-304 Drycleaning solvent, MIL-PRF-680, type II.
00-00-40
Page 4 Rev. 3
E-AB412-PT6T-2
(Cont.d)
C-305 Aliphatic Naphtha, TT-N-95, type II.
C-306 Toluene, A-A-59107.
C-307 Adhesive Silicone, 299-947-152, type I, class 2 or RTV 732 clear or RTV 108
translucent.
C-308 "Adhesive sealant, 299-947-107, type III, class 7, MIL-S-8802, class B2 or Proseal
890-B2".
C-309 Methyl-Ethyl-Ketone (MEK), ASTM D740 (alternate where MEK use prohibited:
C-316 or C-305).
C-310 Adhesive 299-947-107, Type III, class 6.
C-311 Adhesive 299-947-107 Type II, class 4.
C-314 Adhesive 299-947-152, type III or RTV-730 or FRV 1106.
C-316 Acetone ASTM D329.
C-317 Adhesive, epoxy base, heat resistant 299-947-100, type II, class 2, Hysol EA9392 or
Magnobond 6398 or Hysol EA934NA.
C-318 Cleaning compound, alkaline base, detergent, MIL-PRF-87937 type I.
C-320 Sealant MIL-S-22473 grade AV (red) grade CV (blue) grade HV (brown) grade AA
(green) Loctite 222 or grade E (purple) grade T (yellow or green) grade N (green).
C-323 Fairing compound, aerodynamic, epoxy filler, 299-947-072, type I or Hysol EA960.
C-325 Adhesive, rubber base 299-947-107 type II, class 5.
C-326 Denatured alcohol.
C-327 Adhesion promoter, INSTAbond 900.
C-328 Sealing compound, pro-seal 706, class B-2 or PRC-1321, class B-2, or CS3300B,
MIL-S-8784.
C-330 Cleaner, glass and acrylic plastic, GLASS CLEANER.
C-331 Adhesive, room temperature cure, highpeel strength, 299-947-125, type I, Hysol EA
9309NA.
C-337 Primer, MIL-S-23586 (dow corning no. 1200).
C-339 Alcohol, ethyl, MIL-E-463, A-A-59342, grade 3.
C-344 Alcohol phosphoric cleaner, MIL-C-10578, type I.
C-345 Grease removing primer, Scotch-weld 2320.
00-00-40
Rev. 3 Page 5
E-AB412-PT6T-2
(Cont.d)
C-347 Xylene ASTM D846, grade A.
C-349 Decal sealer, SCOTCHCAL No. 3950.
C-350 Ammonium nitrate, technical grade, A-A-59476.
C-352 Sealant, anaerobic retaining compound, ASTM D5363, group 04, class 1, grade 1 or 2,
MIL-R-46082, type I or II.
C-353 Sealing compound firewall, AMS 3374, type I, MIL-S-38249.
C-355 Detergent, mild liquid.
C-363 Adhesive, 299-947-100, type II, class 3, Hysol EA956 or Magnobond 6367.
C-364 Adhesive film, 299-947-038, type I. Use with primer C-063.
C-382 Use item C-308.
C-383 Rubber cement, natural rubber base, low adhesion, No. 4 (not fuel and oil resistant).
C-385 Isopropyl alcohol 99%, TT-I-735.
C-386 Solvent, cleaner, VOC compliant, Prep-Sol 3919S.
C-390 Ethyl acetate TT-E-751.
C-394 De-icing fluid, AMS1424, ARCOPLUS type I or OCTAFLO Type I or OCTAFLO

DILUTE Type I or KILFROST DF or DF Type I.
C-396 Sealant, corrosion inhibitive, MIL-S-29574, AMS 3277, type I, class B.
C-401 Aluminum tape, 3M No. 363.
C-403 Glass cloth, scotchbrand, 299-947-110, type I, 3M No. 361.
C-404 Glass cloth, 0.010 in thick, MIL-C-9084, AMS-C-9084, class 1, type VIIIA/VIIIB.
C-405 Lockwire, AS1000028 suspersedes MS20995C32 (0.032 in Dia.).
C-406 Abrasive cloth or paper, P-C-451, aluminum oxide.
C-407 Abrasive pad, nylon web (scotchbrite) L-P-0050, type I, class 1, size 1.
C-408 Talcum powder, A-A-59303, type T1, MIL-T-50036.
C-410 Packaging tape, waterproof, ASTM D5486/D 5486M, type III.
C-411 Steel wool (do not use on aluminum, magnesium, stainless steel or titanium)
C-412 Wax, MIL-W-18723.
C-415 Corrosion preventive oil.
00-00-40
Page 6 Rev. 3
E-AB412-PT6T-2
(Cont.d)
C-422 Aluminium Wool, A-A-1043, type II, FF-W-1825.
C-423 Abrasive cloth (P-C-458) or paper (P-P-101) (all grits).
C-424 Adhesive compound, 299-947-072 type I.
C-426 Masking tape, 3M No. 232
C-427 Barrier material, grease and water proof, flexible, MIL-PRF-121.
C-428 Caps/Plugs, protective dust & moisture seal, NAS 847, MIL-C-5501.
C-430 Barrier tape, MIL-T-23142.
C-431 Hydrochtoric (muriatic) acid, O-H-765.
C-432 Nitric acid technical, A-A-59105.
C-434 Plating tape, age control.
C-436 Paint remover, MIL-R-81294, type I or II, Turco 5351 (T-5469).
C-438 Tinting medium, A-A-3108, TT-T-390A.
C-439 Aluminum foil tape, 3M No. 425.
C-447 Lockwiew, AS100029 supersedes MS20995C41 (0.041 in dia.).
C-448 Tape (thread) (1/2 in wide).
C-452 Anti-seize compound, MIL-PRF-907, MIL-A-907 ANTISEIZE.
C-456 Tape, adhesive, A-A-59298, MIL-T-23142.
C-464 India stone, SS-S-736.
C-465 Liner material, bell std. 150-044-1.
C-471 Cord, fibrous, nylon, MIL-C-5040, type III.
C-473 Paint remover, solvent type, water rinsable, MIL-PRF-25134.
C-474 Dry blasting abrasive, aluminum oxide or garnet (size specified in text).
C-478 Peel ply.
C-480 Use item C-471.
C-482 Duct tape.
C-483 Reflective tape, MIL-R-13689.
C-486 Cheesecloth, cotton, CCC-C-440, class 1.
00-00-40
Rev. 3 Page 7
E-AB412-PT6T-2
(Cont.d)
C-489 Boric acid solution, A-A-59282.
C-496 Wet blasting abrasive, flint quartz no. 3/0, 3/0 inspection grade.
C-508 Lockwire, AS100026 supersedes MS20995C20 (0.020 in dia.).
C-509 Anti-chafing tape.
C-516 Cloth, cleaning, low-lint.
C-533 Trichlorotrifloroethane, cleaning compound, MIL-C-81302, type II, Freon TF or 113.
C-552 Butyl acetate, contact cleaner.
C-555 Release agent, loctite frekote 44 NC.
C-556 Corrosion preventive compound, MIL-C-6173, grade 2.
C-557 Blade tape, 3M No. 8663 black.
C-558 Adhesive promoter, 3M No. 86A.
C-561 Grease, high pressure, NLGI grade 2, thixogrease.
C-571 Adhesive, Larson L100 or Larson L101.
C-596 Tape, thread sealant and lubricant, PTFE.
C-597 Thread locking compound, MIL-S-46163A, type III, grade R.
C-598 Oil spray, MIL-C-81309D, type III.
6. THE MANUAL - SPECIAL TOOLS AND TEST EQUIPMENT
Certain maintenance procedures require the use of special tools. Special tools required are listed at the beginning of the
applicable maintenance paragraph. Special tools and test equipment are listed in table 2. Each tool a test equipment has an
item number assigned for ease of location and reference. When an item number is a referenced in the manual you may locate
the item through its "T" designator and item number. "T" designators are used only with special tools and test equipment.
Table 2. Special tools and test equipment list
ITEM NO. PART NUMBER NOMENCLATURE USE
T1 BH21830-1 Signal cable assembly Calibration of the power plant and

engine instruments.
T1-1 GS 13217 Propeller protractor (Not illustrated) Rigging elevator.

Alternative for T16-5)
T2 RST1015 Roller staking tool Stake the P/N 412010-421 bearing.
T3 RST 1016 Roller staking tool Stake the P/N 209-031-351 bearing.
00-00-40
Page 8 Rev. 3
E-AB412-PT6T-2
(Cont.d)
T3-1 SWE 107 Power wrench set Remove main rotor must
T4 SWE-124330 Anchor plate assembly Remove and torque retaining nuts:

P/N 204040-115
P/N 204-040-122
T4-1 SWE-126377 Socket Remove main rotor must.
T5 SWE13832-11 Engine adapter Use in conjunction with SWE 13875.
T6 SWE-13832-21 Transmission adapter Use in conjunction with SWE

13875-60.
T7 SWE-13833 Sling assembly Lifting a complete engine, a single

power section or combining gear-box.
T8 SWE-13852-1210 Adapter arm Use in conjunction with

SWE-13855B.
T9 SWE-13852-40 Transmission adapter Use in conjunction with

SWE-13855B.
T10 SWE-138523030 Engine stand adapter Use in conjunction with

SWE-13852-1210 and SWE-13855B.
T11 SWE-13852-3040 Engine stand adapter Use in conjunction with

SWE-13852-1210 and SWE-13855B.
T12 SWE13855B Engine and transmission stand Stand, engine and transmission in
conjunction with SWE-13852-1210,
SWE-13852-40, SWE13852-3030 and
SWE-13852-3040.
T13 SWE-13875 Maintenance transport stand Stand, main transmission, main rotor,
engine assembly in conjunction with
SWE-13832-24, SWE-13832-60,
SWE-13875-20, SWE-13875-30.
T14 SWE-13875-30 Hub and blade adapter Hub and blade storage/transport with
support 214-782-003-1 and adapter
T101263-103.
T15 SWE-13875-60 Transmission mount adapter Transmission removing/storage with

adapter SWE-1383221.
T16 SWE-13875-70 Engine mount adapter Engine storage/maintenance and

installation with adapter
SWE-13832-11.
00-00-40
Rev. 3 Page 9
E-AB412-PT6T-2
(Cont.d)
T16-1 SWE-54C Torque wrench Remove and torque nuts:

204-040-115
204-040-122
T100965 tacking screw set.
T16-2 SWE67B Adapter Remove and torque nuts:

204-040115
204-040-122
(Part of set T100965 tacking screw
set).
T16-3 SWE-63 Work handle Remove and torque nuts:

204-040-115
204-040122
set).
T16-4 SWE-8100 Power wrench Remove and torque nuts:

204-040-115
204-040122
set).
T16-5 TB-107 Clinometer Rigging elevator

(Alternative for T1-1)
T17 T100929 Jacking screw set Remove main transmission

components.
T18 T100965 Power wrench kit includes: T1G-1, Remove and torque nuts:
T1G-2, T1G-3 and T1G-4. 204-040-115
204-040122
T19 T101808-101 Tow bar Link the helicopter to a tow factor.
T20 T101260-101 Bond and proof load fixture Position and bond elastomeric damper
bearing.
T21 T101261-101 Droop restraint tube assembly Folding the main rotor blades.
T22 T101262-119 Bearing replacement tool Remove and install roller bearings.
T23 T101263-101 Adapter assembly Accommodate the main rotor hub to

support P/N 214-782003.
T23-1 T101264-103 Pusher assembly Remove tail rotor gear box.
00-00-40
Page 10 Rev. 3
E-AB412-PT6T-2
(Cont.d)
T24 T101266 Blade bolt tool Remove or install the forward on

leading edge blade attach bolt through
the main rotor hub spindle and the
blade.
T24-1 T101291-103 Swashplate rigging tool To rig swashplate
T25 T101306 External spline wrench Torque nuts, coupling, hydraulic

pump, pinion shaft.
T26 T101307 Wrench assembly Assemble and disassembly the

transmission and gearboxes.
T27 T101308 Jackscrew set Remove input quill from main

transmission, main case hydraulic
pump, output quill, oil pump, input
quill tail rotor.
T28 T101330 Rigging fixture Pilot's cyclic stick rigging.
T29 T101338 Jackscrew set Remove transmission and gearbox

quills.
T30 T101440 Jack set Remove transmission during engine to

transmission alignment.
T31 T101449 Wrench Assemble and disassemble main

transmission and 90° gearbox quills.
T32 T101455 Holding plate assembly Assemble and disassemble

transmission and gearbox quills.
T33 T101456 Wrench Torque to the lower must bearing inner

race P/N 204-040-270.
T34 T101560 Holding Fixture Hold gearbox input quill.
T35 T101564 Holding fixture Hold the 42° gearbox quill sleeves.
T36 T101577 Staking tool Install bearings in tail rotor trunnion

and yoke.
T37 T101579 Alignment tool Check and calibrate drive shaft

alignment engine and main
transmission.
T38 T101581 Maintenance hoist Remove major components.
T39 NOT APPLICABLE
00-00-40
Rev. 3 Page 11
E-AB412-PT6T-2
(Cont.d)
T40 T101586 Pusher set Facilitate installing the input drive

quill into the main transmission.
T41 T101588 Curvic coupling wrench set Hold transmission, input drive shaft
and engine drive shaft adapter.
T41-1 T101599 Pressing tool To support duplex bearing inner race

while pressing the drive pinion of
various transmission quills into the
bearing.
T42 T101626 Sling Lift the main rotor hub and blades as
an assembly.
T43 T101654-101 Bander assembly Bend the main rotor blade trim tab.
T44 T101656-145 Tab bending gage Indicate the angular difference.
T45 T101738-101 RPM test set Functionally bench test RPM limit
detector.
T46 T101807-101 Blade rack Hold all four blades.
T46A T101808-101 Tow Bar For towing helicopter.
T47 T102031-3 Pedestal weldment Support base for the main rotor during
stop maintenance.
T48 T102095 Bearing staking tool set Replacement bearings in fixed flight
control bellcranks.
T48-1 T102118-101 Dehydrator assembly To detect water inside the transmission

assembly during transportation or
storage.
T48-2 T103063 Curvic coupling wrench set Hold transmission, input drive shaft
and engine drive shaft adapter.
T49 T103206-101 Rigging tool assembly Provide proper positioning of the tail
rotor crosshead.
T50 T103211101 Lift cover plate Close the top of transmission and
lifting transmission.
T50-1 T103225-105 and -109 Spacers Tail rotor drive system alignament.
T50-2 T103226 Tail rotor gear box simulator. Tail rotor drive system alignament
T50-3 T103222 Jackscrews Alignment of mast torque tube
00-00-40
Page 12 Rev. 3
E-AB412-PT6T-2
(Cont.d)
T51 T103223-101 and -105 Locator assembly Alignment of a tail rotor shaft bearing
and hanger assembly.
T52 T103224-101 42° gearbox simulator Alignment between hanger to 42°

gearbox and 90° gearbox on the
tailboom.
T53 T103225-101 Bulkhead alignment plate Alignment between hanger bearings

and the 42° gearbox on the tailboom.
T54 T103226-101 90° gearbox plate Alignment hanger bearings, 42°

gearbox and 90° gearbox on the
tailboom.
T55 T103228-101 Bracket assembly Alignment between drive shaft

bearing and hanger assemblies
mounted on the tailboom.
T55-1 T103281-101 Flight controls rigging tool Cyclic control stops rigging.
T55-2 T103281102 Flight controls rigging tool Cyclic control stops rigging.
T55-3 T103286-101 Flight controls rigging tool Maxing lever assembly centering
T55-4 T103287-101 Flight controls rigging tool Collective control stick positioning.
T55-5 T103287-111 Flight controls rigging tool Collective control stick positioning.
T55-6 T103288-101 Flight controls rigging tool Swashplate positioning.
T56 T103262-101 Rigging tool Cyclic flight controls rigging.
T56-1 T103296 Rigging tool Rigging elevator control tube.
T56-2 T103347-101 Flight controls rigging tool Cyclic control stick centering.
T56-3 T103356-101 Flight controls rigging tool Cyclic controls position sensors
rigging
T57 XW 20509 Wrench Adjust spring tension of the

windshield wiper arm
T58 204-010-481-1 Mast nut Lift the entire helicopter.
T59 204-011-178-1 Clevis Lift the entire helicopter.
T60 204-040-001-17 Sight glass tool To obtain back lash measurements of

PAT-5S the various quill in the main
transmission.
00-00-40
Rev. 3 Page 13
E-AB412-PT6T-2
(Cont.d)
T60-1 204-040-929-101 Cover and lift plate Close the top of transmission and
lifting transmission.
T61 214-706104-1 Ground handling wheels Reposition the helicopter by hand.
T61-1 412-782-113 Tiedown sock assembly Main rotor blade unfolding

procedures.
T61-2 412-782-118 Tiedown wand assembly Main rotor blade unfolding

procedures.
T62 214-782-003-1 Support assembly Support the main rotor.
T62-1 412-801-301-137 Rigging tool —
T62-2 412-240-008-101 Holding fixture Remove the tail rotor gearbox adapter
T62-3 412-240-028-101 Mast torquemeter alignment tool Alignment of mast torque tube.
T62-4 412-240-001-101 Wrench Remove and torque main input quill

nut.
T63 2337 Main rotor hub balance fixture Balance the main rotor.
T64 3350 Stand and hoist assembly Support the main rotor or hub and
blade assy.
T65 6404 Vibrex kit (track and balance) Perform main and tail rotor dynamic
balancing and main drive shaft
balancing.
T66 6584 Model 412 vibrex accessory kit Perform rotor dynamic balancing rotor
blade ground maintenance and in
flight tracking, and main drive shaft
balancing.
T67 7BAL052 Balance indicator kit Support and balance the main rotor
hub assy.
T68 THEL087 Tail rotor balance kit Adapt and support the rail rotor hub
trunnion.
T69 7HEL092 Main rotor balance kit Adapt the main rotor hub to the
balance arbor.
T70 Berfield DC400 Fuel quantity test set Testing and calibration extended
Model 412 change fuel quantity indicators.
00-00-40
Page 14 Rev. 3
E-AB412-PT6T-2
(Cont.d)
T71 29333300 Basic RADS AT Kit Perform tracking and balancing of

main rotor, balancing of tail rotor
system and main drive shaft.
T72 NO NUMBER RADS AT accessory Kit. Perform tracking and balancing of

main rotor, balancing of tail rotor
system and main drive shaft.
T73 991D Accelerometer ((Wilcoxu) —
T74 120-035E44-12 Shim, Al Alloy (AR) —
T75 E2-10-1 Cartridge Removal Tool To remove the cartridge element from
the canister type boost pump
T76 T27872-2 Reamer To install collective jackshaft
T77 T103225-119 Alignment Plate To align Tail Rotor Drive System
T78 412-240-033-101 Hanger Simulator To align Tail Rotor Drive System
T81 DPPH200 Push-pull dial gage (spring scale) For rigging
T82 Commercial Inclinometer For rigging
T83 Commercial Spring scale For rigging
T84 Commercial Feeler gage or shim (12.7 mm) For rigging
T85 Commercial Shot bags (9.1 to 13.6 kg) For rigging
T86 CP-293 Filler Installation Tool (C.R. Lawrence To install Passenger Door Window
Co. Dallas Tx.)
T87 LT-112 Retainer Installation Tool (C.R. To install Passenger Door Window
Lawrence Co. Dallas Tx.)
T88 SWE 13860 Adapter To build-up and remove transmission
T89 AN 100036 Cover To build-up and remove transmission
T90 DB-3703-30 Drain line To drain oil
T91 TB107 Clinometer For rigging
T92 T101743-125 Tool set To aligne driveshaft transmission to

engine
00-00-40
Rev. 3 Page 15
E-AB412-PT6T-2
(Cont.d)
T93 211F-3 Deadweight Tester Engine Torque Transmitter adjustment

and functional check
T94 MB-1 Tactaiv Static Field Tester To check leaks of Pitot static system
T95 Barfield Model Pitot Static Tester To check leaks of Pitot static system
1811F-D
T96 Fluke Model 85 Digital multimeter —
T97 JTB Model 3FS Frequency Meter To check frequency of AC inverters.
T98 Barfield Model 2311-F Pressure Tester To check Torque Pressure Indicator
System
T99 Howell H337 Engine Test Set To check tachometer Indicator System
T100 Simmonds P/N Engine Test Set To check Tachometer Indicator

387991-003 System
T101 T102102 Dehydrator Assembly For Preservation in short Term Storage
T102 T102103 Dehydrator Assembly For Preservation in short Term Storage
T103 101-00807 SP Adapter Module —
T104 212-010-710-003 Balance weights For main rotor balancing
T105 Simmonds precision Fuel Quantity Test SEt To check Fuel Quantity
PSD-412-1 and
PSD30-2
T106 Commercial capable of Depth micometer To aligne engine to transmission

measuring 5-65 and 6-7
in depths.
T108 Commercial Slide Hammer with 1/4 x 20 UNC To remove manopole sensor assembly
threaded shaft of main rotor mast.
T109 Commercial Slide Hammer with 1/4 x 28 UNC To remove oil pump
threaded shaft
T110 T103356-101 Position Sensor Rigging Tool —
T111 T103225-109 Bushing —
T112 GS18217 Propeller Protractor For rigging
00-00-40
Page 16 Rev. 3
E-AB412-PT6T-2
(Cont.d)
T113 412-240-002-101 Wrench set To remove and install main input quill
magnetic seal
T114 B67-13000-01 Blade Fold Racks and Support To fold main rotor blades
Equipment
T115 T103063 Engine transmission Driveshaft curvic —

coupling wrench-set
T116 T103225-105 Bushing —
T120 302-00102 Pressure gauge Engine torque transmitter adjustment

and functional check
T121 T101649-101 Brake disc holding tool For Rotor Brake disc
T122 17-TES0060 Rose analysis unit (RAU) Functional test of flight data recorder
system
T123 17-TES0044 Test cable Functional test of flight data recorder

system
T124 17TES0010 Portable analysis unit (PAU) For analyze recorded data from flight
data recorder
T125 17TES0020 Portable printer unit (PPU) For recorder data from flight data
recorder
6-1. SPECIAL TOOLS - MAINTENANCE HOIST
The maintenance hoist (T38) (see figure 1) is provided to remove or install main rotor mast, transmission and engine on
Model 412 helicopter.
6-1-1. Maintenance hoist - installation
1. Attach hookup adapter (4, figure 1) to skid on left side of helicopter using lock pins.
2. The adjustable arm attaches to hard-point on the side of the helicopter. The paint might have to be removed from the
hole in this hard-point to install lock pin.
3. Place threaded end of brace assembly (7) in the hole in roof of helicopter. Retain by threading on brace nut (8).
4. Lay lower tower assembly (3) on ground at right angles to the helicopter with foot facing toward from of helicopter.
Attach lower tower too hook-up adapter (4) using lock pins.
5. Remove lift tube assembly (2) from its storage position inside of lower tower assembly.
00-00-40
Rev. 3 Page 17
E-AB412-PT6T-2
6. Clean pivot tube and teflon bushings on lower tower assembly. Place upper tower assembly (1) over pivot tube of lower
tower assembly.
7. Slip steel handle through short tubes at top of lower tower assembly and bottom of upper tower assembly. Retain with
the lock pin. This is to prevent tower assembly from rotating about lower tower assembly while towers are being
erected.
8. Remove support tube assembly from its storage position on top of boom. Attach top end of support tube assembly to
bracket on underside of boom with lock pin.
9. Attach lift tube assembly (2) to lower side of upper tower (1) with lock pin. The free end of lift tube should face away
from helicopter.
10. Two men can now erect maintenance hoist by starting at top and walking it up like a ladder. When top is several feet
off of the ground one main should push on lift tube assembly (2) while the other pushes on tower.
11. After maintenance hoist is vertical attach brace assembly (7) to lower tower, using lock pin. Before installing lock pin
adjust threaded portion of brace assembly so that maintenance hoist will be vertical.
12. Clamp the bracket that is on end of cable assembly (6) to front of skid tube. The tang on bracket fits inside of eye bolt
on skid tube. Adjust turnbukle until cable assembly (6) is tight.
13. Remove steel handle that is holding upper tower assembly (1) from rotating and place it in horizontal tube on upper
tower. Retain steel handle with lock pin.
14. Remove lift tube assembly (2) from upper tower assembly.
15. Rotate upper tower assembly approximately 80° towards the rear of helicopter.
16. Thread lift tube assembly (2) to adapter on boom.
17. Using lift tube assembly raise boom until it is horizontal. Secure boom in position by attaching lower end of support
tube assembly to the upper tower assembly (1) with lock pin.
6-1-2. Maintenance hoist - operational check
1. The maintenance hoist (T38) is mounted on aft area of landing gear. Cable (6, figure 1) attaches to forward end of skid
tube, and brace secured to helicopter for field use.
2. Maximum operating load of hoist is 410 kg (905 lb). Hoist consists of a support boom with a hand-operated winch,
cable and hook.
CAUTION
HOIST MUST BE CENTERED OVER COMPONENT BEING HOISTED. THE

HOOKUP ADAPTER ADJUSTABLE ARM (9, FIGURE 1) MUST BE
READJUSTED AFTER REMOVAL OF EACH MAJOR COMPONENT OR
BEFORE THE REMOVAL OF THE NEXT MAJOR COMPONENT SO THAT
THE HOOKUP ADAPTER (4) IS CENTERED AND FLUSH WITH SKID TUBE
(5). THIS WILL PREVENT POPPING OF RIVETS ON SADDLE ASSEMBLY
AND GROUND HANDLING WHEEL EYE BOLTS.
3. Upper tower will swivel freely with load applied and provides for in and out movement of hoist assembly.
4. Hoist assembly is self-locking so that the load will stay in position.
5. When rotating upper tower, position load as close to tower as possible.
00-00-40
Page 18 Rev. 3
E-AB412-PT6T-2
NOTE
If transmission is out, and engine is to be removed or installed front of helicopter
will tend to lift. Take precautions to support tailboom.
6. When securing adjustable arm (9) make sure it is as long as possible. Press down on the inboard portion of the
aluminum weldment with foot and make adjustable arm as long as possible.
7. THE MANUAL - REVISION SYMBOLS
The revised text or figure is shown by a vertical line on the external border of the page. If a part of text or illustration would
be revised, the revision will be applied to the module entirely. The minimum unit affected by update is the single module.
8. THE MANUAL - TEMPORARY REVISION
Temporary Revisions are issued when immediate details have to be included in the manual. They are printed on yellow
paper. The Temporary Revisions data can add to or cancel the initial data in the manual. They are numbered one after the
other and given a date. Temporary Revision pages are not written in the List of Effective Pages.
9. THE MANUAL - TORQUES
Torques are specified as either standard or special within this manual. Standard torque values for various type fasteners will
be found in Appendix I. Where applicable, special torques are specified within the text (or on illustrations) within this
manual.
10. THE MANUAL - TERMINOLOGY
10-1. TERMINOLOGY - WARNING, CAUTIONS, AND NOTES
Warnings, cautions, and notes are used throughout this manual to emphasize important and critical instructions as follows:
WARNING
AN OPERATING PROCEDURE, PRACTICE, ETC., WHICH, IF NOT

CORRECTLY FOLLOWED, COULD RESULT IN PERSONAL INJURY OR
LOSS OF LIFE.
CAUTION
AN OPERATING PROCEDURE, PRACTICE, ETC., WHICH, IF NOT STRICTLY

OBSERVED, COULD RESULT IN DAMAGE TO, OR DESTRUCTION OF,
EQUIPMENT.
NOTE
An operating procedure, condition, etc., which is essential to highlight.
00-00-40
Rev. 3 Page 19
E-AB412-PT6T-2
10-2. TERMINOLOGY - USE OF PROCEDURAL WORDS
The concept of procedural word usage and intended meaning which is used throughout this manual is as follows:
"Shall" is used only when application of a procedure is mandatory.
"Should" is used only when application of a procedure is recommended.
"May" and "need not" are used only when application of a procedure is optional.
"Will" is used only to indicate futurity, never to indicate a mandatory procedure.
11. THE MANUAL - WEAR LIMITS
CAUTION
METRIC EQUIVALENTS TO U.S. STANDARD WEIGHTS AND MEASURES

ARE PROVIDED THROUGHOUT THIS MANUAL. WHILE PERFORMING
MEASUREMENTS TO DETERMINE THE SERVICEABILITY OF A
COMPONENT OR TO ESTABLISH A SPECIFIED DIMENSION, ONLY THE
U.S. STANDARD VALUES SHALL BE USED.
Throughout this manual, wear limits are provided to show required fit between mating parts. It is not intended that all
dimensions be checked as a prescribed procedure; however, parts showing evidence of wear or physical damage shall be
checked dimensionally.
Wear limits, fit, and tolerances are integrated into the inspection, repair, and assembly procedures.
Unless otherwise specified, dimensions shall carry the following tolerances on decimals.
DECIMAL TOLERANCE
.XXX ± 0.010 in / ± 0.250 mm
.XX ± 0.03 in / ± 0.75 mm
.X ± 0.1 in / ± 2.5 mm
12. THE MANUAL - REPLACEMENT PARTS AND ASSEMBLIES
Replacement parts and assemblies required for proper maintenance are listed in a companion Illustrated Parts Catalogs
E-AB412-PT6T-4 or E-AB412EP-PT6T-4. These catalogs provide complete nomenclatures, part numbers, and ordering
information. The note in FOREWORD for the interchangeability of part applies.
00-00-40
Page 20 Rev. 3
E-AB412-PT6T-2
8
7
9
4
5
6
1. Upper tower assembly

2. Lift tube assembly
3. Lower tower assembly
4. Hook-up adapter
5. Skid tube
6. Cable assembly
7. Brace assembly
8. Brace nut
9. Adjustable arm
G6AB1016B
Figure 1. Maintenance hoist
00-00-40
Rev. 3 Page 21
E-AB412-PT6T-2
00-00-40
Page 22 Rev. 3
E-AB412-PT6T-2
CHAPTER 06 - DIMENSIONS AND CHARTS

Module Page
Number Title Number
06-00-01 DIMENSIONS AND CHARTS - AIRFRAME PRINCIPAL DIMENSIONS
1. Airframe principal dimensions - description ........................................................................................... 1
06-00-02 DIMENSIONS AND CHARTS - AIRFRAME REFERENCE LINES
1. Airframe reference lines - station lines, buttock lines, and water lines ................................................... 1
06-Index
Page 1
E-AB412-PT6T-2
FIGURES
Figure Page
Number Title Number
06-00-01 DIMENSIONS AND CHARTS - AIRFRAME PRINCIPAL DIMENSIONS
Figure 1. Major components location............................................................................................................................ 2

Figure 2. Airframe principal dimensions....................................................................................................................... 3
06-00-02 DIMENSIONS AND CHARTS - AIRFRAME REFERENCE LINES
Figure 1. Airframe reference lines (sheet 1 of 2) .......................................................................................................... 2
06-Index
Page 2
E-AB412-PT6T-2
06-0 -01 DIMENSIONS AND CHARTS - AIRFRAME PRINCIPAL DIMENSIONS
06-00-01
DIMENSIONS AND CHARTS - AIRFRAME PRINCIPAL DIMENSIONS
1. AIRFRAME PRINCIPAL DIMENSIONS - DESCRIPTION
The figure 1 depicts the major components of the helicopter. The figure 2 depicts principal dimensions of helicopter
airframe. Due to variations in loading and landing gear deflection, all height dimensions are approximate. With ground
handling wheels installed and fully extended, height is increased by 5 in. (12,7 cm).
06-00-01
Page 1
E-AB412-PT6T-2
G6AB0003A
Figure 1. Major components location
06-00-01
Page 2
E-AB412-PT6T-2
G6AB0004A
Figure 2. Airframe principal dimensions
06-00-01
Page 3
E-AB412-PT6T-2
06-00-01
Page 4
E-AB412-PT6T-2
06-0 -02 DIMENSIONS AND CHARTS - AIRFRAME REFERENCE LINES
06-00-02
DIMENSIONS AND CHARTS - AIRFRAME REFERENCE LINES
1. AIRFRAME REFERENCE LINES - STATION LINES, BUTTOCK LINES, AND WATER

LINES
1. GENERAL. Station lines, buttock lines, and water lines are used to determine locations on, and within, the helicopter.
All three are measured in inches from known points therefore these lines will not be expressed in metric equivalents
within this manual.
NOTE
The nose of the helicopter is station -20,0, Station 0 is 20,0 inches aft of the most
forward part of the nose.
2. STATION LINES (STA): Stations are vertical planes perpendicular to, and measured along, the longitudinal axis of
helicopter. Several station lines are shown on figure 1 at recognizable locations on the airframe. Other station locations
can be measured from these lines. Tail boom stations, stations within the baggage compartment stations and stations
along the vertical fin are illustrated in the same manner. These stations are perpendicular to the centerline of tailboom
and fin as applicable because these components are mounted at an angle to the horizontal plane of fuselage.
3. WATER LINE (WL): Water lines are horizontal planes perpendicular to, and measured along, the vertical axis of the
helicopter. Water line 0 is 7,44 in. (18,9 cm) below the lowest point of fuselage as shown on figure 1. Water lines can
be used to measure locations as described for station lines in preceding step.
4. BUTTOCK LINES (BL): Buttock lines are vertical planes perpendicular to, and measured to, the left and right along
the lateral axis of the helicopter. Buttock line 0 is the plane of the vertical centerline of the helicopter. Buttock lines
can be used to measure locations as described for station lines in step 2.
5. TAILBOOM AND BAGGAGE COMPARTMENT STATION LINES: Baggage compartment station lines are
measured from tailboom fuselage attach point to aft end of baggage compartment. These stations are numbered 17,42
through 101,38 inches. Tailboom station lines are measured from aft end of baggage compartment to center of
intermediate gearbox. These are numbered 101,38 through 206,17 inches.
6. ELEVATOR STATION LINES (ES): Elevator station lines are buttock lines extended through the elevator to the
elevator outboard tips. These lines are referred to as ES (elevator stations). Fuselage stations (FS) and bottom stations
(BS) also apply to the elevator.
7. VERTICAL FIN STATION LINES (VFS): Vertical fin stations are parallel vertical lines perpendicular to the
centerline of tail rotor shaft, below leading edge of vertical fin. These stations are measured from vertical fin station
(VFS) 0 which is 1,12 in (2,85 mm) below centerline of tail rotor which is at vertical fin station - 1,12 in. These lines
are referred to as VFS (vertical fin stations). Fuselage stations (FS) also apply to vertical fin.
8. MAIN AND TAIL ROTOR BLADE STATION LINES. Main and tail rotor blade station lines are measured from the
center of hub to tip of blade.
06-00-02
Page 1
E-AB412-PT6T-2
G6AB0001A
Figure 1. Airframe reference lines (sheet 1 of 2)
06-00-02
Page 2
E-AB412-PT6T-2
G6AB0002A
Figure 1. Airframe reference lines (sheet 2 of 2)
06-00-02
Page 3
E-AB412-PT6T-2
06-00-02
Page 4
E-AB412-PT6T-2
CHAPTER 07 - LIFTING, SHORING, RECOVERING AND TRANSPORTING

Module Page
Number Title Number
07-00-00 LIFTING HELICOPTER
1. Lifting helicopter - lifting complete helicopter (main rotor hub installed) ............................................. 1
2. Lifting helicopter - lifting complete helicopter (mast installed) ............................................................. 1
3. Lifting helicopter - lifting complete helicopter (mast removed) ............................................................ 2
4. Lifting helicopter - lifting complete helicopter (transmission removed) ................................................ 2
5. Lifting helicopter - lifting tailboom only ................................................................................................ 2
07-11-01 JACKING HELICOPTER
1. Jacking helicopter - description .............................................................................................................. 1
07-Index
Page 1
E-AB412-PT6T-2
FIGURES
Figure Page
Number Title Number
07-11-01 JACKING HELICOPTER
Figure 1. Hoisting and Jacking .......................................................................................................................................2
07-Index
Page 2
E-AB412-PT6T-2
07-0 -0 LIFTING HELICOPTER
07-00-00
LIFTING HELICOPTER
1. LIFTING HELICOPTER - LIFTING COMPLETE HELICOPTER (MAIN ROTOR HUB

INSTALLED)
SPECIAL TOOLS REQUIRED
NUMBER NOMENCLATURE
T58 MAST NUT
T59 CLEVIS
WARNING
IF MAIN ROTOR HUB HAS BEEN REMOVED DO NOT LIFT HELICOPTER

WITH MAST CAP (412-010-160) INSTALLED. USE CLEVIS (T59) WITH
MAST NUT (T58).
DO NOT USE CLEVIS (T59), TO LIFT HELICOPTER WITH GROSS WEIGHT
IN EXCESS OF 10000 LBS.
1. Attach a hoisting clevis (T59), or equivalent, to eye on bolted down mast cap (412-010-160). Connect suitable hoist
and take up slack.
2. Station a person at tail skid to steady helicopter when hoisting. If lifting beyond reach from ground, use a rope to steady
helicopter.
3. Hoist slowly with a constant lifting force.
2. LIFTING HELICOPTER - LIFTING COMPLETE HELICOPTER (MAST INSTALLED)
NUMBER NOMENCLATURE
T58 MAST NUT
T59 CLEVIS
07-00-00
Page 1
E-AB412-PT6T-2
WARNING
DO NOT LIFT HELICOPTER WITH MAST CAP (412-010-160) INSTALLED.

USE CLEVIS (T59) WITH MAST NUT (T58).
DO NOT USE CLEVIS (T59) TO LIFT HELICOPTER WITH GROSS WEIGHT
IN EXCESS OF 10000 LBS.
1. Attach a hoisting clevis (T59), or equivalent, to eye provided on retaining nut (T58) at top of main rotor mast. Connect
suitable hoist and tack up slack.
helicopter.
3. LIFTING HELICOPTER - LIFTING COMPLETE HELICOPTER (MAST REMOVED)
NUMBER NOMENCLATURE
T60-1 LIFT PLATE AND COVER
T59 CLEVIS
1. Install lift plate (T60-1 or equivalent) on transmission.
2. Attach suitable hoist with clevis (T59 or equivalent) to lifting eye.
helicopter.
4. LIFTING HELICOPTER - LIFTING COMPLETE HELICOPTER (TRANSMISSION

REMOVED)
1. Attach a suitable hoist to pylon lift link (Chapter 63).
helicopter.
5. LIFTING HELICOPTER - LIFTING TAILBOOM ONLY
Hoist tailboom as a separate component with sling positioned at tailboom CG. Use sling manufactured from belting material.
Position a person at each end of tailboom to steady tailboom in sling.
07-00-00
Page 2
E-AB412-PT6T-2
07-1 -01 JACKING HELICOPTER
07-11-01
JACKING HELICOPTER
1. JACKING HELICOPTER - DESCRIPTION
NUMBER NOMENCLATURE
COMMERCIAL HYDRAULIC JACKS (4 EACH)

(TRONAIR P/N 1234-001 OR EQUIVALENT)
WARNING
DO NOT ALLOW PERSONNEL TO CRAWL INTO OR ONTO HELICOPTER

WHILE RAISING OR WHILE HELICOPTER IS SUPPORTED ON JACKS.
ROPE OFF AREA AND DISPLAY SIGNS STATING THIS “HELICOPTER ON
JACKS”.
CAUTION
DO NOT PLACE HELICOPTER ON JACKS IF WIND VELOCITY EXCEEDS 20

KNOTS. HEAD HELICOPTER INTO THE PREVAILING WIND.
PROVIDE SUITABLE SURFACE FOR JACKS TO REST ON (LEVEL HARD

SURFACE OR EQUIVALENT).
NOTE
If possible hook the helicopter to a bridge crane.
1. Raise helicopter as follows:
a. Tie down main rotor blades (Chapter 10).
b. Position a jack under each jack fitting (preferred method) or under each forward jack fitting and one aft jack
fitting (alternate method) and raise helicopter clear of floor (figure 1).
c. Operate jack handles slowly and evenly at all positions, being careful to keep helicopter level, as it is raised to
desired height.
2. Lower helicopter as follows:
a. Slowly and carefully lower all jacks simultaneously.
b. Remove jacks and other equipment from area.
07-11-01
Page 1
E-AB412-PT6T-2
G6AB0005A
Figure 1. Hoisting and Jacking
07-11-01
Page 2
E-AB412-PT6T-2
CHAPTER 08 - LEVELING AND WEIGHING

Module Page
Number Title Number
08-00-00 WEIGHT AND BALANCE
1. Weight and balance - general .................................................................................................................. 1
08-21-01 LEVELING HELICOPTER
1. Leveling helicopter - description ............................................................................................................ 1
08-41-01 BALLAST
1. Ballast - removal of nose and cabin ballast (weight) .............................................................................. 1

2. Ballast - installation of nose and cabin (weight) ..................................................................................... 1
3. Ballast - removal of alternate location (codes [A] [B]) of nose and cabin ballast (weight) ................... 2
4. Ballast - installation of alternate location (codes [A] [B]) of nose and cabin ballast (weight) .............. 5
5. Ballast - removal of tail ballast ............................................................................................................... 5
6. Ballast - installation of tail ballast ........................................................................................................... 6
08-Index
Rev. 2 Page 1
E-AB412-PT6T-2
FIGURES
Figure Page
Number Title Number
Figure 1. Tool application - helicopter leveling plumb bob ...........................................................................................2
08-41-01 BALLAST
Figure 1. Nose and cabin ballast (weight) installation (sheet 1 of 2) .............................................................................3

Figure 2. Nose and cabin ballast alternate location installation (codes [A] [B]) (sheet 1 of 2) .....................................7
Figure 3. Tail ballast (weight) installation......................................................................................................................9
08-Index
Page 2 Rev. 2
E-AB412-PT6T-2
08-0 -0 WEIGHT AND BALANCE
08-00-00
WEIGHT AND BALANCE
1. WEIGHT AND BALANCE - GENERAL
The weight and balance calculations for the helicopter must be performed in accordance with the instructions specified in
the manual E-AB412-PT6T-5.
The allowed C.G. location are specified in manual E-AB412-PT6T-1.
08-00-00
Page 1
E-AB412-PT6T-2
08-00-00
Page 2
E-AB412-PT6T-2
08-21-01
LEVELING HELICOPTER
1. LEVELING HELICOPTER - DESCRIPTION
NOTE
Leveling plate (2, figure 1) is marked in increments of 1/4 degree. The leveling plate
is located on cabin floor just inside left passenger cargo door. A slotted hole is
located in upper door frame above leveling plate to support plumb bob (1).
1. Support helicopter as desired (Chapter 7).
2. Hang plumb bob (1) in slotted opening in door frame with point of plumb bob just above leveling plate (2).
3. Adjust height of jacks to bring plumb bob exactly over the point where two lines intersect at zero degrees on leveling
plate (2). The helicopter will then be leveled longitudinally and laterally.
4. After requirement to level helicopter is complete, remove plumb bob.
5. Remove jacks (Chapter 7).
08-21-01
Page 1
E-AB412-PT6T-2
G6AB0603A
Figure 1. Tool application - helicopter leveling plumb bob
08-21-01
Page 2
E-AB412-PT6T-2
08-41-01 BALLAST
08-41-01
BALLAST
1. BALLAST - REMOVAL OF NOSE AND CABIN BALLAST (WEIGHT)
1. Remove ballast (12, figure 1) as follows:
a. Remove battery (Chapter 96).
b. Remove nuts (11 and 14), washers (10 and 13), and eyebolts (3 and 6).
c. Remove bolts (1 and 7), washers (2 and 8), and brackets (5 and 9).
d. Remove pan (4) and ballast (12).
NOTE
Remove ballast in equal amounts from both sides of nose shelf.
2. Remove ballast (21, 33, 34, 35, and 36) as follows:
a. Remove nuts (22), washers (23), bolts (25), and washers (24).
b. Remove nuts (17), washers (18), bolts (30), and washers (29). Remove ballast (21).
c. Remove nuts (15), washers (16), bolts (32), and washers (31). Remove ballast (36).
d. Remove nuts (19), washers (20), blocks (26), washers (27), and bolts (28). Remove ballast (33, 34, and 35).
2. BALLAST - INSTALLATION OF NOSE AND CABIN (WEIGHT)
1. Refer to E-AB412-PT6T-5 for the procedure to determine amount of ballast and location where ballast is installed. If
ballast is installed or removed from tail skid, refer to Chapter 32. To install or remove ballast in nose compartment,
perform the following steps:
2. Install ballast (12, figure 1) as follows:
a. Remove battery (Chapter 96).
b. Remove nuts (11 and 14), washers (10 and 13), and eyebolts (3 and 6).
c. Remove bolts (1 and 7), washers (2 and 8), and brackets (5 and 9).
d. Remove pan (4).
e. Position ballast (12) on shelf.
f. Position pan (4) on ballast (12).
g. Position brackets (5 and 9) on pan (4).
h. Install eyebolts (3 and 6), washers (10 and 13), and nuts (11 and 14).
i. Install bolts (1 and 7) with washers (2 and 8).
j. Install battery (Chapter 96).
08-41-01
Rev. 3 Page 1
E-AB412-PT6T-2
NOTE
Add ballast in equal amounts to both sides of nose shelf.
3. Install ballast (21, 33, 34, 35 and 36) as follows:
a. Remove nuts (22), washers (23), bolts (25), and washers (24).
b. Remove nuts (17), washers (18), bolts (30), and washers (29).
c. Remove nuts (15), washers (16), bolts (32), and washers (31).
d. Remove nuts (19), steel washers (20), blocks (26), washers (27), and bolts (28).
e. Position required ballast on shelf.
NOTE
For ballast installations using less than the maximum configuration, some
installation hardware may not be required.
f. Install bolts (25), washers (24 and 23), and nuts (22).
g. Install bolts (30), washers (29 and 18), and nuts (17).
h. Install bolts (32), washers (31 and 16), and nuts (15).
i. Install bolts (28) washers (27), blocks (26), washers (20), and nuts (19).
3. BALLAST - REMOVAL OF ALTERNATE LOCATION (CODES [A] [B]) OF NOSE AND

CABIN BALLAST (WEIGHT)
NOTE
Remove ballast in equal amounts from both sides of nose compartment.
1. Remove ballast (21 through 25, figure 2) from left side of nose compartment as follows:
a. Remove bolt (9) and washer (10).
b. Remove nut (18), washer (17), bolt (13), and washer (14).
c. Remove bolt (15) and washer (16).
d. Remove nut (20), washer (19), bolt (11), and washer (12).
e. Remove ballast.
2. Remove ballast (32 through 36) from right side of nose compartment as follows:
a. Remove nut (31), washer (30), bolt (3), and washer (4).
b. Remove nut (27), washer (26), bolt (7), and washer (8).
c. Remove bolt (1) and washer (2).
d. Remove nut (29), washer (28), bolt (5), and washer (6).
e. Remove ballast.
08-41-01
Page 2 Rev. 3
E-AB412-PT6T-2
G6AB0604A
Figure 1. Nose and cabin ballast (weight) installation (sheet 1 of 2)
08-41-01
Rev. 3 Page 3
E-AB412-PT6T-2
NOTES:
Maximum ballast is 37.2 kg (82 pounds) per side. Add ballast symmetrically.
Item (12) 212-030-173-9 ballast not included in 74.40 kg (164 pounds) maximum weight.
1. Bolt 19. Nut

2. Aluminum washer 20. Steel washer
3. Eyebolt 21. Ballast (212-030-245-7)
4. Pan 22. Nut
5. Bracket 23. Steel washer
6. Eyebolt 24. Steel washer
7. Bolt 25. Bolt
8. Aluminum washer 26. Block
9. Bracket 27. Steel washer
10. Aluminum washer 28. Bolt
11. Nut 29. Steel washer
12. Ballast (212-030-173-9) 30. Bolt
14. Nut 32. Bolt
15. Nut 33. Ballast (212-030-245-15)
16. Steel washer 34. Ballast (212-030-245-13)
17. Nut 35. Ballast (212-030-245-11)
18. Steel washer 36. Ballast (212-030-245-9)
G6AB0605B
Figure 1. Nose and cabin ballast (weight) installation (sheet 2 of 2)
08-41-01
Page 4 Rev. 3
E-AB412-PT6T-2
4. BALLAST - INSTALLATION OF ALTERNATE LOCATION (CODES [A] [B]) OF NOSE

AND CABIN BALLAST (WEIGHT)
NOTE
The following installation instructions pertain to a maximum ballast configuration.
Some listed hardware may not be required for partial ballast configurations.
1. Install ballast (21 through 25, figure 2) as follows:
a. Position ballast on lower shelf of nose area for installation.
b. Install bolt (9) with washer (10).
c. Install bolt (13), washers (14 and 17), and nut (18).
d. Install bolt (15) with washer (16).
e. Install bolt (11), washers (12 and 19), and nut (20).
2. Install ballast (32 through 36) as follows:
a. Position ballast on lower shelf of nose area for installation.
b. Install bolt (7), washer (8 and 26), and nut (27).
c. Install bolt (3), washers (4 and 30), and nut (31).
d. Install bolt (1) with washer (2).
e. Install bolt (5), washers (6 and 28), and nut (29).
5. BALLAST - REMOVAL OF TAIL BALLAST
NOTE
If tail skid removal is required, refer to Chapter 32.
1. Determine amount of ballast to be removed. Refer to E-AB412-PT6T-5.
2. Remove both light fairings (1, figure 3) (if required) by removing screws (2) and disconnecting electrical connectors.
NOTE
Washer halves (7 and 11) are used only on end of ballast stack as a filler for clamp
halves (5 and 10).
3. Remove tail skid ballast.
a. Remove nuts (9) and bolt (4) from each end of ballast (weight) halves (6 and 12).
b. Remove clamp halves (5 and 10) and washers halves (7 and 11). Remove ballast halves.
c. Install washer halves (7 and 11) and clamp halves (5 and 10) with bolts (4) and nuts (9) on end of remaining
ballast stack. Tighten securely.
4. Connect electrical connectors and install light fairings (1) with screws (2) (if removed).
08-41-01
Rev. 3 Page 5
E-AB412-PT6T-2
6. BALLAST - INSTALLATION OF TAIL BALLAST
NOTE
If tail skid removal is required, refer to Chapter 32.
1. Determine amount of ballast required. Refer to E-AB412-PT6T-5.
CAUTION
MAXIMUM AMOUNT OF BALLAST PERMITTED IS 22,7 KG.
2. Remove both light fairings (1, figure 3) by removing screws (2) and disconnecting electrical connectors.
NOTE
Washer halves (7 and 11) are used only on end of ballast stack as a filler for clamp
halves (5 and 10).
3. Install tail skid ballast.
a. Position ballast (weight) halves (6 and 12), washer halves (7 and 11) and clamp halves (5 and 10) on tail skid (8).
b. Install bolts (4) and secure with nuts (9).
c. Torque nuts (9) 30 to 35 in-lbf (3.4 to 4.0 Nm).
d. Gently tap clamp halves (5 and 10) with a soft mallet and check the torque. Repeat until torque stabilizes.
e. Install additional ballast as required in the same manner.
f. Inspect roll pin (3) for secure installation.
4. Connect electrical connectors and install light fairings (1) with screws (2).
08-41-01
Page 6 Rev. 3
E-AB412-PT6T-2
1. Bolt 13. Bolt 25. Ballast (212-030-245-015)

2. Steel washer 14. Steel washer 26. Steel washer
3. Bolt 15. Bolt 27. Nut
4. Steel washer 16. Steel washer 28. Steel washer
5. Bolt 17. Steel washer 29. Nut
6. Steel washer 18. Nut 30. Steel washer
7. Bolt 19. Steel washer 31. Nut
8. Steel washer 20. Nut 32. Ballast (212-030-245-007)
9. Bolt 21. Ballast (212-030-245-007) 33. Ballast (212-030-245-009)
10. Steel washer 22. Ballast (212-030-245-009) 34. Ballast (212-030-245-011)
11. Bolt 23. Ballast (212-030-245-011) 35. Ballast (212-030-245-013)
12. Steel washer 24. Ballast (212-030-245-013) 36. Ballast (212-030-245-015)
G6AB0607B
Figure 2. Nose and cabin ballast alternate location installation (codes [A] [B]) (sheet 1 of 2)
08-41-01
Rev. 3 Page 7
E-AB412-PT6T-2
NOTES:
Maximum ballast is 37.2 kg (82 pounds) per side. Add ballast symmetrically.
Item (12) 212-030-173-9 ballast not included in 74.40 kg (164 pounds) maximum weight.
G6AB0606B
Figure 2. Nose and cabin ballast alternate location installation (codes [A] [B]) (sheet 2 of 2)
08-41-01
Page 8 Rev. 3
E-AB412-PT6T-2
15
SEE 3
DETAIL A
14 15
2
NOTE:
1 MAXIMUM AMOUNT OF BALLAST Determine number of weights required from text.

PERMITTED IS 22.7 kg Center of ballast location STA 441.0.
5
1. Light fairing
6 1 2 2. Screw
3. Roll pin
7 4. Bolt
5. Clamp half
4 6. Ballast (weight) half
3 7. Washer half
8 8. Tail skid
9. Nut
10. Clamp half
11. Washer half
1 2 12 1.0 IN 12. Ballast (weight) half
(2.54 cm) 13. Decal
14. Ballast (P/N 204-071-566-3)
11 15. Ballast (P/N 204-071-566-1)
13
10
9
DETAIL A
NOTES:
1 Two ballast (weight) halves make a set.
2 Nominal weight of each ballast (weight) half is 6.3 pounds (2.86 kg).
Actual weight is stamped on each ballast (weight) half.
3 204-071-566-1 ballast installation typical three places.
4 204-071-566-3 ballast.
G6AB0608B
Figure 3. Tail ballast (weight) installation
08-41-01
Rev. 3 Page 9
E-AB412-PT6T-2
08-41-01
Page 10 Rev. 3
E-AB412-PT6T-2
CHAPTER 09 - HANDLING AND TAXIING

Module Page
Number Title Number
09-11-01 TOWING
1. Towing - description ............................................................................................................................... 1

2. Towing - preparation for towing helicopter ............................................................................................ 1
3. Towing - removal of ground handling wheels ........................................................................................ 1
4. Towing - installation of ground handling wheels .................................................................................... 2
5. Towing - towing helicopter ..................................................................................................................... 2
09-Index
Rev. 2 Page 1
E-AB412-PT6T-2
FIGURES
Figure Page
Number Title Number
09-11-01 TOWING
Figure 1. Tow bar and ground handling wheels installation ..........................................................................................4

Figure 2. Crosstube strap installation .............................................................................................................................6
09-Index
Page 2 Rev. 2
E-AB412-PT6T-2
TABLES
Table Page
Number Title Number
09-11-01 TOWING
Table 1. Gross weight requiring strapping ................................................................................................................... 5

Table 2. Aft cross tube pretension values ..................................................................................................................... 5
09-Index
Rev. 2 Page 3
E-AB412-PT6T-2
09-Index
Page 4 Rev. 2
E-AB412-PT6T-2
09-1 -01 TOWING
09-11-01
TOWING
1. TOWING - DESCRIPTION
NOTE
When towing the helicopter over the weights indicated in table 1, Gross Weight
Requiring dedicated device.
NOTE
When a strapping method is used, review the draw-up limits of table 2, Aft
Crosstube Pretension Values.
2. TOWING - PREPARATION FOR TOWING HELICOPTER
NUMBER NOMENCLATURE
T46-A TOW BAR
1. Refer to Chapter 52 for installation requirements for access doors, panel, fairings and covers for towing.
2. Tie down main rotor blades (Chapter 10).
3. Attach tow bar (1, figure 1) to skid gear tow ring and tractor pintle hook. Install safety pin in pintle hook.
3. TOWING - REMOVAL OF GROUND HANDLING WHEELS
1. Attach ground wire to helicopter.
2. Retract wheels (2, figure 1) individually to lower helicopter to skid tube (8) by turning pump valve "T" handle.
3. Pull spring-loaded pin (6) to release cradle (5) from skid tube.
4. Move wheels aft (or forward as applicable) to disengage fixed pin (3) from eyebolt. Remove wheels (2) from skid tube
(8).
09-11-01
Rev. 2 Page 1
E-AB412-PT6T-2
4. TOWING - INSTALLATION OF GROUND HANDLING WHEELS
NUMBER NOMENCLATURE
T61 GROUND HANDLING WHEELS
NOTE
Wheels (2, figure 1) can be installed with fixed pin (3) facing either forward or aft.
Also, wheels (2) can be installed with fixed pin (3) facing forward on one side of
helicopter and fixed pin (3) facing aft on opposite side of helicopter. Helicopter
loading (center of gravity) dictates position in which wheels (2) should be installed.
When wheels (2) are lowered, they should be on or near helicopter center of gravity.
If helicopter center of gravity is aft, install both ground handling wheels (2) with
pins (3) facing forward.
1. Position wheels (2, figure 1) over skid tube (8).
2. Insert pin (3) in eyebolt (9).
3. Align cradle (5) with eyebolt (7) and fully insert spring-loaded pin (6) trough cradle (5) and eyebolt (7) to install wheels
(2).
4. Install wheels (2) on opposite skid tube (8) in the same manner.
CAUTION
DO NOT LEAVE HELICOPTER UNATTENDED WITH GROUND HANDLING

WHEELS IN EXTENDED POSITION.
5. Station a person at tailskid to maintain helicopter in level position
6. Operate handle (4) to extend wheels and raise skid gear clear of ground.
7. Disconnect ground wire.
5. TOWING - TOWING HELICOPTER
NUMBER NOMENCLATURE
T21 DROOP RESTRAIN TUBE ASSEMBLY
09-11-01
Page 2 Rev. 2
E-AB412-PT6T-2
WARNING
T O W I N G H E L I C O PT E R W I T H B L A D E S F O L D E D S H A L L B E
ACCOMPLISHED WITH AGUSTAWESTLAND MAIN ROTOR DROOP
R E S T R A I N T T U B E A S S E M B LY ( T 2 1 ) I N S TA L L E D O R W I T H
AGUSTAWESTLAND APPROVED EQUIVALENT.
WARNING
DO NOT START ENGINE POWER SECTION(S) WITH CROSSTUBES

STRAPPED.
CAUTION
TOWING HELICOPTER ON UNPREPARED SURFACES OR ACROSS

HANGAR TRACKS, ETC., EXCEEDING GROSS WEIGHTS SHOWN IN
TABLE 1 MAY CAUSE A PERMANENT SET IN AFT CROSSTUBE. IN AN
EMERGENCY, HELICOPTER MAY BE TOWED UP TO MAXIMUM GROSS
WEIGHT OF 9500 LBS. BY STRAPPING CROSSTUBES TOGETHER. REFER
TO FIGURE 2.
1. Station a person at tail skid to maintain helicopter in level position during towing operations.
2. Clear towing area of auxiliary support equipment (work stands, power units, etc).
3. Tow or push slowly, balancing helicopter with tail skid.
09-11-01
Rev. 2 Page 3
E-AB412-PT6T-2
1. Tow bar
2. Ground handling wheels
3. Fixed pin
4. Handle
5. Cradle assembly
6. Spring loading pin
7. Eyebolt
8. Skid tube
9. Eyebolt
G6AB0638B
Figure 1. Tow bar and ground handling wheels installation
09-11-01
Page 4 Rev. 2
E-AB412-PT6T-2
Table 1. Gross weight requiring strapping
GEAR AFT CROSSTUBE TUBE STRAP AT:

TYPE PART NUMBER DIA WALL — IN GROSS WEIGHT — LBS
STD 412-050-009-103 3.5 x 0.625 9100
HIGH 412-050-010-103 3.5 x 0.625 8900
Table 2. Aft cross tube pretension values
GEAR AFT CROSSTUBE DIA x WALL COL 1 COL 2

TYPE PART NUMBER — in
draw-up limiting
— in 1 draw-up
STD 412-050-009-103 3.5 x 0.625 3.5 102.0 IN

BETWEEN SKID
TUBE
HIGH 412-050-010-103 3.5 x 0.625 6.5 112.5 IN

BETWEEN SKID
TUBE
NOTES:
DO NOT DRAW-UP BEYOND LIMITS IN COLUMN 2

1
2 BASED ON 3/8" DIA. DRAW-UP CABLE.
09-11-01
Rev. 2 Page 5
E-AB412-PT6T-2
CAUTION
DO NOT ATTEMPT TO REDUCE NATURAL GEAR SPREAD WHILE

LOADED. SNUG UP TURNBUCKLE WITH WEIGHT ON SKID TUBES.
REFER TO TABLE 2.
G6AB0639B
Figure 2. Crosstube strap installation
09-11-01
Page 6 Rev. 2
E-AB412-PT6T-2
CHAPTER 10 - PARKING, MOORING AND STORING

Module Page
Number Title Number
10-11-01 PARKING
1. Parking - normal conditions .................................................................................................................... 1

2. Parking - turbulent conditions ................................................................................................................. 1
3. Parking - high wind conditions................................................................................................................ 2
10-21-01 MOORING
1. Mooring - main rotor blade tiedown provisions ..................................................................................... 1

1-1. Main rotor blade tiedown provisions - main rotor non-folded blade tiedown ............................... 1
1-2. Main rotor blade tiedown provisions - folding/unfolding (using droop restraint assembly) ......... 5
1-3. Main rotor blade tiedown provisions - folding/unfolding
(using blade folding kit P/N 412-706-015-101) ............................................................................ 6
10-31-01 STORING
1. Storing - description ................................................................................................................................ 1

2. Storing - environmental conditions ......................................................................................................... 1
3. Storing - flyable storage .......................................................................................................................... 1
4. Storing - short term storage .................................................................................................................... 4
5. Storing - Intermediate storage.................................................................................................................. 9
6. Storing - long term storage ................................................................................................................... 12
10-Index
Page 1
E-AB412-PT6T-2
FIGURES
Figure Page
Number Title Number
10-11-01 PARKING
Figure 1. Loose equipment .............................................................................................................................................3

Figure 2. Main rotor non-folded blade tiedown .............................................................................................................4
10-21-01 MOORING
Figure 1. Main rotor non-folded blade tiedown .............................................................................................................3

Figure 2. Main rotor droop restraint tube assembly .......................................................................................................4
Figure 3. Main rotor blade folding kit (sheet 1 of 3)......................................................................................................8
10-Index
Page 2
E-AB412-PT6T-2
10-1 -01 PARKING
10-11-01
PARKING
1. PARKING - NORMAL CONDITIONS
NOTE
Use this procedure when forecast wind velocity is less than 20 knots.
1. Park helicopter on a level surface.
2. Retract or remove ground handling wheels (6, figure 1) (Chapter 9) to allow helicopter to rest on skid landing gear.
3. Install engine ejector covers (2).
4. Install engine inlet shield assemblies (4).
5. Install pitot tube covers (9).
6. Install main rotor blade tiedown (module 10-21-01 paragraph "1-1-2. Main rotor non-folded blade tiedown -
installation").
CAUTION
DO NOT EXCEED LOAD AND/OR DEFLECTION LIMITS DURING

TIEDOWN PROCEDURES FOR TAIL ROTOR. MAXIMUM LOAD
ALLOWABLE AT BLADE TIP IS 50 LBS.
7. Install tail rotor tiedown strap (3), to tail rotor blade and footman’s loop (not shown) located on the right side of the
tailboom fin.
8. Disconnect battery.
9. Tighten friction locks on flight controls.
10. Close all doors and windows.
2. PARKING - TURBULENT CONDITIONS
NOTE
This procedure to be used when winds are 20 to 45 knots.
1. Park helicopter on a level surface with helicopter headed into direction of highest forecast winds.
2. Accomplish steps 2. through 10. of paragraph "1. Parking - normal conditions".
10-11-01
Page 1
E-AB412-PT6T-2
3. PARKING - HIGH WIND CONDITIONS
NOTE
Use this procedure when forecast wind velocity is 45 to 75 knots. If forecast wind
velocity is in excess 75 knots, evacuate helicopter to a safe area if possible.
1. If a paved ramp with suitably spaced tiedown rings is available, park helicopter on skid landing gear headed in
direction from which highest forecast winds are expected. Secure mooring shackles (4 and 5, figure 2) to ramp tiedown
rings with rope, cable or manufactured tiedowns. If rope diameter is too large for mooring shackles (4 and 5), attach
larger clevis to each mooring shackle.
2. If suitably spaced ramp tiedowns are not available, park helicopter on an unpaved parking area headed in direction
from which highest forecast winds are expected and retract ground handling wheels. Use mooring anchor or make
“dead man” anchors. Moor helicopters as described in step 1.
3. Fill fuel tank with prescribed fuel (Chapter 12).
4. If storage space and time is available, remove main rotor blades and store. If blades cannot be removed, fold main rotor
blades. Install main rotor droop resistant tube assembly (module 10-21-01 paragraph "1-2-1. Folding/unfolding (using
droop restraint assembly) - unfolding"). If main rotor blades cannot be removed or folded, install main rotor blade
tiedown (module 10-21-01 paragraph "1-1-2. Main rotor non-folded blade tiedown - installation").
5. Accomplish steps 3. through 5. and steps 7. through 10. of paragraph "1. Parking - normal conditions".
6. Secure all ground handling equipment and other objects which might be blown by wind.
7. After winds subside, inspect helicopter carefully for damage which may have been inflicted by flying objects.
10-11-01
Page 2
E-AB412-PT6T-2
G6AB0659A
Figure 1. Loose equipment
10-11-01
Page 3
E-AB412-PT6T-2
G6AB0660A
Figure 2. Main rotor non-folded blade tiedown
10-11-01
Page 4
E-AB412-PT6T-2
10-21-01 MOORING
10-21-01
MOORING
1. MOORING - MAIN ROTOR BLADE TIEDOWN PROVISIONS
Main rotor blades may be tied down in non-folded position or in folded position.
1-1. MAIN ROTOR BLADE TIEDOWN PROVISIONS - MAIN ROTOR NON-FOLDED BLADE TIEDOWN
The main rotor tiedown kit for non-folded blades consists of four sock assemblies (2, figure 1) and one wand (3). The nylon
mesh material sock assemblies include a removal loop (18) and tiedown line (17). Each tiedown line includes a tiedown ring
and AFT BLADE flag (15), a tiedown ring and FWD BLADE flag (16) and snap hook (14).
The wand assembly (3) is used to install the socks on rotor blade tips and to remove socks from blade tips.
The rings and flags (15 and 16) may be positioned on tiedown line (17) so proper tension will be applied when sock (6) is
installed without tying knots in line each time a sock is installed.
1-1-1. Main rotor non-folded blade tiedown - removal
1. Unfold wand (3, detail A, figure 1).
2. Open sock removal hook (13).
3. Remove tiedown line from forward mooring shackle (5).
4. Remove sock (6) from blade (1).
5. Remove other three socks in same manner.
6. Stow wand (3) as follows:
a. Unlock lock (11) and slide to top of tube (10).
b. Rotate lock (11) clockwise 90.
c. Fold tube (12) 180 parallel with tube (10) (detail B).
d. Rotate lock (11) counterclockwise 90.
e. Slide lock (11) down and engage end of lower tube (12).
f. Close spreader arms (9).
g. Close sock removal hook (13).
1-1-2. Main rotor non-folded blade tiedown - installation
1. Position blades (1, figure 1) at 45 angle to fuselage so tiedown lines (17) can be secured at forward and aft mooring
shackles (4 and 5). Vary position slightly if necessary to align tail rotor blade for installation of tiedown strap.
2. Apply rotor brake, if installed.
3. Unfold wand (3) (detail A).
10-21-01
Page 1
E-AB412-PT6T-2
4. Unlock lock (11) by pulling up and rotating lock clockwise 90.
5. Rotate lower tube (12) counterclockwise 180.
6. Rotate lock (11) counterclockwise 90.
7. Slide lock (11) down and engage end of lower tube (12).
8. Open spreader arms (9).
9. Spring arms (9) toward each other and at same time insert spreader arms guides (8) into grommets (7) in sock (2).
10. Use wand (3) to position sock (2) on rotor blade as illustrated. Remove wand by pulling down to disengage spreader
arms (9) and guides (8) from sock.
CAUTION
RING (15) MUST BE IN CORRECT P O S I T I O N O N L I N E

( 1 7 , T O RESULT IN NOT MORE THAN 60 LBS. (27 KG) VERTICAL
TENSION IN LINE (17) AND NOT EXCEEDING 40 IN. (101,6 CM)
DEFLECTION OF MAIN ROTOR HUB AND BLADE (MEASURED FROM
STATIC DROOP AT BLADE TIP), WHEN SNAP HOOK (14) IS FASTENED TO
SHACKLE (4). RING (15) ON LINE (17) CAN BE MOVED TO OBTAIN
CORRECT LINE (17) TENSION AND HUB AND BLADE DEFLECTION.
11. Pass snap hook (14) through mooring shackle (4) and fasten to ring (15).
12. Install remaining three socks in same manner, but fasten snap hook (14) to ring (16) when securing forward blades.
1-1-3. Main rotor non-folded blade tiedown - inspection
1. Inspect four sock assemblies (2, figure 1) for deterioration of fabric, deteriorated tiedown line (17), broken or missing
snaps (14), and deteriorated or missing ring, and flags (15 and 16).
2. Inspect wand (3) for distortion, and for proper operation of spreader arms (9), lock (11) and sock removal hook (13).
10-21-01
Page 2
E-AB412-PT6T-2
G6AB0660A
Figure 1. Main rotor non-folded blade tiedown
10-21-01
Page 3
E-AB412-PT6T-2
The main rotor droop restraint assembly (T21) consist of two locking pins (7) two spindle
pins (2), two blade locks (3) and a tube assembly (8).
G6AB0661A
Figure 2. Main rotor droop restraint tube assembly
10-21-01
Page 4
E-AB412-PT6T-2
1-2. MAIN ROTOR BLADE TIEDOWN PROVISIONS - FOLDING/UNFOLDING (USING DROOP

RESTRAINT ASSEMBLY)
The main rotor droop restraint tube assembly consists of two spindle pins, two blade lock assemblies, two pin locks and tube
assembly with attached lifting ring and cables. The main rotor droop restraint supports two opposing blades while in folded
position and prevents folded blade spindles from rotating.
1-2-1. Folding/unfolding (using droop restraint assembly) - unfolding
1. Remove ball lock pin (1, figure 2) from spindle pin (2). Remove spindle pin (2) from blade lock (3) and spindle grip
(6).
2. Remove expandable bolt (4) from blade (5) and blade lock (3) and rotate blade (5) into position in spindle grip (6).
3. Raise handle on expandable bolt (4). Install expandable bolt (4) in trailing edge hole of spindle grip (6) and blade (5).
Push down handle of expandable bolt (4). Latch spring clip of handle. Install safety lock hair pin (not illustrated) to
hold handle in down position.
4. Connect pitch change links associated with folded blades.
5. With hydraulic systems 1 and 2 off, manually raise or lower collective stick to align holes through spindle grip (6),
yoke (9) and fitting (10) (detail A). Remove pin lock (7) from tube assembly (8).
6. Repeat steps 1. through 4. for opposite blade.
7. Using suitable hoist remove tube assembly (8) from main rotor hub.
1-2-2. Folding/unfolding (using droop restraint assembly) - folding
NUMBER NOMENCLATURE
T21 MAIN ROTOR DROOP RESTRAINT ASSEMBLY
CAUTION
WHEN DROOP RESTRAINT TUBE ASSEMBLY IS INSTALLED, DO NOT

TURN HUB ASSEMBLY WITHOUT FIRST DISCONNECTING PITCH
CHANGE LINKS TO PREVENT LOADING OF PITCH CHANGE BEARINGS.
1. Position main rotor hub and blades as shown figure 2. Using suitable hoist position tube assembly (8) on main rotor
hub.
2. With hydraulic systems 1 and 2 off and blades in normal (not folded) position, manually position cyclic stick to
position holes through spindle grips (6) and holes through yoke (9) and fittings (10), with mismatch as equal as
possible (detail A).
3. Install tube assembly (8) using locking pins (7). Raise or lower collective stick as necessary to align holes in spindle
grip, yoke, and fitting.
4. Disconnect pitch change links associated with blades to be folded.
5. Remove safety lock hair pin (not illustrated) from lower end of expandable bolt (4). Raise bolt handle and remove bolt
(4). Partially rotate blade. Place blade lock (3) in position and insert expandable bolt (4) through blade lock (3) and
blade (5). Install spindle pin (2) through blade lock (3) and spindle grip (6).
10-21-01
Page 5
E-AB412-PT6T-2
6. With spindle pin (2) raised slightly, rotate blade (5) until pin (2) can be pushed down into locking hub of blade lock
(3). Secure spindle pin (2) by installing ball lock pin (1) through hole in lower end of spindle pin (2).
7. Opposite blade is folded in same manner.
1-3. MAIN ROTOR BLADE TIEDOWN PROVISIONS - FOLDING/UNFOLDING (USING BLADE FOLDING
KIT P/N 412-706-015-101)
NUMBER NOMENCLATURE
T114 BLADE FOLD RACKS AND SUPPORT EQUIPMENT
The main rotor blade folding kit consists of two blade folding racks with attached struts and blade cradles, and cradle straps.
The aft blade folding rack attaches to hard points on tailboom and the forward blade folding rack attaches to hard points on
nose.
1-3-1. Folding/unfolding (using blade folding kit P/N 412-706-015-101) - folding
1. Ensure collective is lowered and cyclic is approximately centered.
2. Install blade folding racks 1 and 2, figure 3 on the nose and tail.
3. Position blue blade in forward upper cradle (3) and red blade in aft upper cradle (6). Secure blades with cradle straps
(7).
4. Raise cradle height adjustment rods (8) to support blade weight to remove pressure on blade attachment bolts (9).
5. Remove safety pin lock (10, detail C) from bottom of expandable bolt (9). Raise bolt handle and remove expandable
bolts from trailing edge of blue and red blades.
CAUTION
BLUE AND RED BLADES WILL REMAIN IN THEIR CRADLES.
6. Turn main rotor clockwise (viewing from top) so that green blade moves to the front and orange blades moves to rear.
7. Secure blades in lower cradles (4 and 5) with cradle straps.
8. Store expandable bolts (9, detail C) by inserting bolts through trailing holes in spindle grips (11). Push down handle
of expandable bolts. Latch spring clip of handle over end of bolts. Secure with safety pin lock (10).
1-3-2. Folding/unfolding (using blade folding kit P/N 412-706-015-101) - unfolding
CAUTION
FAILURE TO FOLLOW THESE PROCEDURES WILL CAUSE DAMAGE TO

ROTOR AND CONTROL SYSTEMS.
1. Release tail rotor tiedown if installed.
10-21-01
Page 6
E-AB412-PT6T-2
2. Release straps securing green and orange blades.
3. Remove stored expandable bolts (9, figure 3) by removing safety pin lock (10) from spring clip of handle. Unlatch and
pull handle up and bolts out of spindle grips (11).
CAUTION
BLUE AND RED BLADES WILL REMAIN IN THEIR CRADLES.
4. Turn the main rotor counter clockwise (viewing from the top) so that green blade moves aft and orange blade moves
forward to their original position.
5. Install the expandable blade bolts (9) in blue and red blades as follows.
6. Insert bolts through trailing holes in spindle grips (11). Push down handle of expandable bolts.
7. Latch spring clip of handle over end of bolts. Secure with safety pin lock (10).
8. Lower height adjustment rods (8).
9. Remove blade folding racks (1 and 2) from helicopter.
10-21-01
Page 7
E-AB412-PT6T-2
G6AB0985A
Figure 3. Main rotor blade folding kit (sheet 1 of 3)
10-21-01
Page 8
E-AB412-PT6T-2
G6AB0986A
10-21-01
Page 9
E-AB412-PT6T-2
G6AB0987A
10-21-01
Page 10
E-AB412-PT6T-2
10-31-01 STORING
10-31-01
STORING
1. STORING - DESCRIPTION
This section provides preparation procedures to place helicopter in storage for a period of six months or less and
depreservation procedures to activate the helicopter after storage. This procedures is divided into three categories of storage:
flyable storage, short term storage, and intermediate storage.
Storage of helicopter includes corrosion control which consists primarily of preventing moisture from contacting exposed
metal surfaces by the use of preservatives.
2. STORING - ENVIRONMENTAL CONDITIONS
The existing environment conditions and available facilities must be taken into account when helicopter is to be placed in
storage. A choice of storage procedures is permissible for short periods of storage. For example, a choice must be made
between flyable storage and short term storage for any period of time up to 45 days. The decision will be based on such on
site conditions as availability of men and materials, equipment necessary to perform ground run-ups, or motoring of engines,
defueling and purging of fuel cells and other similar elements. Wet weather conditions promotes corrosion, rot, mildew, and
mold. To prevent these deteriorating effects, perform inspections regularly and take proper preventive maintenance action.
The following practices should be used as a guide during exceptionally wet weather conditions:
1. Prevent rot, mildew, and mold from forming on nonmetallic materials by keeping them clean and as dry as possible.
Keep fabric material in the helicopter clean.
2. Treat for visible corrosion in accordance with Appendix I.
3. Keep fuel cells full to reduce condensation in the cells.
4. Store helicopter in a hangar or shed if space permits.
3. STORING - FLYABLE STORAGE
MATERIALS REQUIRED
NUMBER NOMENCLATURE
C-002 HYDRAULIC FLUID
C-126 CORROSION PREVENTIVE COMPOUND
C-304 SOLVENT
C-410 PACKING TAPE
C-427 BARRIER MATERIAL
Flyable storage (no time limit) is the prescribed procedure to maintain a stored helicopter in an operable condition. If daily
use is impossible or impractical, this procedure will keep the helicopter in the best possible condition. It requires periodic
attention. Date and type of storage must be recorded in helicopter records.
10-31-01
Page 1
E-AB412-PT6T-2
1. General preparation.
a. Preservation should be accomplished in an uninterrupted series of operations. When periods of interruption are
necessary, temporary protection shall be provided for partially processed items, as required, to avoid
contamination.
b. The prevention of corrosion depends on the control of moisture. One method is ventilation. On days when the
relative humidity is 55 percent or below, windows and other openings can be temporarily opened to allow
circulation of air through the helicopter. Use fans or blowers when available.
c. Ensure water drain holes are free from obstruction and are kept open for the duration of the storage period.
d. Lubricate the helicopter prior to placing it in storage in accordance with Lubrication Chart in Chapter 12.
2. Preparation.
a. Power train.
(1) Check and service power train system.
b. Engine
(1) Exercise every precaution to keep the engine and accessories clean. Keep the air intake duct, plenum
chamber, and compressor inlet screens clean and free of foreign materials. Clean and preserve engines, as
required.
(2) Start engines. (Refer to E-AB412-PT6T-1 Flight Manual).
(3) Operate the engines for approximately 10 minutes at flight idle speed. Check all instruments for normal
operation and ensure that the engine temperature has stabilized. (Refer to E-AB412-PT6T-1 Flight
Manual).
NOTE
This warm-up may be omitted if the helicopter was recently operated and is known
to be dry.
(4) Allow engines to cool and spray accessible engine surfaces with corrosion preventive compound (C-126).
Clean and preserve engines.
(5) Install engines inlet plug assemblies and exhaust protective covers. If engine covers are not available, seal
the air inlet and exhaust openings with barrier material (C-427) and secure with tape (C-410).
(6) Cover additional engine cowling openings in a similar manner as outlined in preceding step 5.
(7) Record the date engines were placed in flyable storage in helicopter records.
c. Hydraulic system.
(1) Check the hydraulic reservoirs and service as necessary with hydraulic fluid (C-002). (Refer to Chapter 12
for hydraulic reservoir servicing procedure).
d. Fuel system.
(1) Drain water from the fuel cells.
(2) Service fuel cells to normal capacity after each engine preservation run.
NOTE
Fuel cells filled to normal capacity will reduce fuel contamination by condensation.
10-31-01
Page 2
E-AB412-PT6T-2
e. Airframe.
(a) Install pilot tube cover, or if the cover is not available, wrap the pilot tube with barrier material (C-427) and
secure with tape (C-410).
(b) Install helicopter all weather covers, if available.
(c) Open (pull out) all circuit breakers.
(d) Close doors.
(e) Install static ground wire.
3. Maintenance during flyable storage.
a. Helicopters in flyable storage will be inspected and the following instructions.
b. Perform a preventive maintenance storage inspection at least once every 14 day, more frequently if required by
local environmental conditions.
CAUTION
ENSURE THAT IGNITION CIRCUIT BREAKERS ARE OPEN (PULLED OUT)

AND FUEL SHUTOFF VALVE IS CLOSED.
4. To establish an inspection program for storage helicopters E-AB412-PT6T-6, may be used as a guide for areas to be
covered and frequency of inspection. The inspection program shall include the following:
a. When the helicopter protective covers are not available, the areas concerned will be protected with barrier
material (C-427) secured with tape (C-410). Barrier material should be installed to prevent the accumulation of
water on the surface. Provide drains if necessary. Replace barrier materials or protective covers that are damaged
or deteriorated.
b. Determine maximum helicopter interior temperatures during hot weather conditions. This temperature
information can be obtained from standard thermometers temporarily installed in the helicopter. Record interior
temperatures at regular intervals during the hottest part of the day. Ventilate the helicopter if interior temperature
exceeds 135°F (57°C). Provide forced air ventilation if normal ventilation procedures are not adequate to prevent
condensation, mildew, and corrosion.
c. Inspect and treat helicopter for corrosion (refer to Appendix I).
d. Inspect static ground wires, rotor tiedown straps, and mooring devices (ropes, cables, rods, or eyes) at regular
intervals. Inspect tiedown devices immediately after the helicopter has been subjected to winds exceeding 35
knots. Replace ground wires, mooring devices, or tiedown straps which are deformed or deteriorated.
e. If possible, the helicopter should be stored in a hangar or under a shed roof. Otherwise, it should be parked and
moored in accordance with this chapter.
f. Enter the type of storage and the date helicopter was placed in storage in helicopter records.
5. Depreservation and activation
a. Remove protective covers and stow in designated location.
b. Remove all barrier material and tape; remove tape residue with solvent (C-304).
c. Clean helicopter as necessary.
10-31-01
Page 3
E-AB412-PT6T-2
d. Open all doors and ventilate helicopter.
e. Remove main rotor and tail rotor tiedown, if applicable.
f. Perform daily inspection in accordance with E-AB412-PT6T-6.
g. Record the date the helicopter was prepared for service in helicopter records.
h. Remove static ground wire that was installed storage.
4. STORING - SHORT TERM STORAGE
MATERIALS REQUIRED.
NUMBER NOMENCLATURE
C-010 LUBRICATING OIL
C-304 SOLVENT
C-410 PACKING TAPE
C-426 MASKING TAPE
C-598 OIL SPRAY
NUMBER NOMENCLATURE
T101 DEHYDRATOR ASSEMBLY
Short term storage (1 to 45 days) is used to store a helicopter up to 45 days with very little attention during the storage period.
a. Ensure all removed components are preserved and stowed within the helicopter in suitable containers.
b. Ensure a record of all removed or disconnected parts is provided in helicopter records.
c. Check fuel, oil, and hydraulic lines and hoses for leakage or damage.
d. Lubricate the helicopter in accordance with Lubrication Chart, Chapter 12.
e. Ensure bolts, washers, and nuts, which are removed during disassembly, are coated with a light coat of corrosion
preventive compound (C-101) and reinstalled, as removed from the component, unless otherwise specified.
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E-AB412-PT6T-2
f. Record the date and type of storage in helicopter records.
2. Preservation.
a. Engine and power train system.
NOTE
If either engine is operable, complete preservation per steps 1. through 5. If either
engine is inoperable, proceed to step 6.
(1) Prior to engine runup, add corrosion preventive concentrate (C-124) to transmission and tail rotor gearbox
oil systems at a rate of one-half ounce for each quart of oil capacity.
NOTE
Preventive concentrate (C-124) need not to be flushed from transmission and
gearboxes for depreservation and activation.
(2) Preserve engines in accordance with Engine Manufacturer Manual, Chapter 67, Preparation for Storage
and Service.
CAUTION
DO NOT ALLOW SOLVENT TO COME IN CONTACT WITH DRIVESHAFT

BOOTS. CONTAMINATION OF BOOTS WITH SOLVENT WILL REQUIRE
BOOT REPLACEMENT.
(3) Clean the exposed metal surfaces of the power train system with a clean cloth dampened with solvent
(C-304).
(4) Check the power train lubrication system including the sight gages. Service power train lubrication system
in accordance with Chapter 12.
(5) Coat all exposed metal surfaces with corrosion preventive compound (C-101).
(6) Remove transmission oil filler cap and tail rotor gearbox filler cap assembly. Install T101 dehydrator on
transmission and T102 dehydrator on tail rotor gearbox. Cover breather holes in transmission and gearbox
with barrier material (C-427) and secure with type (C-410). The preservation procedures in paragraph "3.
Storing - flyable storage" complete the preservation of transmission and gearbox.
(7) Install engine inlet and exhaust protective covers, or seal openings with barrier material (C-427) and tape
(C-410).
(8) If engine cannot be motored, preserve power train as follows:
(a) Preserve engine fuel system in accordance with engine manufacturers maintenance manual.
(b) Remove main rotor. (Refer to Chapter 62).
(c) Remove mast assembly. (Refer to Chapter 63).
(d) Spray inside of transmission, through top opening, with approximately one gallon of lubricating oil
(C-010). While spraying, manually rotate internal gears and bearings with input drive quill. Spray
lower end of mast and into mast bearing.
(e) Reinstall mast assembly. (Refer to chapter 63). Apply fingerprint remover (C-105), to all unpainted
surfaces of mast assembly. Wipe mast dry with clean lint-free cloth. Apply corrosion preventive
compound (C-101) to all unpainted surfaces.
10-31-01
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E-AB412-PT6T-2
(f) Reinstall main rotor. (Refer to Chapter 62).
(g) Be sure intermediate and tail rotor gearboxes have been filled with lubricating oil (C-101) to the
proper level. Transmission may have become overfilled during step 8.d. If so, drain to proper level.
(h) Cover cowling openings and breather holes in transmission and gearboxes with barrier material
(C-427) and secure with tape (C-410).
(i) Install engine inlet and exhaust protective covers, or seal openings with barrier material (C-427) and
tape (C-410).
b. Fuel system.
(1) Drain any water from the fuel cells. Maintain fuel cells at the full level for the duration of the storage
period. Full cells help reduce fuel contamination by condensation.
c. Hydraulic system.
(1) Fill hydraulic reservoir to overflow with hydraulic fluid (C-002).
(2) Wipe exposed portions of hydraulic actuator piston with lint-free cloth moistened with hydraulic fluid
(C-002).
d. Rotor and controls.
(1) Lubricate rotor system in accordance with Lubrication Chart, Chapter 12.
(2) Apply fingerprint remover (C-105) to all unpainted metal surfaces. Remove any residue of fingerprint
remover with solvent (C-304).
(3) Wipe all parts with clean, lint-free cloth, and apply corrosion preventive compound (C-101) on all
unpainted metal surfaces not in contact with bearings.
(4) Clean main rotor blades.
(5) Apply a light, even coat of (C-598) to entire painted area of rotor blades.
e. Battery.
(1) Disconnect battery and allow to remain in helicopter.
(2) Wrap battery quick-disconnect with barrier material (C-427) and secure with tape (C-410).
f. Instruments.
(1) Install cover on each pitot tube. Add masking tape (C-426) over static ports, as applicable.
g. Avionics equipment.
(1) Remove headset-microphones and store in secure inside storage area.
(2) Leave all other avionic equipment installed in helicopter.
h. Landing gear.
(1) Place blocks or shoring under skid tubes to provide free air passage.
(2) Clean cross tubes and skid tube, and treat for corrosion in accordance with Appendix I.
(3) Repaint any exposed metal surfaces. If the paint system cannot be touched up, coat the bare metal surfaces
with corrosion preventive compound (C-101).
i. Airframe.
(1) Park and moor helicopter with main and tail rotor tiedowns installed.
(2) Close compartment doors.
10-31-01
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E-AB412-PT6T-2
(3) Close and secure all cowling, inspection panels, and covers.
(4) Close all openings, not already covered with barrier material (C-427) and secure with tape (C-410).
(5) Open (pull out) all circuit breakers.
(6) Install static ground wire.
3. Maintenance during short term storage.
a. Perform applicable portions of storage inspection at least once every 30 days and paragraph "3. Storing - flyable
storage" Visually inspect dehydrators for approximation of the degree of saturation of desiccant. If dehydrator
assembly is a dark blue color, this is acceptable. If dehydrator assembly is a light beige or pink color, replace
dehydrator with new unit.
b. If condition change so a helicopter prepared for short term storage must remain in storage for a longer period of
time, represerve the helicopter in accordance with paragraph "5. Storing - Intermediate storage" Do not renew
short term storage.
c. Engines. Refer to engine maintenance manual for preservation and depreservation.
4. Inspection: Perform inspection procedures.
5. Depreservation and activation.
a. Airframe.
(1) Remove protective covers and stow in designated location.
(2) Remove all barrier material and tape; remove tape residue with solvent (C-304).
(3) Open compartment doors and ventilate the helicopter.
(4) Remove main and tail rotor tiedowns.
b. Landing gear.
(1) Remove blocks from under skid gear.
a. Avionics.
(1) Secure headset-microphones from storage area and install in helicopter.
b. Battery.
(1) Remove barrier material ant tape from quick-disconnect plug.
(2) Service and connect battery.
c. Instruments.
(1) Remove pitot covers and store with other protective covers.
(2) Remove barrier material and tape from static vents in airspeed system; remove tape residue with solvent
(C-304).
d. Rotor and controls.
(1) Clean main and tail rotor assemblies with solvent (C-304). Wipe dry with lint-free cloth.
(2) Lubricate in accordance with Lubrication Chart in Chapter 12.
e. Power train assembly.
(1) Remove (T101) dehydrator from transmission and install plug. Remove T102 dehydrators from
intermediate and tail rotor gearboxes and replace filler caps.
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E-AB412-PT6T-2
(2) Fill transmission, and tail rotor gearbox, as necessary, with approved lubricating oil in accordance with
Chapter 12. Install oil cap in transmission and oil filler cap in tail rotor gearbox.
(3) Check and clean transmission oil filters.
CAUTION

BOOTS. CONTAMINATION OF BOOTS WITH SOLVENT WILL REQUIRE
BOOT REPLACEMENT.
(4) Clean driveshafts as necessary with solvent (C-304).
f. Fuel system.
(1) Check fuel cells for the presence of water and drain water as necessary.
(2) Fill fuel cells, as necessary, with approved fuel in accordance with Chapter 12.
g. Hydraulic system.
(1) Clean exposed portion of hydraulic actuator piston with a clean cloth dampened with hydraulic fluid
(C-002) and service reservoirs to full level.
(2) Coat hydraulic actuator piston rods with a light coat of hydraulic fluid (C-002).
h. Engine.
(1) Refer to Engine Maintenance Manual.
i. Miscellaneous.
(1) Clean helicopter as necessary.
(2) Ensure all removed components have been reinstalled on the helicopter. Check helicopter records for
components that have been removed or disconnected. Check for subsequent installation or connection.
(3) Ensure systems have been properly depreserved and serviced before any system or component operational
check is performed.
(4) Perform necessary inspection required in accordance with E-AB412-PT6T-6.
(5) Remove static ground wire that was installed for storage.
(6) Record the date the helicopter was prepared for service in helicopter records.
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Page 8
E-AB412-PT6T-2
5. STORING - INTERMEDIATE STORAGE
MATERIALS REQUIRED.
NUMBER NOMENCLATURE
C124 CORROSION PREVENTIVE COMPOUND
C-304 SOLVENT
C-410 PACKING TAPE
NUMBER NOMENCLATURE
Intermediate storage (46 to 180 days) is the type storage to be used for helicopters that will be inactive for more than 45 days
but not exceeding 180 days.
NOTE
The corrosion preventive concentrate is effective only if it is completely mixed with
the oil so as to coat all surfaces. Run up the engine to provide power to the
transmission, intermediate, and tail rotor gearboxes until the normal operating
temperature is reached. Run at this temperature for 5 minutes minimum.
a. Prior to engine runup add corrosion preventive concentrate (C-124) to transmission and gearbox oil systems at
the rate of one-half ounce of corrosion preventive concentrate for each quart of oil capacity. Flushing of
transmission and gearbox oil systems is not required during depreservation and activation of helicopter.
2. General inspection.
a. Inspect the helicopter in accordance with E-AB412-PT6T-6 and as follows:
(1) Ensure all removed components are preserved and either stowed in the helicopter or at a designated
location as prescribed in the respective paragraph.
(2) Main rotor blades will be removed and placed in a storage container and stored under cover.
(3) Ensure a record of all removed or disconnected components is entered in helicopter records.
(4) Check fuel, oil, and hydraulic lines and hoses for leakage.
(5) Lubricate the helicopter in accordance with Lubrication Chart, Chapter 12.
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E-AB412-PT6T-2
(6) Ensure bolts, washers, and nuts, which are removed during disassembly are coated with a light coat of
corrosion preventive compound (C-101) and reinstalled, as removed, from the component, unless
otherwise specified.
b. Record the type and date of storage in helicopter records.
3. Preservation.
a. Preserve the engine and power train system in accordance with paragraph "4. Storing - short term storage"
b. Preserve the engine in accordance with Engine Maintenance Manual.
c. Fuel system.
(1) Drain and purge fuel cells. (Refer to Chapter 12).
d. Hydraulic system.
(1) Process the hydraulic system for storage in accordance with paragraph "4. Storing - short term storage".
e. Main rotor and controls.
(1) Main rotor and controls will be preserved in accordance with paragraph "4. Storing - short term storage".
Main rotor blades will be removed, preserved in accordance with paragraph "4. Storing - short term
storage", step 2.(d), placed in a storage container, and stored under cover.
f. Battery.
(1) Remove battery and store in appropriate storage area.
(2) Clean battery compartment and accessories in accordance with battery manufacturers manual. Service and
store battery.
(3) Wrap battery quick-disconnect plug with barrier material (C-427) and secure with tape (C-410).
g. Instruments.
(1) Process instruments in accordance with paragraph "4. Storing - short term storage".
h. Avionic equipment.
(1) Process avionic equipment in accordance with paragraph "4. Storing - short term storage".
i. Utility equipment.
(1) Remove, apply tag, and store first aid kits and other equipment subject to mildew or deterioration in a
secure storage area.
j. Landing gear.
(1) Process landing gear in accordance with paragraph "4. Storing - short term storage".
k. Airframe.
(1) Park and moor helicopter with tail rotor tiedown installed.
(2) Close and secure all cowling, inspection panels, and covers.
(3) Close all openings in the fuselage, not already covered with barrier material (C-427) and secure with tape
(C-410).
(4) Open (pull out) all circuit breakers.
(5) Install static ground wire.
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E-AB412-PT6T-2
4. Maintenance during intermediate storage.
a. Helicopters in intermediate storage will be inspected in accordance with E-AB412-PT6T-6 and the following:
(1) Perform applicable portion of a storage inspection performed at least once every 30 days in accordance
with maintenance manual. Visually inspect dehydrator assembly for approximation of the degree of
saturation of dessicant. If dehydrator assembly is a dark blue color, this is acceptable. If the dehydrator
assembly is a light beige or pink color, replace dehydrator with a new unit.
(2) If conditions change so a helicopter prepared for intermediate storage must remain in storage for a longer
period of time, represerve the helicopter.
b. Engine.
5. Inspection: Perform inspection procedures in accordance with paragraph "3. Storing - flyable storage".
6. Depreservation and activation.
a. Airframe.
(1) Remove protective covers and stow in designated location.
(2) Remove all barrier material and tape; remove tape residue with solvent (C-304).
(3) Open all doors and ventilate helicopter.
(4) Remove tail and main rotor tiedowns.
b. Landing gear.
(1) Remove blocks from under skid gear.
c. Avionics.
(1) Remove headset-microphones from storage and install in helicopter.
d. Instruments.
(1) Remove pitot covers and store with other protective covers.
(2) Remove barrier material and tape from static vents in airspeed system; remove tape residue with solvent
(C-304).
e. Battery.
(1) Remove battery from storage, service and install in helicopter.
(2) Remove barrier material and tape from quick-disconnect plug.
(3) Connect battery.
f. Rotor and controls.
(1) Clean main and tail rotor assemblies with solvent (C-304). Wipe dry with lint-free cloth.
(2) Install main rotor blades.
(3) Lubricate in accordance with Lubrication Chart, Chapter 12.
g. Utility equipment.
(1) Remove first aid kit(s) and other equipment from storage and install in helicopter.
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E-AB412-PT6T-2
h. Hydraulic system.
(1) Clean exposed portion of hydraulic actuator piston with clean cloth dampened with hydraulic fluid
(C-002).
(2) Coat hydraulic actuator piston rods with a light coat of hydraulic fluid (C-002).
(3) Service hydraulic reservoirs. (Refer to Chapter 12).
i. Fuel system.
(1) Fill fuel cells with approved fuel in accordance with Chapter 12.
(2) Accomplish engine fuel system priming in accordance with Engine Maintenance Manual.
j. Power train assembly.
(1) Remove transmission and tail rotor gearbox, dehydrator assemblies T101 and T102. Fill transmission and
tail rotor gearbox with lubricating oil (C-010) in accordance with servicing diagram in maintenance
manual. Install oil filler cap in transmission and oil filler cap assembly in tail rotor gearbox assembly.
(2) Check and clean transmission oil filters.
CAUTION

BOOTS CONTAMINATION OF BOOTS WITH SOLVENT WILL REQUIRE
BOOT REPLACEMENT.
(3) Clean driveshafts as necessary with solvent (C-304).
k. Engine.
l. Miscellaneous.
(1) Clean helicopter as necessary.
(2) Ensure all removed components have been reinstalled. Check helicopter records for record of components
that have been removed or disconnected. Check for subsequent installation or connection.
(3) Ensure systems have been properly depreserved and serviced before any system or component operational
check is performed.
(4) Perform any necessary inspections required in accordance with E-AB412-PT6T-6.
(5) Remove static ground wire that was installed for storage.
(6) Record the date the helicopter was prepared for service in helicopter records.
6. STORING - LONG TERM STORAGE
For storage beyond 180 days renew intermediate storage procedures in accordance with paragraph "5. Storing - Intermediate
storage".
10-31-01
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E-AB412-PT6T-2
CHAPTER 11 - PLACARDS AND MARKINGS

Module Page
Number Title Number
11-01-01 DECALS APPLICATION
1. Decals application - description............................................................................................................... 1
11-Index
Page 1
E-AB412-PT6T-2
11-Index
Page 2
E-AB412-PT6T-2
1 -01-01 DECALS APPLICATION
11-01-01
DECALS APPLICATION
1. DECALS APPLICATION - DESCRIPTION
MATERIALS REQUIRED
NUMBER NOMENCLATURE
C-233 POLYURETHANE ENAMEL
C-305 ALIPHATIC NAPHTHA
C-306 TOLUENE
C-349 EDGE SEALER
C-385 ISOPROPYL ALCOHOL
C-426 MASKING TAPE
C-516 CLEAN CLOTH
NOTE
Bonding surfaces must be nonporous.
1. Remove dirt, grease, wax, or other contaminants from the surfaces to be bonded, as follows:
a. For non-metallic and painted surfaces, clean with a cloth moistened with aliphatic naphtha (C-305). Dry the
surfaces with a clean cloth (C-516) before the aliphatic naphtha (C-305) evaporates.
CAUTION
DO NOT ALLOW TOLUENE (C-306) TO MAKE CONTACT WITH PAINTED

OR NON METALLIC SURFACES. DAMAGE TO THE SURFACE MAY
OCCUR.
b. For bare metal surfaces, clean with a clean cloth moisted with toluene (C-306). Dry the surfaces with a clean
cloth (C-516) before toluene (C-306) evaporates.
2. Apply the pressure-sensitive (adhesive-backed) decal to the bonding surface, as follows:
a. Apply the decal at temperatures above 60° F (16°C) for best results. Otherwise, first apply solvent (refer to the
manufacturer’s instructions) or isopropyl alcohol (C-385) to the decal.
b. Remove the adhesive protection from one edge of the decal with a quick smooth movement.
c. Carefully align the decal in the correct position.
11-01-01
Page 1
E-AB412-PT6T-2
d. Put the peeled edge of the decal on the edge of the bonding surface and apply firm pressure with your finger
along the same edge.
NOTE
For application of large decals, use a plastic squeegee with a firm pressure.
e. While you continue to remove the adhesive protection, apply finger pressure to the remaining part of the decal
until the entire decal is applied. For the best result, hold the opposite edge away from the surface until the entire
decal is applied.
f. Make sure there are no air bubbles trapped under the decal. Otherwise, make a hole in the bubble with a pin and
press with your finger or a squeegee to remove the air.
3. Edge seal or fully coat the decal with the applicable coating, as follows:
a. Apply masking tape (C-426) 1/8 inch (3 mm) away from the edge and all around the decal.
NOTE
A clear polyurethane enamel (C-233) may be used to seal decals applied to all types
of exterior finishes.
b. For the sealing of exterior decals, apply the same material for the exterior painting. For example, if the exterior
paint is polyurethane enamel (C-233), then use a clear polyurethane enamel (C-233).
c. For the sealing of interior decals, apply a clear decal sealer (C-349).
d. Remove the masking tape (C-426) from around the decal when the coating is dry.
11-01-01
Page 2
E-AB412-PT6T-2
CHAPTER 12 - SERVICING

Module Page
Number Title Number
12-00-00 SERVICING
1. Servicing - general .................................................................................................................................. 1
12-11-01 MAIN FUEL SYSTEM
1. Main fuel system - description ................................................................................................................ 1

2. Main fuel system - fueling/defueling preparation ................................................................................... 1
3. Main fuel system - fueling ...................................................................................................................... 2
4. Main fuel system - defueling .................................................................................................................. 3
5. Main fuel system - purging fuel cells ..................................................................................................... 4
6. Main fuel system - long range fuel cells (160 gallon - 606 liter), kit no. 412-706-007-101/103
(if installed) ............................................................................................................................................. 5
12-12-01 ENGINE OIL SYSTEM
1. Engine oil system - description ............................................................................................................... 1
12-13-01 HYDRAULIC SYSTEMS AND FLIGHT CONTROLS
1. Hydraulic system - description ............................................................................................................... 1

2. Hydraulic system - rotor brake servicing ................................................................................................ 1
3. Hydraulic system - change of hydraulic fluid specification ................................................................... 2
12-14-01 TRANSMISSION OIL SYSTEM
1. Transmission oil system - description .................................................................................................... 1

2. Transmission oil system - seepage rates ................................................................................................. 1
12-15-01 TAIL ROTOR AND INTERMEDIATE GEARBOX OIL SYSTEM
1. Tail rotor and intermediate gearbox oil systems - description ................................................................ 1

2. Tail rotor and intermediate gearbox oil systems - seepage rates ............................................................ 1
3. Tail rotor and intermediate gearbox oil systems - changing oil brands or type ...................................... 1
12-16-01 GROUND WHEEL ACTUATOR OIL SYSTEM
1. Ground wheel actuator oil system - description ..................................................................................... 1
12-17-01 BATTERY SERVICING
1. Battery servicing - description ................................................................................................................ 1
12-18-01 RESCUE HOIST (212-8800-01-1019) GEARBOX OIL SYSTEM [B]
1. Rescue hoist (212-8800-01-1019) gearbox oil system [B] - description ................................................ 1
12-Index
Rev. 3 Page 1
E-AB412-PT6T-2
CONTENTS - MAINTENANCE PROCEDURES (CONT.D)

Module Page
Number Title Number
12-21-01 LUBRICATION
1. Lubrication - description .........................................................................................................................1

2. Lubrication - lubricant (204-040-755-005) restrictions ..........................................................................2
3. Lubrication - flex coupling lubrication log .............................................................................................3
12-Index
Page 2 Rev. 3
E-AB412-PT6T-2
FIGURES
Figure Page
Number Title Number
12-00-00 SERVICING
Figure 1. Servicing locations ......................................................................................................................................... 4
Figure 1. Rotor brake servicing...................................................................................................................................... 7
Figure 1. Lubricating points (sheet 1 of 4)..................................................................................................................... 7
12-Index
Rev. 3 Page 3
E-AB412-PT6T-2
TABLES
Table Page
Number Title Number
12-00-00 SERVICING
Table 1. Servicing .........................................................................................................................................................2
Table 1. Lubrication chart .............................................................................................................................................3

Table 2. Flex couplings lubrication log (example only) ...............................................................................................6
12-Index
Page 4 Rev. 3
E-AB412-PT6T-2
12-0 -0 SERVICING
12-00-00
SERVICING
1. SERVICING - GENERAL
CAUTION
STRAINED OR DISCOLORED SIGHT GAGE GLASSES MAY GIVE FALSE

INDICATION OF OIL/FLUID QUANTITY. IF FALSE INDICATION IS
SUSPECTED, SHAKE HELICOPTER BY TAIL SKID AND OBSERVE SIGHT
GAUGE OIL/FLUID MOVEMENT. REPLACE ANY SIGHT GAUGE GLASS
THAT DOES NOT PROVIDE ADEQUATE INDICATION OF FLUID LEVEL.
This chapter contains instructions to replenish fuel, lubricating oil, hydraulic fluid, and to lubricate the helicopter. Defueling
and fuel cell purging instructions are also included.
In figure 1 are identified servicing points, defueling and drain valve locations. In table 1 are specified usable materials for
fuel, lubricating oil, hydraulic fluid, battery, fire extinguishers.
12-00-00
Rev. 3 Page 1
E-AB412-PT6T-2
Table 1. Servicing
FUEL
RESERVOIRS TYPE OF MATERIAL CAPACITY
TO BE NATO U.S.
SPECIFICATION GRADE Liters REMARKS
SERVICED SYMBOLS Gals.
[A] [B] Main cells MIL-T-5624 and CPW 204** JP-4* F-40 810 214 *Alternate fuel
MIL-T-5624, grade
JP-5 (NATO F-44)
[C] [D] Main cells MIL-T-5624 and CPW 204** JP-4* F-40 1277 1277 337.5
Auxiliary tanks MIL-T-5624 and CPW 204** JP-4* F-40 617 163 ** Commercial
(long range) specification ASTM
D—1655 Jet A, Jet
A—1, Jet B
Auxiliary tanks MIL-T-5624 and CPW 204** JP-4* F-40 140 37
(seat type)
LUBRICANTS
RESERVOIRS TYPE OF MATERIAL CAPACITY
TO BE NATO U.S. REMARKS
SPECIFICATION Liters
SERVICED SYMBOLS Gals.
Transmission MIL-L-23699B* 0-156 10.4 2.70 *Alternate
Engine No. 1 MIL-L-23699B and PWA 0-156 6.1 1.6 MIL-L-7808E (NATO
0-148)
521**
Engine No. 2 MIL-L-23699B and PWA 0-156 6.1 1.6 **For commercial
equivalent oils refer to
521** E-AB412-PT6T-1 and
Engine combining MIL-L-23699B and PWA 0-156 4.7 1.2 Pratt and Whitney
gearbox aircraft engine service
521** bulletin No. 5001.
42° gearbox MIL-L-23699B* 0-156 0.18 0.04
90° gearbox MIL-L -23699B* 0-156 0.24 0.06 (See NOTES).
[B] Rescue hoist MIL-L-23699* 0-156 0.3 0.08 MIL-L-7870 oil
gearbox (when available) is to
Rescue hoist MIL-L-7808 0-148 0.3 0.08 be preferred.
gearbox
(BL20200)
HYDRAULIC FLUID
RESERVOIR TO MATERIAL NATO CAPACITY
BE SERVICED SPECIFICATION SYMBOLS Liters U.S. Gals.
No. 1 hydraulic system MIL-PRF-5606 *** H-515 4.5 plus 2.5 1.2 plus 0.65
(Reservoir) (Reservoir)
*** Do not substitute other
hydraulic fluids. Comply
with Note 8.
No. 2 hydraulic system MIL-PRF-5606 *** H-515 4.7 plus 2.5 1.25 plus 0.65
(Reservoir) (Reservoir)
*** Do not substitute other
hydraulic fluids. Comply
with Note 8.
[B] [C] No. 3 hydraulic system MIL-PRF-5606 H-515 5.0 1.32
Handling wheels MIL-PRF-5606 H-515 0.6 0.16
Rotor brake (lf installed) MIL-PRF-5606 H-515 0.47 0.12
12-00-00
Page 2 Rev. 3
E-AB412-PT6T-2
(Cont.d)
NOTES:
1. Change oil in engine power sections and combining gearbox at intervals stated in Pratt and Whitney Aircraft of
Canada PT6T-3B maintenance manual, but if spectrometric oil analysis is not used, change oil filter at 400 hours or
9 months, whichever comes first.
2. Make entry in helicopter and engine log books to indicate type oil used to service engine, transmission, etc. to
prevent subsequent servicing with a different type of oil.
3. Do not use MIL-L-23699, ASTO 555, Royco 500 or Royco 555 lubricating oil when ambient temperature falls
below -40 °F (-40 °C).
4. Do not mix MIL-PRF-7808 (C-010), MIL-PRF-23699 (C-011), DOD-PRF-85734 (C-030) type oils, or other
lubricating oils. If oil does become mixed (by adding oil of a different type) or if oil type must be changed due to
availability of oil currently being used, or oil change is required due to climatic conditions, comply with the
following:
a. Drain lubricating oil from system. Inspect and clean filter and strainers in affected system.
b. Fill oil system with lubricating oil to be used.
c. Operate system for a period of 30 minutes to 1 hour to heat oil to operating temperature. Shut down engine.
d. Inspect and clean system oil filters and strainers. If heavy contamination of filters and strainers is noted, repeat
steps a through d. If little or no contamination of filers and strainers is noted, release helicopter for service and
proceed with steps e. and f.
e. Operate helicopter for 5 hours and inspect and clean system oil filters and strainers. If no unusual
contamination is noted, continue with step f.
f. Operate helicopter for 10 hours (for a total of 15 hours after completion of step d. and inspect and clean system
oil filters and strainers. If no unusual contamination is noted, return to normal inspection interval.
5. Use lubrication oils listed in list 2 and/or other oils listed in E-AB412-PT6T-1 in the helicopter transmission and
gearboxes.
6. Change oil and filter in transmission every 1/2 TBO hours or 12 months, whichever comes first. (Refer to
E-AB412-PT6T-6).
7. Change oil in intermediate and tail rotor gearboxes at 300 hours or 180 days, whichever comes first.
NOTE
When adding hydraulic fluid, the same specification of hydraulic fluid already
used in the hydraulic systems shall be used. However, in circumstances where
emergency top-off or inadvertent mixing may occur, it is acceptable to use
hydraulic fluid of the other approved specification. No further maintenance action
will be required.
8. The helicopters were initially filled with hydraulic fluid MIL-PRF-5606 (C-002). At initial hydraulic fluid
conversion from MIL-PRF-5606 (C-002) to MIL-PRF-87257 (C-072) it is recommended the replace of old decals
with appropriate new decals. To change the specification of hydraulic fluid, refer to module 12-13-01 paragraph "3.
Hydraulic system - change of hydraulic fluid specification". Make an entry in the helicopter log book to indicate the
specification of hydraulic fluid used to service hydraulic systems and the rotor brake to prevent subsequent servicing
with a different specification of hydraulic fluid.
12-00-00
Rev. 3 Page 3
E-AB412-PT6T-2
G6AB0850A
Figure 1. Servicing locations
12-00-00
Page 4 Rev. 3
E-AB412-PT6T-2
12-1 -01 MAIN FUEL SYSTEM
12-11-01
MAIN FUEL SYSTEM
1. MAIN FUEL SYSTEM - DESCRIPTION
The main fuel system includes interconnected cells which are serviced through a single filler located on right side of
helicopter. Two grounding jacks are located near the filler port.
An electrically operated sump drain valve, a manual sump drain valve, and a defuel valve are mounted on each sump plate.
The sump plate is accessible through access panels on each side of bottom of helicopter. Button-type fuel drain valve
switches which actuate sump drain valves are mounted under passenger/cargo doors on each side of helicopter.
2. MAIN FUEL SYSTEM - FUELING/DEFUELING PREPARATION
WARNING
USE EXTREME CAUTION DURING FUELING/DEFUELING PROCEDURES.

FUEL IS EXTREMELY FLAMMABLE AND MAY BE IGNITED BY STATIC OR
FRICTION SPARKS, HOT EXHAUST PIPES, LIGHTED CIGARETTES,
ELECTRICAL DEVICES OR SIMILAR IGNITION SOURCES.
PERSONNEL SHOULD NOT BE ABOARD HELICOPTER DURING FUELING/

DEFUELING PROCEDURES.
WHEN HELICOPTER FUEL COMES IN CONTACT WITH SKIN, A SOLVENT

ACTION OCCURS WHICH REMOVES NATURAL FATS AND OIL THAT MAY
EXPOSE THE SKIN TO INFECTIOUS DERMATOSIS. EXTENSIVE VAPOR
I N H A L AT I O N M AY C A U S E S E R I O U S I L L N E S S . A C C I D E N TA L
SWALLOWING OF FUELS WILL RESULT IN INTERNAL INJURY AND
POSSIBLY DEATH. PERSONNEL WHO ARE SUBJECTED TO SPLASHED OR
SPRAYED FUEL SHOULD REMOVE CONTAMINATED CLOTHING AS
S O O N A S P OS S I B L E A N D WA S H D O W N/ S H O W E R W I T H L AR G E
AMOUNTS OF WATER. DO NOT REMOVE CONTAMINATED CLOTHING
NEAR POTENTIAL IGNITION SOURCES.
1. Allow only qualified personnel engaged in fueling/defueling operations in the area. Allow no one to carry matches,
cigarette lighters, or other sparking or flame producing devices in the area.
2. Do not perform fueling/defueling operations when high winds are considered hazardous or when electrical storms are
within 3 miles (5 kilometers) of the area.
3. Do not allow personnel fueling/defueling the helicopter to wear shoes with protruding nails or taps, or static producing
clothing such as nylon, rayon or wool.
4. Do not perform fueling/defueling near a drainage ditch or similar low place where combustible vapors may
accumulate.
5. Do not perform fueling/defueling in a hanger. Position helicopter at least 50 ft (15 m) from any building or smoking
area, and at least 500 ft (152 m) from any radar system.
12-11-01
Rev. 3 Page 1
E-AB412-PT6T-2
6. Do not allow another aircraft to operate within 100 ft (30 m) of the area.
7. Position servicing unit as far from helicopter as hose will permit, and such that it may be driven or towed away in case
of an emergency. Set parking brake.
8. Position a fully charged 50 lb (22 kg) CO2 fire extinguisher with an extension assembly in an accessible place. Ensure
fire extinguishers on service unit are readily available.
9. Maintain clear paths for immediate evacuation of personnel and vehicles in case of emergency.
10. Do not allow other aircraft within 20 ft (6 m) of helicopter.
11. If fuel cell filler cap is to be removed for any reason other than fueling, grasp helicopter grounding jack adjacent to
fuel cell filler cap with bare hand to dissipate static electricity prior to removing cap.
WARNING
ACCOMPLISH THE BONDING PROCEDURES IN THE FOLLOWING STEP IN

ORDER LISTED OR STATIC ELECTRICITY MAY CAUSE FUEL TO IGNITE
AND CAUSE INJURY OR DAMAGE TO EQUIPMENT.
12. Bond fueling/defueling equipment and helicopter as follows prior to removing fuel hose filler dust cap and/or
helicopter fuel cell filler cap or prior to using defueling valve.
a. Bond fueling equipment to the helicopter by use of a cable.
b. Bond fuel hose nozzle with a nozzle bonding cable to one of the helicopter grounding jacks.
3. MAIN FUEL SYSTEM - FUELING
1. Accomplish fueling preparation steps outlined in paragraph "2. Main fuel system - fueling/defueling preparation".
2. Ensure helicopter electrical power is off. If electrical power is required, turn BATTERY BUS 1 and 2 switches ON and
position remaining switches as required prior to start of fueling operation. Do not accomplish further switching until
fueling is complete except as required by an emergency condition.
3. Confirm fuel in fueling vehicle is correct type prior to refueling. Refer to module 12-00-00 table 1 for list of approved
fuels.
NOTE
Comply with bonding instructions in paragraph "2. Main fuel system - fueling/
defueling preparation", step 12., prior to accomplishing following steps.
4. Remove fuel hose nozzle dust cap.
5. Remove fuel cell filter cap.
CAUTION
DO NOT LEAVE NOZZLE UNATTENDED AT ANY TIME DURING

REFUELING OPERATION.
6. Fill fuel cells and then remove hose nozzle from fuel cell.
12-11-01
Page 2 Rev. 3
E-AB412-PT6T-2
7. Install filler cap and nozzle dust cap.
8. Place BATTERY BUS switches and required system switches to OFF, if required.
9. Remove fuel hose nozzle bonding cable from helicopter grounding jack.
10. Remove bonding cable from helicopter and fueling equipment.
11. In the event of a fire emergency, accomplish the following as quickly as possible.
a. Stop fuel flow.
b. Separate helicopter and service unit.
c. Sound alarm.
d. Attempt rescue and contain fire.
4. MAIN FUEL SYSTEM - DEFUELING
1. Accomplish defueling preparation steps outlined in paragraph "2. Main fuel system - fueling/defueling preparation".
NOTE
If helicopter is being defueled with defueling type vehicle, accomplish steps 1.
through 15.
NOTE
If helicopter is being defueled with boost pumps, accomplish step 16.
2. Notify fire department of defueling operation, location, anticipated start time and estimated time of completion.
3. Ensure all electrical power is off.
NOTE
Comply with bonding instructions in paragraph "2. Main fuel system - fueling/
defueling preparation", step 12., prior to accomplishing the following steps.
4. If helicopter is being defueled because of accident, or incident, or if quality of fuel is questionable, sample and test
drained fuel. Dispose of fuel or return fuel to storage as test results indicate.
NOTE
Comply with grounding instructions in paragraph "2. Main fuel system - fueling/
defueling preparation", step 12., prior to accomplishing the following steps.
5. Ensure all helicopter electrical power is off. If electrical power is required, turn BATTERY BUS switches ON and
position other switches as required prior to starting defueling operation. Do not accomplish additional switching until
defueling is complete except as required by an emergency condition.
6. Remove filler cap and insert defueling tube/hose into helicopter fuel cell or attach defueling hose to defueling valve
on sump with MS33656E12 fitting.
7. Pump fuel from helicopter. Stop pump as soon as fuel flow stops.
8. Remove defueling tube/hose and replace filler cap. Disconnect defuel tube/hose ground wire from helicopter.
12-11-01
Rev. 3 Page 3
E-AB412-PT6T-2
9. Remove access plates under fuel cell sumps.
10. Position suitable container under helicopter.
11. Remove plugs from defuel valves.
12. If aft cells were defueled through filler cap in step 5., attach defueling hose to defueling valve on sump with
MS33656E12 fitting and remove remaining fuel.
13. Disconnect cable from helicopter and defueler equipment. Move defueler away from helicopter.
14. Dispose of fuel as noted in step 4.
15. Purge fuel cells as outlined in paragraph "5. Main fuel system - purging fuel cells".
16. Defuel with helicopter boost pumps as follows:
a. Accomplish steps 2. through 5. above.
b. Disconnect engine fuel pressure hose above engine deck. Connect a suitable hose to engine fuel pressure
connection that will transfer fuel to a suitable container or servicing unit.
c. Open fuel cell interconnect valves and actuate appropriate boost pump to pump fuel out of helicopter.
d. Shut off boost pump as soon as fuel flow stops.
e. Attach defueling hose to defueling valve on sump with MS33656E12 fitting and remove remaining fuel.
f. Install hose disconnected in step b.
g. Disconnect grounding cables.
h. Dispose of fuel as noted in step 4.
i. Purge fuel cells (paragraph "5. Main fuel system - purging fuel cells").
5. MAIN FUEL SYSTEM - PURGING FUEL CELLS
MATERIALS REQUIRED
NUMBER NOMENCLATURE
C-426 MASKING TAPE
WARNING
O N A S T I L L D AY ( N O W I N D C O N D I T I O N ) , F U E L VA P O R C A N
ACCUMULATE IN AREA OF HELICOPTER (EVEN IN AN OPEN AREA),
POSSIBLY PRODUCING AN EXPLPOSIVE MIXTURE. UNDER THIS
CONDITION, PERSONNEL SHOULD BE CLEARED FROM AREA EVEN
AFTER PURGE LINES ARE INSTALLED AND INERT GAS IS FLOWING
UNTIL EIGHT HOURS OF PURGING IS COMPLETED.
1. Defuel helicopter (paragraph "4. Main fuel system - defueling").
12-11-01
Page 4 Rev. 3
E-AB412-PT6T-2
NOTE
Use dry, filtered, compressed air, or inert gas (nitrogen or carbon dioxide) as
outlined in steps 2. and 3.
2. Purge fuel cells using dry, filtered, compressed air as follows:
a. Open all sump drains and drain lines.
b. Insert compressed air hose in cell filler inlet under cap and seal with masking tape (C-426).
c. Blow air through cell at 60 to 100 psi (414 to 689 kPa) for a period of eight hours.
d. Remove air hose from cell inlet. Wait one hour.
e. Check interior of fuel cell with explosimeter (combustible gas indicator calibrated for fuel vapors) for level of
vapors.
f. Explosimeter reading shall be less than 20% on the Lower Explosion Limit (LEL) scale. If reading is more than
20%, repeat steps a. through c. until reading is less than 20%.
3. Purge fuel cells using inert gas (nitrogen or carbon dioxide) as follows:
WARNING
REMOVE FIBER HORN WHEN USING A FIRE EXTINGUISHER BOTTLE AS

A SOURCE OF CARBON DIOXIDE (CO2) FOR PURGING FUEL CELLS.
GROUND NOZZLE TO HELICOPTER. DISCHARGE CO2 INTO FUEL CELL
SLOWLY (ONE POUND PER MINUTE). RAPID PASSAGE OF GAS THROUGH
A HOSE CAN GENERATE STATIC ELECTRICAL CHARGES. RAPID
DISCHARGE OF GAS ALLOWS RAPID EXPANSION OF GAS (LOWERING
THE TEMPERATURE WITH POSSIBLE DAMAGE TO CELL AS A RESULT).
NITROGEN OR OTHER INERT GAS MAY BE USED WITH THE SAME
PRECAUTIONARY MEASURES OUTLINED ABOVE.
a. Open all sump drains and drain lines.
b. Insert gas hose in cell filler inlet and seal with masking tape (C-426).
c. Blow inert gas through cells for a period of eight hours.
d. Shut off inert gas flow and remove gas hose from cell inlet. Wait one hour.
e. Check interior of fuel cell with explosimeter (combustible gas indicator calibrated for fuel vapors) for level of
fuel vapors.
f. Explosimeter reading shall be less than 20% on the Lower Explosion Limit (LEL) scale. If reading is more than
20%, repeat steps a. through c. until reading is less than 20%.
4. Fog interior of fuel cell with lubricating oil (C-009). Close drains and replace filler cap. Do not close vents.
6. MAIN FUEL SYSTEM - LONG RANGE FUEL CELLS (160 GALLON - 606 LITER), KIT
NO. 412-706-007-101/103 (IF INSTALLED)
Refer to module 25-71-01 "AUXILIARY FUEL TANKS (LONG RANGE) (P/N 412-706-007-109 AND 110)" for
maintenance instructions and refer to illustrated parts catalog for illustrated parts list.
12-11-01
Rev. 3 Page 5
E-AB412-PT6T-2
12-11-01
Page 6 Rev. 3
E-AB412-PT6T-2
12-12-01 ENGINE OIL SYSTEM
12-12-01
ENGINE OIL SYSTEM
1. ENGINE OIL SYSTEM - DESCRIPTION
The engine assembly has three independent oil systems, each with its own filler and oil level sight gauge. Fillers and gauges
for left and right engine power sections are outboard of accessory gearboxes and are accessible by opening engine cowling.
The third gauge is on aft side of reduction gearbox, with access through aft right engine cowl below exhaust ejectors. The
third system oil filler is located in aft top fairing between exhaust ejectors. The third oil system cooler and strainer may be
drained by opening drain valve located on engine deck. Use extreme care to avoid excessive oil spillage if chip detector plug
is removed to completely drain system. Refer to module 12-00-00 table 1 for list of approved lubricating oils and for location
of fillers. Refer to Chapter 79 for additional engine oil system information.
12-12-01
Rev. 3 Page 1
E-AB412-PT6T-2
12-12-01
Page 2 Rev. 3
E-AB412-PT6T-2
12-13-01
HYDRAULIC SYSTEMS AND FLIGHT CONTROLS
1. HYDRAULIC SYSTEM - DESCRIPTION
Access to hydraulic reservoirs is gained by opening forward pylon fairing. System 1 reservoir is on right side and System 2
reservoir is on left side. Pressure and return filters, with red pop-out indicators which will be visible when filter requires
change, are located in integrated valve and filter assemblies in pylon. System 1 integrated valve and filter assembly is located
at lower front center of lift beam. System 2 integrated valve and filter assembly is on aft side of left beam.
NOTE
When adding hydraulic fluid, the same specification of hydraulic fluid already used
in the system shall be used. However, in circumstances where emergency top-off or
inadvertent mixing may occur, it is acceptable to use hydraulic fluid of the other
approved specification. No further maintenance action will be required. To change
the specification of hydraulic fluid used in the system, refer to paragraph "3.
Hydraulic system - change of hydraulic fluid specification".
For servicing fluids, refer to module 12-00-00 table 1.
The filter may be checked from inside cabin area through an access door on forward side of pylon structure. A supplemental
indicator is located to right of helicopter centerline at W.L. 22,00 in, and is visible through the lower right nose window.
With engine operating and hydraulic circuit breakers closed, a green or black indication verifies systems are operating
without clogging. Under the same circumstances, a red or alternative black and white indication warns of an impending
bypass condition.
2. HYDRAULIC SYSTEM - ROTOR BRAKE SERVICING
MATERIALS REQUIRED
NUMBER NOMENCLATURE
C-002 or C-072 HYDRAULIC FLUID
The rotor brake hydraulic system is a separate, self-contained system. Refer to module 12-00-00 SERVICING for approved
hydraulic fluid and for location of fillers.
1. Fully apply rotor brake.
2. Remove reservoir filler cap (1, figure 1) of rotor brake master cylinder (3), located on top, right forward area of cabin
roof.
3. Check fluid level of reservoir is 0.50 in (12.7 mm) below bottom of filler neck.
12-13-01
Rev. 3 Page 1
E-AB412-PT6T-2
NOTE
When adding hydraulic fluid, the same specification of hydraulic fluid already used
in the system shall be used. However, in circumstances where emergency top-off or
inadvertent mixing may occur, it is acceptable to use hydraulic fluid of the other
approved specification. No further maintenance action will be required. To change
the specification of hydraulic fluid used in the system, refer to paragraph "3.
Hydraulic system - change of hydraulic fluid specification".
4. If fluid level is low, replenish with hydraulic fluid (C-002) or hydraulic fluid (C-072).
5. Install reservoir filler cap (1).
6. Release rotor brake by returning rotor brake handle (4) of rotor brake master cylinder (3) to stow position.
3. HYDRAULIC SYSTEM - CHANGE OF HYDRAULIC FLUID SPECIFICATION
MATERIALS REQUIRED
NUMBER NOMENCLATURE
NOTE
Hydraulic fluid (C-002) and hydraulic fluid (C-072) are compatible and can be
mixed.
NOTE
Hydraulic fluid (C-072) MIL-PRF-87257 has been introduced to replace
MIL-PRF-5606 (C-002) due to better characteristics of MIL-PRF-87257. At initial
hydraulic fluid conversion it is recommended the replace of old decals with
appropriate new decals.
NOTE
In the event operators subsequently wish to convert their hydraulic systems to use
hydraulic fluid (C-002) MIL-PRF-5606 or hydraulic fluid (C-072) MIL-PRF-87257,
the following procedure is provided. Although the procedure is written with respect
to converting from hydraulic fluid (C-002) MIL-PRF-5606 to hydraulic fluid
(C-072) MIL-PRF-87257, the hydraulic fluid types specified in each step may be
reversed to convert from hydraulic fluid (C-072) MIL-PRF-87257 to hydraulic fluid
(C-002) MIL-PRF-5606.
Complete each of the three hydraulic fluid conversion phases as follows:
PHASE 1:
NOTE
The hydraulic cart must conform to the requirements of Chapter 29.
1. Prepare the hydraulic cart as follows:
12-13-01
Page 2 Rev. 3
E-AB412-PT6T-2
NOTE
If the hydraulic cart does not have dual system hoses, do the following procedure
before doing step 2. for the hydraulic system No. 1 and before doing step 2. for the
hydraulic system No. 2.
a. Drain the hydraulic cart until 50% of the hydraulic fluid (C-002) stays in the cart. Add hydraulic fluid (C-072)
in the hydraulic cart until it is full.
NOTE
If the hydraulic cart does not have dual system hoses, do the following on the
hydraulic system No. 1 and then repeat the procedure on the hydraulic system No. 2.
2. Do the following steps on the hydraulic system No. 1 and No. 2 and the flight controls:
a. Connect the hydraulic cart to the hydraulic test couplings of the hydraulic system No. 1 and No. 2 under the left
sliding door of the helicopter.
b. Turn electrical power on or apply external power to the helicopter.
c. Turn the hydraulic cart on and apply 1000 PSI (6895 kPa) of pressure to both hydraulic systems.
d. Let the hydraulic cart run for 30 minutes.
e. Move the collective stick, cyclic stick, and pedals to operate all the flight control actuators through full travel
for a minimum of five cycles.
f. Operate the HYDR SYS No. 1 and HYDR SYS No. 2 switches between the ON and OFF positions five times
in approximately 2-second intervals.
g. Turn the hydraulic cart off.
h. Turn the electrical power off or disconnect external power from the helicopter.
i. Disconnect the hydraulic cart from the hydraulic test couplings of the hydraulic system No. 1 and No. 2.
3. For the rotor brake do as follows:
a. Remove the applicable doors and panels to get access to the bleed valves of the rotor brake assembly.
NOTE
There is more than one type of rotor brake assembly. Use the correct instructions.
b. Bleed each bleed valve of the brake assembly in accordance with the instructions provided in Chapter 63, then
service the master cylinder with hydraulic fluid (C-072) (paragraph "2. Hydraulic system - rotor brake
servicing").
c. Repeat step b.
d. Install the previously removed doors and panels.
PHASE 2: After 3 flight hours or 2 weeks following Phase 1.
NOTE
If the hydraulic cart does not have dual system hoses, do the following procedure
before doing step 2. for the hydraulic system No. 1 and before doing step 2. for the
hydraulic system No. 2.
12-13-01
Rev. 3 Page 3
E-AB412-PT6T-2
a. Fully drain the hydraulic cart.
b. Fill the hydraulic cart to 75% of the total capacity with hydraulic fluid (C-072) and the remaining 25% with
hydraulic fluid (C-002).
NOTE
a. Connect the hydraulic cart to the hydraulic test couplings of the hydraulic system No. 1 and No. 2 under the left
b. Turn electrical power on or apply external power to the helicopter.
c. Turn the hydraulic cart on and apply 1000 PSI (6895 kPa) of pressure to both hydraulic systems.
d. Let the hydraulic cart run for 30 minutes.
e. Move the collective stick, cyclic stick, and pedals to operate all the flight control actuators through full travel
f. Operate the HYDR SYS No. 1 and HYDR SYS No. 2 switches between the ON and OFF positions five times
g. Turn the hydraulic cart off.
h. Turn the electrical power off or disconnect external power from the helicopter.
i. Disconnect the hydraulic cart from the hydraulic test couplings of the hydraulic system No. 1 and No. 2.
NOTE
servicing").
c. Repeat step b.
PHASE 3: After 3 flight hours or 2 weeks following Phase 2.
a. Fully drain the hydraulic cart.
b. Fill the hydraulic cart with hydraulic fluid (C-072) until it is full.
NOTE
12-13-01
Page 4 Rev. 3
E-AB412-PT6T-2
a. Remove the forward pylon fairing to get access to the hydraulic reservoirs.
b. Disconnect the hose from the suction outlet fitting of the hydraulic system No. 1 and No. 2 reservoirs and drain
the hydraulic fluid in a suitable container.
c. Connect the hose to the suction outlet fitting of the hydraulic system No. 1 and No. 2 reservoirs. Tighten the hose.
d. d. Fill the hydraulic system No. 1 and No. 2 reservoirs with hydraulic fluid (C-072) up to the correct level.
NOTE
e. Connect the hydraulic cart to the hydraulic test couplings of the hydraulic system No. 1 and No. 2 under the left
f. Disconnect the return hoses from the hydraulic cart and route them into an appropriate container to collect the
discarded hydraulic fluid.
g. Turn electrical power on or apply external power to the helicopter.
NOTE
To avoid wasting fluid, perform all steps below in tight sequence without leaving the
system pressurized unnecessarily. If stops are required to prepare the next step, turn
the hydraulic cart off.
h. Turn the hydraulic cart on and apply 1000 PSI (6895 kPa) of pressure with a flow of 3 gal/min (11 L/min) only
to the hydraulic system No. 1. The hydraulic system No. 2 must stay unpressurized.
i. Move the collective stick, cyclic stick, and pedals to operate all the flight control actuators through full travel
j. Operate the HYDR SYS No. 1 and HYDR SYS No. 2 switches between the ON and OFF positions five times
k. Let the hydraulic cart run for 1 minute.
l. Turn the hydraulic cart off.
m. Turn the hydraulic cart on and apply 1000 PSI (6895 kPa) of pressure with a flow of 3 gal/min (11 L/min) only
to the hydraulic system No. 2. The hydraulic system No. 1 must stay unpressurized.
n. Move the collective stick, cyclic stick, and pedals to operate all the flight control actuators through full travel
o. Operate the HYDR SYS No. 1 and HYDR SYS No. 2 switches between the ON and OFF positions five times
p. Let the hydraulic cart run for 1 minute.
q. Turn the hydraulic cart off.
r. Connect the return hoses to the hydraulic cart.
s. Turn the hydraulic cart on and apply 1000 PSI (6895 kPa) of pressure with a flow of 5 gal/min (19 L/min) to
both hydraulic systems.
t. Let the hydraulic cart run for 5 minutes.
u. Turn the hydraulic cart off.
12-13-01
Rev. 3 Page 5
E-AB412-PT6T-2
v. Turn the electrical power off or disconnect external power from the helicopter.
w. If required, add hydraulic fluid (C-072) in the reservoirs of the hydraulic system No. 1 and No. 2 up to the correct
level.
x. Replace the four hydraulic filter assemblies (Chapter 29).
y. Disconnect the hydraulic cart from the hydraulic test couplings of the hydraulic system No. 1 and No. 2.
z. Install the previously removed doors and panels.
NOTE
servicing").
c. Repeat step b.
12-13-01
Page 6 Rev. 3
E-AB412-PT6T-2
1. Reservoir filler cap

2. Packing
3. Rotor brake master cylinder
4. Rotor brake handle
G6AB0007B
Figure 1. Rotor brake servicing
12-13-01
Rev. 3 Page 7
E-AB412-PT6T-2
12-13-01
Page 8 Rev. 3
E-AB412-PT6T-2
12-14-01 TRANSMISSION OIL SYSTEM
12-14-01
TRANSMISSION OIL SYSTEM
1. TRANSMISSION OIL SYSTEM - DESCRIPTION
The transmission sump case serves as the reservoir for the transmission. The filler is located on upper right side of
transmission and is accessible when forward pylon fairing is opened. Oil level sight gages may be viewed through right side
of pylon support structure in cabin. A sump drain valve is located directly beneath the sump. An external filter, in return line
from oil cooler, is located inside pylon structure at right side and has a red pop-out indicator which is visible when filter is
in impending bypass condition. Drain valves in oil cooler lines are accessible through bottom fuselage skin inboard of F.S.
169.0. Refer to module 12-00-00 "SERVICING" table 1 for list of approved lubricating oils and for location of filler. Refer
to Chapter 63 for additional transmission oil system information.
2. TRANSMISSION OIL SYSTEM - SEEPAGE RATES
Main transmission oil seepage shall not exceed 2 drops per minute from any single source or shall not exceed a total of 15
drops per minute from all sources on transmission.
12-14-01
Page 1
E-AB412-PT6T-2
12-14-01
Page 2
E-AB412-PT6T-2
12-15-01 TAIL ROTOR AND INTERMEDIATE GEARBOX OIL SYSTEM
12-15-01
TAIL ROTOR AND INTERMEDIATE GEARBOX OIL SYSTEM
1. TAIL ROTOR AND INTERMEDIATE GEARBOX OIL SYSTEMS - DESCRIPTION
Oil level in intermediate and tail rotor gearboxes may be checked on sight gages. Oil is replenished through integral filler
ports. Refer to module 12-00-00 "SERVICING" table 1 for list of approved lubricating oils and for location of fillers.
2. TAIL ROTOR AND INTERMEDIATE GEARBOX OIL SYSTEMS - SEEPAGE RATES
Gearbox oil seepage shall not exceed 2 drops per minute from any single source or shall not exceed a total of 6 drops per
minute from all sources on a gearbox.
3. TAIL ROTOR AND INTERMEDIATE GEARBOX OIL SYSTEMS - CHANGING OIL

BRANDS OR TYPE
If changing oil brands or type, refer to module 12-00-00 "SERVICING" table 1 for procedure and requirement.
12-15-01
Rev. 3 Page 1
E-AB412-PT6T-2
12-15-01
Page 2 Rev. 3
E-AB412-PT6T-2
12-16-01 GROUND WHEEL ACTUATOR OIL SYSTEM
12-16-01
GROUND WHEEL ACTUATOR OIL SYSTEM
1. GROUND WHEEL ACTUATOR OIL SYSTEM - DESCRIPTION
When a decreased extension in the actuator piston is noticed, service the actuator as required. Refer to module 12-00-00
"SERVICING" table 1 for approved hydraulic fluid. For this operation, remove the filler cap on the pump assembly and fill
to level maintaining the pump in vertical position.
12-16-01
Page 1
E-AB412-PT6T-2
12-16-01
Page 2
E-AB412-PT6T-2
12-17-01 BATTERY SERVICING
12-17-01
BATTERY SERVICING
1. BATTERY SERVICING - DESCRIPTION
The battery is installed in the nose compartment of the helicopter and is accessible by opening the nose door.
As the battery is of nickel-cadmium type, the electrolyte level shall be normally checked only at the intervals of time
corresponding to the periodical inspections of the helicopter or following a failure of the voltage adjustment unit causing the
battery to suffer a high charging voltage. Check the electrolyte level 3 or 4 hours after the battery has been charged. If the
level cannot be easily checked, a glass or plastic tube of a length of approx. 15 cm (6 in.), with an internal diameter of approx
5 mm (0.2 in.) and with both ends open, can be used. Remove plugs from vents of the battery cells and insert the plastic or
glass tube. Plug the upper end of tube with a finger and remove. If level is 1.5 to 3 mm (0.06 to 0.12 in) it can be considered
satisfactory. Add distilled water if necessary.
CAUTION
DO NOT USE WATER CLASSIFIED AS "WATER FOR BATTERIES".

THIS IS DISTILLED WATER THAT MAY HAVE BEEN USED FOR
SULPHURIC ACID. THIS TYPE OF WATER MAY DAMAGE
NICKEL-CADMIUM BATTERIES.
CAUTION
DO NOT ADD DISTILLED WATER TO THE BATTERY WHEN INSTALLED

ON THE HELICOPTER BECAUSE THE ELECTROLYTE LEVEL OF THE
NICKEL-CADMIUM BATTERY MAY DECREASE WHEN THE BATTERY IS
DISCHARGED AND WILL INCREASE AS THE BATTERY IS CHARGED.
12-17-01
Page 1
E-AB412-PT6T-2
12-17-01
Page 2
E-AB412-PT6T-2
12-18-01 RESCUE HOIST (212-8800-01-1019) GEARBOX OIL SYSTEM [B]
12-18-01
RESCUE HOIST (212-8800-01-1019) GEARBOX OIL SYSTEM [B]
1. RESCUE HOIST (212-8800-01-1019) GEARBOX OIL SYSTEM [B] - DESCRIPTION
The rescue hoist gearbox is filled with lubricating oil. Refer to module 12-00-00 "SERVICING" table 1 for approved
hydraulic fluid.
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E-AB412-PT6T-2
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12-21-01
LUBRICATION
1. LUBRICATION - DESCRIPTION
Figure 1 illustrates each area that requires lubrication with grease-type lubricant. The legend of this illustration lists items
to be lubricated. Table 1 lists required lubrication, interval, and lubricant type.
The intervals specified are the maximum permitted under normal operation. Do not exceed these intervals. It may be
necessary to decrease the interval of servicing when the operating conditions are more severe.
1. After each day of operation in rain, snow, or after washing helicopter, all exposed control bearings should be purge
lubricated to remove trapped moisture and ensure a lubricant film is applied to susceptible surfaces.
2. Parking helicopters outside in a heavy dew environment requires all exposed control bearings be purge lubricated
every seven days to ensure no voids exist that could trap moisture.
3. If helicopter is stored for periods in excess of 45 days without operation or service, purge-lubricate all bearings.
WARNING
P R I O R TO L U B R I C AT I N G, V E R I F Y T H E C O N T E N T O F G R E A S E
DISPENSING EQUIPMENT. IF THERE IS PARTIAL SEPARATION OF THE
LUBRICATION OIL FROM THE THICKENING AGENT, OIL MAY BE
REMIXED THOROUGHLY WITH THE THICKENING AGENT TO RESTORE
THE ORIGINAL LOAD CARRYING CAPABILITIES. IF THERE IS A LOSS OF
LUBRICATING OIL FROM THE THICKENING AGENT, DISCARD THE
ENTIRE CONTENTS OF THE GREASE DISPENSING EQUIPMENT AND
REPLACE WITH A SUITABLE SUPPLY OF APPROVED LUBRICANT (IL
GEN-03-93).
CAUTION
DO NOT USE HIGH CAPACITY/HIGH VELOCITY GREASE GUNS ON THE

COMPONENTS. THE USE OF HIGH CAPACITY/HIGH VELOCITY GREASE
GUNS CAN RESULT IN DAMAGE.
If it becomes necessary to change the brand of grease, remove the old grease by purging until only new grease is present,
except as otherwise specified.
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E-AB412-PT6T-2
NOTE
Prior to and following grease lubrication, visually examine grease fittings for
presence of the spring loaded steel ball. If the steel ball is not visible, does not spring
back to the closed position, the grease fitting indicates excessive leakage, or it is
difficult to inject grease during lubrication, replace the grease fitting. If the grease
fitting is removed due to the spring loaded steel ball not being visible, insert a small
steel probe into the back of the grease fitting to confirm the presence of the steel ball.
If it is identified that the steel ball is not present in the grease fitting, further
investigation is required to ensure that the steel ball has not migrated into the
component and caused damage. Discard grease fittings that have been removed.
2. LUBRICATION - LUBRICANT (204-040-755-005) RESTRICTIONS
MATERIALS REQUIRED
NUMBER NOMENCLATURE
C-015 LUBRICANT (TUBE PACK) 204-040-755-005
WARNING
LUBRICANT MAY CAUSE EYE AND SKIN IRRITATION. AVOID CONTACT

WITH EYES, SKIN AND CLOTHING. WASH THOROUGHLY AFTER
HANDLING.
NOTE
Do not exceed lubrication intervals specified on lubrication chart.
CAUTION
LUBRICANT IN ORIGINAL TUBES AND COMPONENTS CONTAINING

LUBRICANT 204-040-755-005 (TUBE PACK) (C-015) MUST BE STORED AT
MODERATE AMBIENT TEMPERATURES, PREFERABLY LESS THAN 80°F
(26.7°C). ELEVATED STORAGE TEMPERATURES PROMOTE OIL
SEPARATION FROM THE LUBRICANT.
1. Lubricant 204-040-755-005 shelf life is four years from packing date on container.
NOTE
Make sure grease is thoroughly mixed prior to use.
2. In-stock components which utilize lubricant 204-040-755-005 must be pulled from stock and relubricated upon
expiration of the original 4-year shelf life of the lubricant.
3. Once a component lubricated with lubricant 204-040-755-005 goes into service, the relubrication interval is dictated
by the calendar and service-time schedule whether the component is installed on a helicopter or is subsequently
removed and returned to stock as a spare on the shelf.
12-21-01
Page 2 Rev. 3
E-AB412-PT6T-2
3. LUBRICATION - FLEX COUPLING LUBRICATION LOG
The flex coupling lubrication log, as shown on table 1 shall be maintained any time a component using 204-040-755-005
lubricant is installed on helicopter. This log shall be maintained listing date 204-040-755-005 lubricant was applied in
component. This lubricant carries an operational hour and a calendar life as specified in this chapter. Lubricant shall be
replaced at requirement occurring first (hours/months).
Table 1. Lubrication chart
INTERVAL NOMENCLATURE LUBRICANT REMARKS
25 hours, more frequent if Tail rotor trunnion Grease MIL-PRF-81322 Do not intermix grease types. Purge
required by bearings (two) until same grease appears
environmental conditions
25 hours and on assembly Tail rotor crosshead Grease MIL-PRF-81322 Two shots each 25 hours. Do not
bearing intermix grease types
25 hours, more frequent if Drive link (two places) Grease MIL-PRF-81322 Do not intermix grease types. Purge
required by until same grease appears
25 hours, more frequent if Rephasing lever bearings Grease MIL-PRF-81322 Do not intermix grease types. Purge
required by (four places) until same grease appears
25 hours, more frequent if Swashplate inner ring Grease MIL-PRF-81322 Do not intermix grease types. Purge
required by trunnion rod ends (two) until same grease appears. Comply
environmental conditions and collective lever with Note 8 (figure 1)
trunnion rod end (one)
25 hours, more frequent if Collective hub and sleeve Grease MIL-PRF-81322 Do not intermix grease types. Purge
required by (two fittings) until same grease appears.
25 hours, more frequent if Swashplate bearings Grease MIL-PRF-81322 Do not intermix grease types Purge
required by (two) until same grease appears
50 hours, more frequent if Anti-torque flight control Grease MIL-PRF-81322 Fittings not present on all
required by tube bearings helicopters. Do not intermix grease
environmental conditions types. Purge until same grease
appears
100 hours Cargo hook universal and Grease MIL-PRF-81322 Refer to Chapter 25
latch
300 hours or anytime the Tail rotor hanger Grease - MOBIL 28 no Slowly pump grease into fitting
bearings is inspected bearings (four) substitution until it may be seen around bearings
seal.
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Rev. 3 Page 3
E-AB412-PT6T-2
(Cont.d)
600 hours or 6 months Tail rotor driveshaft flex Grease 204-040-755-005 Comply with figure 1, notes 6 and 7
whichever occurs first couplings (four)
600 hours or 6 months Intermediate gearbox Grease 204-040-755-005 Comply with figure 1, notes 6 and 7
whichever occurs first flex couplings (two)
600 hours or 6 months Tail rotor gearbox flex Grease 204-040-755-005 Comply with figure 1, notes 6 and 7
whichever occurs first coupling (one)
600 hours or 6 months Transmission tail rotor Grease 204-040-755-005 Comply with figure 1, notes 6 and 7
whichever occurs first drive quill flex coupling
(one)
600 hours or 12 months Main driveshaft Grease 204-040-755-005 Comply with figure 1, Note 6
whichever occurs first couplings (two)
On assembly Main rotor blade bolts Grease (C-561) After final torque, overcoat
(four) or grease (C-172) non-expanding blade bolt head, nut,
washer, and exposed threads with
corrosion preventive compound
MIL-PRF-16173, Grade I
On assembly Main rotor hub to mast Grease (C-561) Apply thin coat of grease to mating
or grease (C-172) surfaces of mast, splines, upper and
lower cones, and cap assembly
taking care that grease is not
allowed on teflon of cone or mating
surfaces with teflon.
On assembly Mast and splined plate Grease (C-561) Apply grease to mast and splined
splines or grease (C-172) plate splines.
On assembly and after Tail rotor cross-head Grease MIL-PRF-81322 Fill cavity with grease at assembly.
each 50 hours of splines Then apply two shots after
operation installation. Do not intermix grease
type.
50 hours, more frequent if Tail rotor control level Grease MIL-PRF-81322 Do not intermix grease types. Purge
required by (three places) until same grease appears.
On assembly Tail rotor control tube Lubricating oil Coat tube in area of bearing.
MIL-L-7808
MIL-L-23699
On assembly Tail rotor control race Grease (C-001) Hand pack. Do not intermix grease
MIL-PRF-81322 types.
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E-AB412-PT6T-2
(Cont.d)
On assembly Tail rotor gearbox output Grease Apply a thin coat of grease to
shaft splines to tail rotor mating surface of tail rotor gearbox
hub trunnion splines output shaft splines and tail rotor
hub trunnion splines.
On assembly Tail rotor crosshead Grease (C-001) Apply a thin film of grease at
splines MIL-PRF-81322 assembly. Do not intermix grease
types.
On assembly Ground handling wheel Grease (C-001) Do not intermix grease types. Purge
bearings MIL-PRF-81322 until same grease appears.
On assembly and each 6 Ground handling wheel Grease (C-001) Do not intermix grease types. Purge
months axle pivot bearing, MIL-PRF-81322 until same grease appears.
trunnions, and pins
On assembly and after Droop restraint arm, Grease (C-001) Do not intermix grease types. Purge
each 25 hours of inboard clevis race two MIL-PRF-81322 until same grease appears.
operation fittings (four places)
Every 25 hours of Bearing assembly, Grease (C-001) Do not intermix grease types. Purge
operation Pendulum absorbers MIL-PRF-81322 until same grease appears.
main rotor hub (eight
places)
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Rev. 3 Page 5
E-AB412-PT6T-2
Table 2. Flex couplings lubrication log (example only)
DATE
PART MODEL DATE AIRFRAME
NOMENCLATURE GREASE
NUMBER AFFECTED LUBRICATED HOURS
MANUFACTURED
Main Driveshaft All
Transmission Tail Rotor All

Drive Output Coupling
Tail Rotor Driveshaft (1) HP/EP

Hanger (4) SP
Intermediate Gearbox SP
Input Quill
Intermediate Gearbox All

Output Quill
Tail Rotor Gearbox Input SP

Quill
Tail Rotor Driveshaft HP/EP

Coupling Assemblies
12-21-01
Page 6 Rev. 3
E-AB412-PT6T-2
SEE DETAIL F SEE DETAIL

SEE DETAIL G B AND C
MAIN DRIVESHAFT COUPLINGS

MAST SPLINES (2 PLACES)
HANGER BEARINGS
(4 PLACES)
SEE NOTE 2
BLADE BOLTS
(8 PLACES)
SEE NOTE 4
SEE DETAIL A
FLEX COUPLINGS
(8 PLACES)
SEE NOTE 7
SEE DETAIL D
ANTI-TORQUE CONTROL SEE DETAIL E

TUBE BEARINGS
(4 PLACES)
SEE NOTE 3
NOTES:
1 MIL-PRF-81322 Grease is recommended for all applications which previously used MIL-G-25537 grease, but intermixing of
greases is prohibited. When changing from one grease to the other, purge old grease with grease gun until new grease
appears or disassemble and clean old grease, then apply new grease.
2 Lubricate tail rotor hanger bearing with Mobil 28 conforming to MIL-PRF-81322 grease. Lubricate bearing by slowly pumping
grease into fitting until grease may be seen around bearing seal. Use extreme care because excessive pump pressure may
push seal from bearing.
3. All models will not have lubrication fittings on anti-torque control tube bearings. Purge lubrication only required when grease fit-
ting is installed.
4. Coat all bolted joints and faying surfaces on hub and swashplate with corrosion preventive compound MIL-C-16173 grade 1,
external.
5. Some environmental conditions that require additional lubrication are listed below:
If helicopter is operated in rain showers or snow, or if helicopter is washed, purge-lubricate all exposed control bearings to
remove trapped moisture and ensure that a lube film is applied to all working surfaces.
If helicopter is parked in a heavy dew environment, purge-lubricate all exposed control bearings every seven days to ensure
that no voids exist that could trap moisture.
If helicopter is stored for periods in excess of 45 days without operation or service, purge-lubricate all grease bearings.
6. Grease, 204-040-755-5, has a shelf storage life of 4 years whether stored in original container or in a component. If a compo-
nent is not put in service prior to expiration of the 4 year shelf life of the grease, component shall be relubricated prior to instal-
lation on a helicopter. After initial operation of component on the helicopter, refer to lubrication chart for lubrication intervals.
(The application of torque constitutes placement into service).
7. Refer to Chapter 65 for instructions to lubricate flexible couplings.
8. At 300 hour inspection, purge lubricate swashplate and collective lever trunnions and trunnion rod ends as follows: Rotate and
simultaneously purge lubricate trunnions and trunnion rod ends to remove as much of “old” lubricant as possible.
G6AB0008B
Figure 1. Lubricating points (sheet 1 of 4)
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E-AB412-PT6T-2
G6AB0009B
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E-AB412-PT6T-2
G6AB0010A
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G6AB0011A
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E-AB412-PT6T-2
CHAPTER 18 - VIBRATION AND NOISE ANALYSIS AND ATTENUATION

Module Page
Number Title Number
18-00-00 VIBRATION AND NOISE ANALYSIS AND ATTENUATION
1. Vibration and noise analysis and attenuation - general .......................................................................... 1
18-11-01 ROTOR SMOOTHING AND VIBRATION ANALYSIS
1. Rotor smoothing and vibration analysis - sources of vibrations ............................................................. 1

1-1. Sources of vibrations - description ................................................................................................ 1
1-2. Sources of vibrations - main rotor vibration .................................................................................. 1
1-3. Sources of vibrations - tail rotor vibrations ................................................................................... 1
1-4. Sources of vibrations - other vibrations ......................................................................................... 1
2. Rotor smoothing and vibration analysis - rotor tracking and balancing ................................................. 1
2-1. Rotor tracking and balancing - main rotor track and balance ........................................................ 2
2-2. Rotor tracking and balancing - tail rotor track and balance ........................................................... 2
3. Rotor smoothing and vibration analysis - control of main rotor vibration ............................................. 2
3-1. Control of main rotor vibration - main rotor vibration .................................................................. 2
18-12-01 MAIN ROTOR BALANCING (ROTOR ANALYSIS AND DIAGNOSTIC SYSTEM, MODEL AT
(RADS AT))
1. Main rotor balancing - rotor vibration measurement instrumentation .................................................... 1

2. Main rotor balancing - main rotor system color coding ......................................................................... 2
3. Main rotor balancing - rads at installation .............................................................................................. 3
4. Main rotor balancing - flight tests to smooth rotor ................................................................................ 13
5. Main rotor balancing - using diagnostics .............................................................................................. 15
6. Main rotor balancing - advanced editing features ................................................................................. 18
6-1. Advanced editing features - making adjustments ........................................................................ 18
7. Main rotor balancing - product balance ................................................................................................. 25
8. Main rotor balancing - setting autorotation rpm ................................................................................... 28
9. Main rotor balancing - ride quality guidelines ...................................................................................... 29
18-12-02 MAIN ROTOR BALANCING - TROUBLESHOOTING
1. Main rotor balance - troubleshooting ...................................................................................................... 1
18-12-03 TAIL ROTOR BALANCING (SCIENTIFIC ATLANTA ROTOR ANALYSIS AND

DIAGNOSTIC SYSTEM, MODEL AT (RADS AT))
1. Tail rotor balancing - control of tail rotor vibration ............................................................................... 1

2. Tail rotor balancing - installation of the RADS ...................................................................................... 1
3. Tail rotor balancing - tests to balance the tail rotor ................................................................................ 2
4. Tail rotor balancing - making tail rotor balance adjustments ................................................................. 2
5. Tail rotor balancing - tracking tail rotor ................................................................................................. 3
18-12-04 TAIL ROTOR BALANCING - TROUBLESHOOTING
1. Tail rotor balancing - troubleshooting .................................................................................................... 1
18-Index
Rev. 3 Page 1
E-AB412-PT6T-2

Module Page
Number Title Number
18-12-05 BALANCING MAIN DRIVESHAFT (SCIENTIFIC ATLANTA ROTOR ANALYSIS AND

1. Balancing main drive shaft - control of main driveshaft vibration .........................................................1

2. Balancing main driveshaft - installation of RADS ..................................................................................1
3. Balancing main driveshaft - tests to balance driveshaft ..........................................................................8
4. Balancing main driveshaft - using diagnostics ........................................................................................8
5. Balancing main driveshaft - making adjustments ...................................................................................8
6. Balancing main driveshaft - troubleshooting ........................................................................................10
18-13-01 MAIN ROTOR TRACKING AND BALANCING (CHADWICK HELMUTH VIBREX

EQUIPMENT, MODEL 177M OR EQUIVALENT)
1. Main rotor tracking and balancing - rotor vibration measurement instrumentation ...............................1
1-1. Rotor vibration measurement instrumentation - installation ..........................................................1
2. Main rotor tracking and balancing - strobe tracking - main rotor blades ................................................3
3. Main rotor tracking and balancing - track and balance - main rotor........................................................7
3-1. Track and balance - main rotor - preparation .................................................................................7
3-2. Track and balance - main rotor - working main rotor ...................................................................10
3-3. Track and balance - main rotor - main rotor autorotation rpm adjustment ..................................20
3-4. Track and balance - main rotor - working main rotor 2/rev vibration ..........................................25
18-13-02 TAIL ROTOR HUB AND BLADE TRACKING AND BALANCING (CHADWICK-HELMUTH
VIBREX EQUIPMENT, MODEL 177M OR EQUIVALENT)
1. Tail rotor hub and blade tracking and balancing - tail rotor hub and blade operational check ...............1
2. Tail rotor hub and blade tracking and balancing - tail rotor troubleshooting .........................................1
3. Tail rotor hub and blade tracking and balancing - tail rotor hub and blade flag tracking .......................1
4. Tail rotor hub and blade tracking and balancing - tail rotor tracking and balancing with
chadwick-helmuth vibrex equipment (dynamic method) ........................................................................2
4-1. Tail rotor tracking and balancing with chadwick-helmuth vibrex equipment (dynamic
method) - tail rotor tracking ...........................................................................................................2
5. Tail rotor hub and blade tracking and balancing - tail rotor balancing ...................................................4
18-13-03 BALANCING MAIN DRIVESHAFT (CHADWICK-HELMUTH VIBREX EQUIPMENT,

MODEL 177M OR EQUIVALENT)
1. Balancing main driveshaft - control of main driveshaft vibration ..........................................................1
18-Index
Page 2 Rev. 3
E-AB412-PT6T-2
FIGURES
Figure Page
Number Title Number
(RADS AT))
Figure 1. Main rotor color coding .................................................................................................................................. 5

Figure 2. Accelerometer locations ................................................................................................................................. 6
Figure 3. Magnetic pickup and interrupter..................................................................................................................... 7
Figure 4. Magnetic port/azimuth.................................................................................................................................... 8
Figure 5. Passive optical tracker location and cable routing.......................................................................................... 9
Figure 6. Optical tracker angle..................................................................................................................................... 10
Figure 7. Location of paint and tape for tracking ........................................................................................................ 11
Figure 8. Main rotor proper RADS configuration ....................................................................................................... 12
Figure 9. Main rotor smoothing CADU screen............................................................................................................ 16
Figure 10. Main rotor move log ..................................................................................................................................... 17
Figure 11. Adjustments on 412-015-300 main rotor blade ............................................................................................ 22
Figure 12. Tab gage for three-tab rotor blades............................................................................................................... 23
Figure 13. Main rotor hub balance weights ................................................................................................................... 24
Figure 14. Autorotation descent rotor rpm chart............................................................................................................ 30
Figure 15. 2/Rev chart.................................................................................................................................................... 31
Figure 1. Lead - lag trending (sheet 1 of 2) ................................................................................................................... 3

Figure 2. Flow chart for troubleshooting main rotor ..................................................................................................... 5
Figure 3. 2/Rev chart...................................................................................................................................................... 6
18-12-03 TAIL ROTOR BALANCING (SCIENTIFIC ATLANTA ROTOR ANALYSIS AND

Figure 1. Equipment installation, tail rotor balancing ................................................................................................... 4

Figure 2. RADS configuration, tail rotor balancing....................................................................................................... 5
Figure 4. CADU screen for tail rotor balance ................................................................................................................ 7
Figure 5. Tail rotor dynamic balance weight adjustment (sheet 1 of 2) ........................................................................ 8
Figure 6. Tail rotor pitch link rigging .......................................................................................................................... 10
Figure 1. Troubleshooting optical pickup ...................................................................................................................... 2

Figure 1. Equipment installation, main driveshaft balancing ........................................................................................ 3

Figure 3. Optical sensor and bracket.............................................................................................................................. 5
Figure 4. Reflector tape installation, main driveshaft .................................................................................................... 6
Figure 5. RADS configuration for balancing main driveshaft....................................................................................... 7
Figure 6. Cadu screen, main driveshaft balancing ......................................................................................................... 9
Figure 7. Troubleshooting optical pickup .................................................................................................................... 12
Figure 8. 1/Rev driveshaft balance chart with script file 412-41 - main transmission ................................................ 13
18-Index
Rev. 3 Page 3
E-AB412-PT6T-2
FIGURES (CONT.D)
Figure Page
Number Title Number

Figure 1. Chadwick - helmuth equipment hook-up........................................................................................................2

Figure 2. Main rotor blade reflective tape installation ...................................................................................................5
Figure 3. Strobex reflector patterns ................................................................................................................................6
Figure 4. Blade configuration.........................................................................................................................................8
Figure 5. Tab gage for three-tab rotor blades .................................................................................................................9
Figure 6. Flow chart working model 412 rotor with three - tab blades........................................................................13
Figure 7. Sample form used to record 1/rev vibration levels and rotor moves ............................................................14
Figure 8. M412/Pen hub balance chart.........................................................................................................................15
Figure 9. M412/Pen in flight lateral 1/rev chart ...........................................................................................................16
Figure 10. Autorotation descent rotor RPM chart ..........................................................................................................17
Figure 11. Vertical 1/rev chart........................................................................................................................................18
Figure 12. Adjustments on 412-015-300 main rotor blade ............................................................................................21
Figure 13. M412/pen hub balance for lateral in letdown chart ......................................................................................22
Figure 14. Lateral 1/rev vibration letdown.....................................................................................................................23
Figure 15. Accelerometer support for measuring cabin 2/rev levels..............................................................................26
Figure 16. Main motor 2/rev reduction chart .................................................................................................................27
18-13-02 TAIL ROTOR HUB AND BLADE TRACKING AND BALANCING (CHADWICK-HELMUTH
Figure 1. Tail rotor reflection target installation at tail rotor hub...................................................................................5

Figure 2. Tail rotor reflection target installation at tail rotor tips...................................................................................6
Figure 3. Tail rotor reflection target images for “in track” and “out of track” condition...............................................7
Figure 4. Tail rotor dynamic balance weight..................................................................................................................9
18-13-03 BALANCING MAIN DRIVESHAFT (CHADWICK-HELMUTH VIBREX EQUIPMENT,

MODEL 177M OR EQUIVALENT)
Figure 1. Combining gearbox accelerometer .................................................................................................................4

Figure 2. Transmission input quill accelerometer ..........................................................................................................5
Figure 3. Reflector positioning and bolt pattern identification ......................................................................................6
Figure 4. Balance moves recording form .......................................................................................................................7
Figure 5. Balance chart - combining gearbox end of engine to transmission (main drive shaft)...................................8
Figure 6. Balance chart - transmission end of engine (main drive shaft).......................................................................9
18-Index
Page 4 Rev. 3
E-AB412-PT6T-2
TABLES
Table Page
Number Title Number
18-11-01 ROTOR SMOOTHING AND VIBRATION ANALYSIS
Table 1. Excitation frequencies and sources................................................................................................................. 2
(RADS AT))
Table 1. Test conditions.............................................................................................................................................. 13

Table 2. Product balance adjustment combinations .................................................................................................. 27
Table 3. Example of track change with a shifting hub ............................................................................................... 32
Table 1. Troubleshooting main rotor vibration............................................................................................................. 1

Table 2. Troubleshooting RADS main rotor ............................................................................................................... 2
Table 3. Troubleshooting chart when no changes are identified .................................................................................. 7
Table 4. Troubleshooting rotor blade problems ........................................................................................................... 8
Table 5. Troubleshooting main rotor hub/control system faults................................................................................. 10
Table 1. Troubleshooting tail rotor balance.................................................................................................................. 1

Table 1. Helicopter code [D] main drive balance criteria............................................................................................. 1

Table 2. Hardware and weight.................................................................................................................................... 10
Table 3. Troubleshooting driveshaft balance.............................................................................................................. 10

Table 1. Rotor configuration log ................................................................................................................................ 24
18-Index
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E-AB412-PT6T-2
18-Index
Page 6 Rev. 3
E-AB412-PT6T-2
18-0 -0 VIBRATION AND NOISE ANALYSIS AND ATTENUATION
18-00-00
VIBRATION AND NOISE ANALYSIS AND ATTENUATION
1. VIBRATION AND NOISE ANALYSIS AND ATTENUATION - GENERAL
This chapter provides information and procedures required to maintain helicopter with respect to quality of the ride and
control of rotating component generated vibration. The instrument recommended to support the model 413 is the Scientific
RADS AT. This instrument replaces the Chadwick-Helmuth Vibrex system as the primary support equipment for the current
configuration of the helicopter. Procedures are provided for the Vibrex where that system is still functional.
18-00-00
Page 1
E-AB412-PT6T-2
18-00-00
Page 2
E-AB412-PT6T-2
18-1 -01 ROTOR SMOOTHING AND VIBRATION ANALYSIS
18-11-01
ROTOR SMOOTHING AND VIBRATION ANALYSIS
1. ROTOR SMOOTHING AND VIBRATION ANALYSIS - SOURCES OF VIBRATIONS
1-1. SOURCES OF VIBRATIONS - DESCRIPTION
Many types of vibrations are present in the helicopter at low to moderate levels. The main sources of these vibrations are
the main rotor, tail rotor, and engine-to-transmission (main) drive shaft. Other dynamic components (hydraulic pump, oil
cooler fan, etc.) can generate vibrations at various frequencies. These vibrations are generally at such a low level, they are
seldom perceived (table 1). The primary source of vibrations is the main rotor. Main rotor vibrations occur at 1/rev (once
per revolution), 2/rev (twice per revolution), 4/rev (four times per revolution), and 8/rev (eight times per revolution)
frequencies. The magnitude of 1/rev and 2/rev vibrations in the cabin area is influenced by the condition of main rotor
blades, main rotor hub, and control system components.
1-2. SOURCES OF VIBRATIONS - MAIN ROTOR VIBRATION
Vibrations can be reduced in magnitude or eliminated by repairing or replacing worn or unserviceable components and by
tracking and balancing the main rotor. The installation, condition, and compatibility of lead-lag dampers have the most
impact upon the ability to obtain, and maintain, a low level of 1/rev and 2/rev vibration. Additionally, degradation in any of
the hub or control system elastomeric bearings will affect the level of 1/rev vibration. As opposed to the earlier version of
the main rotor blade, P/N 412-015-200-111, the later version blades, P/N 412-015-300-109, will seldom cause an
uncorrectable 1/rev vibration unless damaged or improperly repaired. The 4/rev vibrations are controlled by the pendulum
absorbers in the rotor and by the tightness of the instrument panel and nose structure. An increase in 4/rev in cabin area can
signify degradation of pendulum support bearings or even a loosening of helicopter nose structure. This increase can also
be caused by improperly accomplished nose structure modifications and loose components in nose such as the battery or
avionic equipment. Main rotor 8/rev vibrations are always present. However, vibrations at this frequency generally do not
affect ride quality.
1-3. SOURCES OF VIBRATIONS - TAIL ROTOR VIBRATIONS
Vibrations from the tail rotor can occur at the 1, 2, and 4/rev levels. In general, only the 1/rev vibration can be corrected or
reduced by tracking and balancing the tail rotor.
1-4. SOURCES OF VIBRATIONS - OTHER VIBRATIONS
A high frequency vibration and pulsation noise in cabin can be caused by the engine-to-transmission driveshaft. This
vibration can be eliminated by proper balancing of the engine-to-transmission driveshaft (module 18-12-05 paragraph "1.
Balancing main drive shaft - control of main driveshaft vibration" or module 18-12-03 paragraph "1. Tail rotor balancing -
control of tail rotor vibration").
2. ROTOR SMOOTHING AND VIBRATION ANALYSIS - ROTOR TRACKING AND

BALANCING
Rotor tracking and balancing procedures using Scientific Atlanta Rotor Analysis and Diagnostic System, Model AT (RADS
AT).
18-11-01
Page 1
E-AB412-PT6T-2
2-1. ROTOR TRACKING AND BALANCING - MAIN ROTOR TRACK AND BALANCE
For main rotor track and balance adjustments using RADS AT equipment, refer to module 18-12-01 "MAIN ROTOR
BALANCING (ROTOR ANALYSIS AND DIAGNOSTIC SYSTEM, MODEL AT (RADS AT))".
2-2. ROTOR TRACKING AND BALANCING - TAIL ROTOR TRACK AND BALANCE
For tail rotor track and balance procedures using RADS AT equipment, refer to module 18-12-03 "TAIL ROTOR
BALANCING (SCIENTIFIC ATLANTA ROTOR ANALYSIS AND DIAGNOSTIC SYSTEM, MODEL AT (RADS
AT))".
3. ROTOR SMOOTHING AND VIBRATION ANALYSIS - CONTROL OF MAIN ROTOR

VIBRATION
3-1. CONTROL OF MAIN ROTOR VIBRATION - MAIN ROTOR VIBRATION
The most common vibration felt by crew and passengers is main rotor generated 1/rev (one beat per revolution), 2/rev (two
beats per revolution), and 4/rev (four beats per revolution). In table 1 is shown the frequencies of these vibrations. In general
only the 1/rev and 2/rev can be controlled by adjusting the main rotor system. The 4/rev levels are dependent on the condition
of the pendulum absorbers and the condition of the fuselage (primarily the nose and instrument panel structure) and are not
significantly effected by standard track and balance adjustments or rotor system component changes.
Table 1. Excitation frequencies and sources
VIBRATION SOURCE APPROX APPROX

RPM HZ
1/Rev Main Rotor 324 5,40
2/Rev Main Rotor 648 10,80
4/Rev Main Rotor 1,296 21,60
1/Rev Tail Rotor 1,662 27,70
2/Rev Tail Rotor 3,324 55.30
1/Rev Lower Hydraulic Pump 4,300 71,70
1/Rev Tail Rotor Driveshaft 4,302 71,70
1/Rev Transmission Input Shaft 6,600 110,00
1/Rev Upper Hydraulic Pump 6,600 110,00
4/Rev Tail Rotor 6,648 110,60
Oil Cooler 8,200 136,00
Rotor Brake 8,300 138,00
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(Cont.)
VIBRATION SOURCE APPROX APPROX

RPM HZ
Lower Hydraulic Pump Piston Passage Frequency 30,120 502,00
1/Rev Power Turbine 33,020 550,33
Upper Planetary Gear Mesh 38,556 642,60
Upper Hydraulic Pump Piston Passage 46,200 770,00
Lower Hydraulic Pump 2 x Piston 60,240 1004,00
Oil Cooler Fan Blade Passage 87,960 1466,00
90 Gearbox Gear Mesh 94,620 10577,00
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18-11-01
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18-12-01 MAIN ROTOR BALANCING (ROTOR ANALYSIS AND DIAGNOSTIC SYSTEM, MODEL AT (RADS AT))
18-12-01
MAIN ROTOR BALANCING (ROTOR ANALYSIS AND DIAGNOSTIC
SYSTEM, MODEL AT (RADS AT))
1. MAIN ROTOR BALANCING - ROTOR VIBRATION MEASUREMENT

INSTRUMENTATION
NUMBER NOMENCLATURE
AN970-5 WASHERS (AR)
MS21042L5 NUTS (2)
NAS1305-32 BOLTS (2)
NAS6603-7 BOLTS (5)
T71 BASIC RADS AT KIT

WITH BASIC SOFTWARE
BASIC RADS OPERATING SYSTEM 3,10AO OR GREATER
412_41 VERSION 5,22 OR GREATER FOR USE ON SHIPS WITH
204-031-927-105 PYLON MOUNTS
412_50 VERSION 5,24 OR GREATER FOR USE ON SHIPS WITH
204-031-927-107 PYLON MOUNTS.
T72 ACCELEROMETER CABLE (ADDITIONAL)
T72 212/412 OPTICAL TRACKER BRACKET
T72 ACCELEROMETER
BRACKETS (STIFF)
T72 (Part of) 212/412 OPTICAL TAIL ROTOR ADAPTER
T74 SHIM, LAMINATED,

ALUMINUM ALLOY (AR)
T93 ACCELEROMETER (3 TOTAL)
The primary instrumentation for measuring rotor vibration is the Rotor Analysis and Diagnostic System, Model AT (RADS
AT). The RADS AT automates the acquisition of blade track and vibration data as well as corrective actions required to
accomplish tracking and balancing. Also, the RADS AT automatically obtains blade sweep (lead-lag) information which
helps to locate problem components in the hub and rotating control system. RADS AT consists of the following:
1. A harmonic analysis system to measure main rotor, tail rotor, and engine-to-transmission driveshaft induced vibrations
at multiple frequencies.
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2. A passive and/or an active optical tracker to measure individual blade track and lead-lag variations. The passive optical
tracker is used for day-only operations. The active optical tracker can be used for either day or night operations.
3. A diagnostic program which defines rotor adjustments required to track and balance main rotor and to balance tail rotor
and engine-to-transmission (main) driveshaft.
4. A spectrum analysis program (FFT) which allows the operator to determine magnitude and frequency of any vibration
present in helicopter.
NOTE
To change from vibrex equipment to RADS AT, most sensors and cables can be
used. Contact Scientific Atlanta, San Diego, CA, for help in making the conversion.
5. Three main versions of Model 412 rotor analysis and diagnostics software are available as follows:
a. Basic RADS operating system should be 3,10AO or greater.
b. 412-41 version 5,22 or greater for use on shifts with 204-031-927-105 pylon mounts.
c. 412-50 Version 5,24 or greater for use on ships with 204-031-927-107 pylon mounts.
6. Determine version of software loaded into control and data unit (CADU) of RADS AT as follows:
a. Select MANAGER option from MAIN MENU screen and then select STATUS.
b. Use down arrow key to view pages of CADU status.
c. Find Page 3 which lists current aircraft software that is loaded.
7. Various accelerometers may be used with RADS AT. Match accelerometers and software as follows:
a. Using CADU select MANAGER option from MAIN MENU screen and then select STATUS.
b. Use down arrow key to view pages of CADU status.
c. Find page listing accelerometers versus software. Select accelerometers which are compatible with software or
change types of accelerometers in software by selecting SETUP in MANAGER section. Scroll to
ACCELEROMETERS and, by pressing right or left cursor keys, various accelerometers may be chosen.
NOTE
Failure to select and verify accelerometers match software will result in inaccurate
vibration data or no vibration data measured at all.
2. MAIN ROTOR BALANCING - MAIN ROTOR SYSTEM COLOR CODING
CAUTION
ENSURE COLOR CODE INTEGRITY IS MAINTAINED ON MAIN ROTOR

BLADES, HUB, AND ROTATING CONTROL COMPONENTS.
When installing main rotor hub and blade, verify color code as follows:
1. Red color code on hub and blade is adjacent to master spline on mast and hub splined plate.
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2. Remaining hub and blades are installed (figure 1) using direction of rotation as a guide. When properly color coded,
upper blades will be red and blue, lower blades will be green and orange.
3. Rotating control components are coded accordingly.
3. MAIN ROTOR BALANCING - RADS AT INSTALLATION
MATERIALS REQUIRED
NUMBER NOMENCLATURE
C-405 LOCKWIRE
C-482 TAPE
C-483 TAPE, REFLECTIVE
1. Locate DAU (29328200) in cabin aft of crew compartment in a convenient area.
2. Using a 29313000 or 29329700 accelerometer bracket (or equivalent) install one 991D accelerometer on bottom edge
of instrument panel in front of pilot cyclic with connector toward right side of helicopter. Connect end of accelerometer
cable (291056000 and 29105605) to lateral accelerometer. Route to DAU so it does not foul controls. Connect to ACC
#1 port (figure 2).
3. Using a 29313000 or 29329700 accelerometer bracket (or equivalent), install one 991D accelerometer on front face of
instrument panel inboard of pilot ash tray oriented vertically with connector down. Connect end of an accelerometer
cable to vertical accelerometer, route to DAU so it can not foul controls. Connect to ACC #2 port (figure 2).
NOTE
This installation is for helicopters with the 204-031-927-107 pylon mounts only.
4. Using a 29313000 or 29329700 accelerometer bracket (or equivalent), install one 991D fore-and-aft accelerometer on
bottom edge of instrument panel in front of pilot cyclic with connector pointed forward. Connect accelerometer cable
to fore-and-aft accelerometer, route to DAU so it can not foul controls. Connect to ACC #3 port (figure 2).
5. Remove outer jam nut from magnetic rpm sensor (27288400) and insert into magnetic sensor support bracket at rear
of swash plate inner ring (5, figure 3). Reinstall outer jamnut and loosely tighten so only one thread is showing beyond
jam nut. Rotate rotor so magnetic interrupter is next to sensor. Adjust both jam nuts until gap between sensor and
interrupter is 0.025 in (0.63 mm). Tighten both jamnuts while maintaining this spacing and secure with lockwire
(C-405). Connect aircraft magnetic sensor cable to sensor and tighten to secure.
6. Connect magnetic sensor cable (29105403) to magnetic sensor port on copilot side of center pedestal (figure 4).
Connect opposite end of cable to TACHO #1 on DAU.
7. Connect 28 VDC power cable (29104700) to 28 VDC port on copilot side of pedestal (figure 4). Connect opposite end
of cable to 28 VDC connector on the DAU.
8. Install day-night optical tracker (4, figure 5) as follows:
a. Remove screws (1) left side of upper nose panel.
b. Position tracker bracket (8) on left nose panel and secure using bolts (7).
c. Torque bolts (7) 15 to 20 in-lbs (1.69 to 2.69 Nm).
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d. Install the day-night optical tracker (4) on bracket (8) using bolts (9), washers (3), and nut (5). Tighten upper
bolt enough to allow tracker to be moved by hand.
NOTE
Use an inclinometer to verify the angle of tracker when first installed on a new
mount. Scribe mark angle on mount so subsequent installations will not require an
inclinometer for alignment.
e. Set angle of tracker (4) as shown in figure 6 depending on mode of operation to be used (day or night). Once
tracker (4, figure 5) is angled properly, torque nuts (5) 80 to 120 in-lbs (9.04 to 14.376 Nm). Reverify and correct
angle if necessary.
9. Connect tracker cable (6) to tracker (4) and route through lower front edge of copilot door. Secure cable to nose using
tape (C-482). Route cable in cabin to avoid flight controls and connect to Tracker #1 on DAU.
CAUTION
DO NOT BLOCK STATIC PORTS ON SIDE OF NOSE WHEN ROUTING

CABLE.
10. Connect CADU (29314101) to DAU using communications cable (2932501).
11. Install reflective tape (C-483) on trailing edge of each blade for night tracking (figure 7). Paint leading edge of each
blade black for daylight tracking.
12. The RADS is now installed and ready to smooth the rotor system. When correctly installed, RADS should be
configured as shown in figure 8.
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NOTE:
The interrupter should be over the magnetic pickup when the rotor is in the above position.
G6AB0538B
Figure 1. Main rotor color coding
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1. Vertical accelerometer
2. Accelerometer brackets
3. Lateral accelerometer
4. Accelerometer cables
5. F/A accelerometer (412_50)
G6AB0539B
Figure 2. Accelerometer locations
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1. Magnetic field interrupter (red swashplate horn)

2. Magnetic pickup support bracket
3. Pickup cable 1
4. Magnetic pickup 2
5. Swashplate inner ring
6. Swashplate outer ring
NOTES:
1 Part of RADS AT kit or Chadwick-Helmuth basic Vibrex system C.
2 Other end connects to the ROTO TRACK SIGNAL/BLADE BALANCER RECPT. on right side of pedestal.
G6AB0540B
Figure 3. Magnetic pickup and interrupter
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2. Helicopter magnetic pickup receptacle
3. Power receptacle
4. Copilot right pedal
NOTE:
Cables go to the lateral, vertical and fore-and-aft accelerometers.
G6AB0425B
Figure 4. Magnetic port/azimuth
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CAUTION
DO NOT LET TRACKER CABLE

OR TAPE COVER AIRSPEED
STATIC PORTS.
1. Screw
2. Door
3. Washer or shim
4. Passive optical tracker
5. Nut
6. Tracker cable
7. Bolt
8. Tracker bracket
9. Bolt
G6AB0542B
Figure 5. Passive optical tracker location and cable routing
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G6AB0543A
Figure 6. Optical tracker angle
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NOTES:
1 Apply a layer of clear cellophane or masking tape between the blade and reflective tape, to aid in removal of reflective tape.
2 If tracker errors occur on bright sunny days, the entire lower surface of the blade may be painted black between the outboard
and midspan tab. Do so if existing paint is faded or existing paint is not black.
G6AB0544B
Figure 7. Location of paint and tape for tracking
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G6AB0545A
Figure 8. Main rotor proper RADS configuration
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4. MAIN ROTOR BALANCING - FLIGHT TESTS TO SMOOTH ROTOR
In table 1 are shown test conditions used by various flight plans to smooth the rotor. It is recommended all flight tests be
conducted at a light gross weight as this is the configuration for which RADS diagnostics have been optimized. The
recommended configuration is two/three crew and 500 to 1500 lbs of fuel. Two flight plans are used to smooth the rotor
system. These are:
Table 1. Test conditions
TEST DESCRIPTION 412_41/412_50

I.D. FLIGHT PLAN
INITIAL FLIGHT FRAHM D/S TAIL
Idle Flat Pitch at 62% RPM X X
FPG100 Flat Pitch at 100% RPM X X
100TQ 100% RPM at 27% Mast O O

Torque
Hover Hover into wind; IGE X X
Climb 1000 FPM Climb at 60 Kts X
120K Level Flight at 120 Kts at 100% X

RPM
120/97 Level Flight at 120 Kts at 97% O

RPM
VNE Dive to 140 Knots X
L/Down 1000 FPM Descent at 60 Knots X
97% Level Flight at 120 Kts at 97% X

RPM

RPM

RPM

RPM

RPM

RPM
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E-AB412-PT6T-2
(Cont.d)
TEST DESCRIPTION 412_41/412_50
I.D. FLIGHT PLAN
INITIAL FLIGHT FRAHM D/S TAIL
FPGDS Flat Pitch 100% RPM — Twin X

Engine
FPGTL Flat Pitch 97% — 100% RPM X

— Single or Twin Engine
X = Test conditions for both 412_41 and 412_50

O = Additional Test for 412_50
INITIAL: The purpose of this mode is to track rotor on ground and in hover and to balance rotor while on the ground. This
mode is used to set up rotors with one or more major component changes prior to flight (i.e. blade, hub, pitch link, etc.). This
mode does not reduce vibration in hover and is designed to provide level of 1/rev on first flight which allows complete flight
envelope to be checked. This mode has been successfully completed when balance on ground is below 0.2 IPS and track of
blades at idle and FPG100 are within 2.0 mm of ± 20 mm position and hover track is within 4 mm of ± 20 mm.
FLIGHT: The purpose of this mode is to smooth the rotor system. This mode works best when the INITIAL has been
accomplished first. This mode is used alone when a rotor is being resmoothed as part of routine maintenance (no major
component changes). This mode also optimizes track spread versus airspeed which normally will minimize 2/rev levels. This
mode has been completed when flight crew is satisfied with the ride or diagnostics indicate that no further improvement can
be made. Refer to paragraph "9. Main rotor balancing - ride quality guidelines" on ride quality guidelines.
1. In the 412-41 program for ships with 204-031-927-105 mounts, these two flight plans are called INITIAL and
FLIGHT. In 412-50 program for ships with 204-031-927-107 mounts, these programs are:
a. INT-LOW: INITIAL mode with low landing gear.
b. INT-HIGH: INITIAL mode with high/float landing gear.
c. FLI-LOW: FLIGHT mode with low landing gear.
d. FLI-HIGH: FLIGHT mode with high/float landing gear.
2. Smooth rotor with RADS as follows:
a. Ensure system is installed (paragraph "3. Main rotor balancing - rads at installation").
b. Turn on CADU to view main screen. Use arrow keys to select AIRCRAFT TYPE and press DO. Use arrows to
highlight either 412-41 or 412-50 (depending on pylon mount configuration) and press DO to select.
c. With aircraft type selected, press DO to select or define TAIL NUMBER of aircraft (AgustaWestland prefers
operator to use S/N and not registration number). When TAIL NUMBER has been highlighted or defined, press
DO to select.
d. With aircraft type and tail number defined, press DO to select FLIGHT PLAN. In this case, a determination to
run an Initial or Flight to smooth the rotor is required. INITIAL sets up new or overhauled rotors for flight and
FLIGHT smooths rotor in flight. When using 412-50 program, define type of skid gear.
e. With type, number, and plan selected, CADU screen should look similar to examples in figure 9. With CADU
properly configured, press F1 to initiate MEASUREMENT mode of RADS.
f. Once measurement mode has been activated, the list of test conditions to be conducted will appear. Refer to
table 1 for test definition if required.
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g. With list of test conditions displayed, operate helicopter and obtain data at each designated test condition which
can be achieved by highlighting test condition and pressing DO once to arm system and a second time to initiate
data collection sequence when helicopter has stabilized on the test condition. Repeat individual test at least three
times if a warning appears before terminating the test flight and troubleshooting the system.
h. Once all data has been obtained, shut down helicopter and select DIAGNOSTICS (if all test conditions have
been obtained) or press QUIT, then select SAVE and EXIT. Select DIAGNOSTICS to determine what, if any,
corrective action is required (paragraph "5. Main rotor balancing - using diagnostics").
i. Repeat step e. through h. until an acceptable ride is obtained. If an acceptable ride cannot be obtained or other
problems are encountered, refer to module 18-12-02 paragraph "1. Main rotor balance - troubleshooting" for
recommended corrective action.
j. All data has been obtained for a test condition if the word DONE appears after the test. Partial data has been
obtained if PARTIAL appears and no data has been obtained if FAIL appears.
k. Note what error messages say. Do not continue if failure is an obvious system fault as this will only waste time.
Take corrective actions displayed on screen and refer to module 18-12-02 paragraph "1. Main rotor balance -
troubleshooting" for additional troubleshooting steps.
l. Tracker faults are most likely when pointed directly at the sun. Adjust orientation of the helicopter if a tracker
fault occurs.
5. MAIN ROTOR BALANCING - USING DIAGNOSTICS
Once data has been obtained and Diagnostics entered:
1. A screen comparing measured levels to predefined limits will appear on screen. These limits are not true limits or
vibration target levels, but are programmed into RADS to allow the use of RESOLVE TO LIMIT feature in RADS
diagnostics to optimize number of adjustments specified to smooth rotor. This feature eliminates unnecessary
adjustments which can be called out to work rotor when all adjustments are specified without control. If RADS
indicates all measurements are within limits, and/or ride is acceptable to the crew, press QUIT to return to main menu.
If any measurements are outside limits and ride is considered unacceptable to crew, press DO to begin diagnostic
analysis.
2. The default setting for diagnostics is RESOLVE TO LIMIT. As diagnostics are entered, RADS will begin to count
down number of moves required to reach target levels below predefined limits. This counting down eliminates less
meaningful adjustments and takes approximately three minutes with newer CADU’s type.
3. Upon completion of analysis, a list of adjustments will be displayed. Record these adjustments on a form similar to
that shown in figure 10. Make adjustments specified as described in paragraph "6-1. Advanced editing features -
making adjustments". If adjustment cannot be made as defined, approximately the same result can be obtained by
making opposite move on opposite blade. If the operator does not want to make a specific move (such as a produce
balance move), adjustment can be turned off using EDIT ADJUSTABLES mode in DIAGNOSTICS menu. To deselect
this adjustment, select edit adjustable option and press DO. Select adjustment to be turned-off (only Y adjustments are
on), and press F1 to change from on to off (Y to N). Press DO to recalculate adjustments to be made.
4. Once adjustments to be made have been defined and recorded, return to main menu by selecting MAIN MENU from
DIAGNOSTICS MENU.
5. When in INITIAL mode if all test conditions are not measured, the following editing adjustments are required to
calculate correct set of adjustments:
a. Idle Only: Turn off all adjustments except pitch links.
b. 100% RPM only: Turn off all adjustments except hub weights.
c. Idle and 100% only: Turn off product balance weights.
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6. When in FLIGHT mode, never turn off hub weights. Ignore weight moves below 0.3 weights. No track data: Turn off
the adjustments for the red and green blades.
7. On initial runs with new blades or pitch links, it is best to make at least one idle run to correct large track errors prior
to conducting full initial test plan.
8. As experience is gained with the RADS, the operator may want to use other diagnostic options available. These options
are described in paragraph "6. Main rotor balancing - advanced editing features".
9. Never turn on red or green hub weights.
G6AB0546A
Figure 9. Main rotor smoothing CADU screen
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G6AB0547A
Figure 10. Main rotor move log
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6. MAIN ROTOR BALANCING - ADVANCED EDITING FEATURES
The RADS incorporates a number of editing features which the operator can use to optimize diagnostics. The 412-41 and
412-50 program use the option called RESOLVE TO LIMIT as default analysis. Listed below are the basic features of
options available from the DIAGNOSITCS MENU:
1. EDIT ADJUSTABLES: This feature allows operator to specify which adjustments are valid to be used in analysis. A
‘Y’ allows adjustments to be used and ‘N’ disallows its use. F1 allows changing of an adjustment status for use in an
additional calculation. F2 and F3 disallow either a blade or an adjustment. F4 returns setting to original default. When
editing has been completed and DO is pressed, the RADS will recalculate adjustments using only the new adjustments
allowed.
2. EDIT DEFAULTS: This feature allows operator to specify maximum number of moves, based upon predefined
LIMITS or by a set number specified by the RADS. The features available under this option are:
a. MAXIMUM NUMBER OF ADJUSTMENTS: This specifies maximum number of adjustments to be made. A

‘00’ allows RADS to use all adjustments. Placing a number will limit RADS to specify that number of moves
only (the best combination). For example, if ‘4’ is specified, the four best moves will be displayed.
b. RESOLVE TO LIMIT: The standard mode for INITIAL is OFF which allows all adjustments to be used to obtain
optimum track and ground balance. The standard mode for FLIGHT is ON which allows the system to calculate
the least number of adjustments to reduce 1/rev levels to below predefined limits. This is a significant time saver
as it allows only meaningful adjustments to be used. It is possible to use arrow keys to select OFF in FLIGHT
mode. This allows all adjustments to be used to target an optimum 1/rev level. This should only be done in
conjunction with selecting 6 or less adjustments as MAXIMUM NUMBER to minimize needless adjustments.
In combination (i.e. OFF and 6), the system will calculate the best set of moves (limited to number selected) to
reduce 1/rev levels.
6-1. ADVANCED EDITING FEATURES - MAKING ADJUSTMENTS
6-1-1. Making adjustments - pitch links
MATERIALS REQUIRED
NUMBER NOMENCLATURE
C-405 LOCKWIRE
Pitch links are used to track rotor at idle and to minimize lateral 1/rev experienced during flight. RADS AT equipment or
vibrex charts are used to determine pitch link adjustments. When adjusting a pitch link, the smallest meaningful move is one
flat (0.6 or above one flat). All moves greater than one flat are rounded to the nearest 0.5 flat.
If a very large adjustment is required, use upper rod end bearing. The ratio is 1/2 turn of upper rod end bearing equals a 12
flat turn of pitch link.
NOTE
When working newly installed rotors, set pitch link to nominal setting (refer to
Chapter 62).
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WARNING
THE MAXIMUM ALLOWABLE EXPOSED THREADS SHALL NOT EXCEED

11 ON PITCH LINK UPPER ROD END BEARING AND 8 ON THE LOWER
ROD END BEARING.
1. Review RADS AT correction data to determine which pitch link(s) is (are) to be adjusted. Ensure amount and direction
for each pitch link adjustment is recorded.
NOTE
Using a grease pencil or a felt tip marker, mark position of pitch link to rod end
bearing before making any adjustment.
2. Remove lockwire and loosen nuts of selected pitch link.
3. Refer to decal on pitch link (Chapter 62) and turn tube in required direction while counting off number of flats needed
to make adjustment.
CAUTION
ENSURE ROD END BEARINGS REMAIN CENTERED IN CLEVISES WHILE

TIGHTENING NUTS.
4. Center upper rod end bearing in clevis of applicable pitch horn. Center lower rod end bearing in clevis of re-phasing
lever. Hold tube and torque nuts (Chapter 62).
5. To adjust upper rod end bearing only, loosen nut on rod end bearing, remove cotter pin, nut, and washer. Use work aid
(Chapter 62) to remove bolt and washer from pitch horn and pitch link.
NOTE
Install all bolts in rotating controls with heads in direction of rotation.
6. After adjustment of upper rod end bearing, center bearing in pitch horn. Install bolt, washers, and nut. Torque nut.
Torque nut on upper rod end bearing Chapter 62. Install cotter pin.
CAUTION
ENSURE ROD END BEARINGS REMAIN CENTERED IN CLEVIS WHILE

TIGHTENING NUTS.
7. If upper rod end bearing did not require adjustment, center bearing in clevis of pitch horn and torque nut (Chapter 62).
8. Lock wire lower nut to insert using lockwire (C-405).
9. After completion of rotor smoothing, apply corrosion preventive compound (C-101) to threads of pitch link.
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6-1-2. Making adjustments - trim tabs
NUMBER NOMENCLATURE
T43 TRIM TAB BENDER
T44 TRIM TAB GAGE
Trim tab locations are shown in figure 11. Outboard trim tabs (9) are used for initial ground tracking and
are the primary adjustment for reducing vertical 1/rev in flight. Midspan trim tabs (6) are used as a secondary adjustment.
The main purpose is to maintain proper track separation in flight. The next purpose is to supplement outboard trim tab if a
very large adjustment of outboard trim tab is required during both initial tracking and vibration phases. Maintaining proper
track separation with airspeed ensures low 2/rev levels. The inboard trim tabs are used if vertical 1/rev at VNE and/or during
a 60 knot/1000 rpm letdown cannot be made acceptable while maintaining an acceptable vertical 1/rev at 120 knots IAS.
The trim tab adjustments, as indicated by RADS AT equipment, are made equal and opposite in both blades of the pair.
Outboard trim tabs are adjusted using the trim tab gage (T44) (figure 12) and trim tab bender (T43).
1. Review RADS AT correction data to identify trim tabs to be adjusted and amount of adjustment.
2. Install trim tab bender (T43) on trim tab to be adjusted as follows:
NOTE
Install trim tab bender so angle indicator is on bottom side of trim tab.
a. Slightly loosen wingnuts on trim tab bender until bender can be slipped onto trim tab.
b. Position trim tab bender so there is a 0.125 in (3.2 mm) gap between leading edge of trim tab bender and trailing
edge of blade. Ensure trim tab bender is square with trim tab.
c. Tighten wingnuts until trim tab bender is tight on trim tab.
3. Place trim tab gage outboard of outboard trim tab, outboard of midspan trim tab, or inboard of inboard trim tab as
applicable. The spring clip of trim tab gage shall be on bottom. Adjust position of trim tab gage on blade until trailing
edge of blade and angle of angle indicator of trim tab bender is flush with trim tab gage surface.
4. Determine angle of trim tabs using trim tab gage. Use trim tab gage marked STA 258 (-200BLD) to read outboard trim
tab angle. Use trim tab gage marked STA 200,1 (-300 BLD) to read angle of midspan trim tab (figure 12). Use inboard
tab side of trim tab gage to read angle of inboard trim tab.
5. Use trim tab bender to adjust trim tab to required angle.
NOTE
Maximum allowable adjustment for midspan and outboard tab is ± 7. Maximum
allowable adjustment for inboard tab is ± 15.
6. Repeat step 1. through 5. until all outboard, midspan, and inboard trim tabs are adjusted.
7. After all trim tab adjustments have been made and verified, loosen wingnuts on trim tab bender and remove bender
and trim tab gage from blade.
18-12-01
Page 20 Rev. 2
E-AB412-PT6T-2
NOTE
When making small adjustments (less than 1.5), slightly overcorrect, then bend trim
tab back to desired setting. This ensures trim tab setting will hold without creeping
back to original position.
6-1-3. Making adjustments - hub balance weights
NUMBER NOMENCLATURE
T104 BALANCE WEIGHTS
T107 BALANCE WEIGHTS
Hub balance weights (figure 13) are called for by the number of T104 weights (0.25 lb or 113 g) required. On RADS AT
equipment, these are identified as WEIGHTS. A 0.5 weight adjustment is achieved by using one T107 weight (0.14 lb or 63
g). In general, weight moves are made only to trailing edge location. The leading edge locations are used only when eight
large weights have been added to trailing edge. After eight weights have been added to trailing edge, add remaining weights
to leading edge location.
1. Review RADS AT correction data to determine which hub balance weight adjustments are required. Round
adjustments to nearest 0.5 weight.
2. Inspect hub to determine current balance weight configuration.
3. Determine required addition or subtraction of weights to make indicated adjustment.
4. Install required number of weights in locations shown in figure 13. Equalize number of weights on each side of balance
location arm. Do not exceed eight weights at any balance location.
5. Use required length of NAS6205 bolts to secure weights to balance arm. Ensure a minimum of two threads extend
beyond MS21042L5 nut. Torque bolt 100 to 140 in-lbs (11.30 to 15.82 Nm).
NOTE
Use small steel washers to compensate for bolts slightly longer than needed for hub
balance weights installed.
18-12-01
Rev. 2 Page 21
E-AB412-PT6T-2
1. Main rotor blade

2. Rear product balance pocket
3. Forward product balance pocket
4. Stainless steel tip cap
* 5. Adjustable trailing edge
6. Midspan trim tab
7. Inboard trim tab
8. Balance box cover screws
9. Outboard trim tab
* Factory adjustment only
G6AB0548B
Figure 11. Adjustments on 412-015-300 main rotor blade
18-12-01
Page 22 Rev. 2
E-AB412-PT6T-2
G6AB0549A
Figure 12. Tab gage for three-tab rotor blades
18-12-01
Rev. 2 Page 23
E-AB412-PT6T-2
G6AB0550A
Figure 13. Main rotor hub balance weights
18-12-01
Page 24 Rev. 2
E-AB412-PT6T-2
7. MAIN ROTOR BALANCING - PRODUCT BALANCE
MATERIALS REQUIRED
NUMBER NOMENCLATURE
C-307 ADHESIVE
NUMBER NOMENCLATURE
T117 PRODUCT BALANCE WEIGHTS
Once a main rotor has been product-balanced, it should not require additional product balancing until a blade is replaced, or
an existing blade is refinished, repaired, or otherwise altered. Therefore, when trimming a previously worked main rotor,
use pitch link adjustments and/or hub balance weight adjustments to correct balance. Product balance adjustments are
defined as the number of T118 weights added or removed from rear product balance pocket (2, figure 11). The forward
product balance pocket (3) and rear product balance pocket are at different blade stations. A different amount of weight must
be adjusted in each pocket to achieve the same balancing result.
To simplify product balance adjustment, table 2 shows combinations of weights needed to adjust product balance while
maintaining mass balance of blade. The smallest meaningful adjustment is a 0.5 weight adjustment. The following is an
example of how to use table 2.
EXAMPLE: The RADS AT data indicate to product balance the blue coded blade –0.4 weight. In table 2 shows this
adjustment is rounded to a –0.5 weight. Remove balance box covers screws (8, figure 11). Remove balance box covers. The
rear product balance pocket (2) is found to have one T118 weight installed. The forward product balance pocket (3) is found
to have one T119 weight installed.
Two possible combinations of adjustments will yield a –0.5 weight move. The table shows the first option is to remove T118
weight from rear product balance pocket, to add three T117 weights to this pocket, and to add two T117 weights, one
AN970-3 washer, and one AN970-4 washer to forward product balance pocket (3). The table shows the second option is to
remove three T117 weights from rear product balance pocket and add two T117 weights, one AN970-3 washer, and one
AN970-4 washer to forward product balance pocket. However, the rear product balance pocket does not have three T117
weights installed. Therefore, the second option can not be accomplished. Use first option to make required product balance
adjustment. Refer to actual procedure for removal and installation of weight hold down nuts, balance box covers, and
balance box cover screws.
18-12-01
Rev. 2 Page 25
E-AB412-PT6T-2
NOTE
Use the following conversions to convert from one weight (or set of weights) to
another.
Six 412-015-052-101 weights = one 412-015-053-101 weight.
Five 412-015-052-101 weights = one 412-015-056-101 weight.
Three AN970-4 washers = one 412-015-052-101 weight.
Two AN970-3 washers = one AN970-4 washers.
Four 412-015-052-101 weights + two AN970-4 washers + two AN970-3 washers =

one 412-015-056-101 weight.
1. Review RADS AT correction data to determine which blades require product balancing. Make balance adjustments in
increments no smaller than 0.5 weight.
2. For each blade requiring product balancing, remove cover screws (8, figure 11) from covers of forward product
balance pocket (3) and rear product balance pocket (2). Remove covers.
3. Identify and note weights installed in both pockets and refer to table 2 for required adjustment of weights.
NOTE
If required adjustment of weights can be made, proceed to step 4. If required
adjustment of weights cannot be made, perform step 7. Recalculate corrections
(module 18-12-01 paragraph "1. Main rotor balancing - rotor vibration measurement
instrumentation") using RADS AT equipment, and return to step 1. above.
4. Remove weight hold down nuts from forward product balance pocket and/or rear product balance pocket, as required,
to permit removal and addition of weights.
5. Add or remove weights to make adjustment described in table 2.
6. Install hold down nuts removed in step 4. Torque nuts 15 to 20 in-lbs (1.69 to 2.26 Nm).
7. Install cover on forward product balance pocket and on rear product balance pocket. Use balance box cover screws
removed during step 2.
8. Perform test flight (E-AB412-PT6T-1). If ride is satisfactory, proceed to step 9. If ride is not satisfactory, repeat step
1. through 8.
9. Upon completion of product balancing, perform the following steps as soon as practical.
a. Remove and discard all balance box cover screws (8, figure 11). Remove cover from forward product balance
pocket (3) and rear product balance pocket (2).
b. Replace all hold down nuts (MS21042L3) which were removed and installed during product balancing. Torque
nuts 15 to 20 in-lbs (1.69 to 2.26 Nm). Apply adhesive (C-307) to new hold down nuts and screw heads.
c. Apply adhesive (C-307) to mating surfaces of cover and blade pocket. Install cover on forward product balance
pocket and on rear product balance pocket.
d. Install new balance box cover screws. Apply adhesive (C-307) to screw heads before installation. Smooth
adhesive squeeze-out flush with contour of blade. Allow adhesive to cure before flight.
NOTE
Curing sealant at lower temperatures requires more time.
18-12-01
Page 26 Rev. 2
RADS AT ROUNDED OPTION FORWARD PRODUCT REAR PRODUCT
Rev. 2
INCREMENTS VALUE NO. BALANCE POCKET BALANCE POCKET
ADD REMOVE ADD REMOVE
0 to 0.3 0 1 --- --- --- ---
0 to -0.3 0 1 --- --- --- ---
0.3 to 0.7 0.5 1 Two 412-015-052-101 One 412-015-056-101 Three 412-015-052-101 ---
One AN970-3
One AN970-4
0.3 to 0.7 0.5 2 --- Two 412-015-052-101 Three 412-015-052-101 ---
One AN970-3
One AN970-4
-0.3 to -0.7 -0.5 1 Two 412-015-052-101 --- Three 412-015-052-101 One 412-015-053-101
One AN970-3
One AN970-4
-0.3 to -0.7 -0.5 2 Two 412-015-052-101 --- --- Three 412-015-052-101

One AN970-3
One AN970-4
0.8 to 1.3 1 1 --- One 412-015-056-101 One 412-015-053-101 ---
-0.8 to -1.3 -1 1 One 412-015-056-101 --- --- One 412-015-053-101

Table 2. Product balance adjustment combinations
NOTES:
1. The standard load of product balance for the 412-015-300-109 blade is a total of 0.3 lb (135 g), one 412-015-056-101 weight and one 412-015-052-101 weight,
in the forward product balance pocket and 0.35 lb (158 g), one 412-015-053-101 weight and one 412-015-052-101 weight, in the rear product balance pocket.
If serious problems occur with balancing the rotor, return the blades to the standard load of product balance and rework the rotor
2. One 412-015-052-101 weight weighs 0.05 lb (23 g). One 412-015-053-101 weight weighs 0.30 lb (135 g). One 412-015-056-101 weight weighs 0.25 lb (117 g).
3. Decide on the best move (s) that can be made from the options presented. Make the entire group of moves shown for the option chosen.
It may be necessary to add and subtract weights from the same product balance pocket to accomplish the adjustment.
18-12-01
Page 27
E-AB412-PT6T-2
E-AB412-PT6T-2
8. MAIN ROTOR BALANCING - SETTING AUTOROTATION RPM
MATERIALS REQUIRED
NUMBER NOMENCLATURE
C-405 LOCKWIRE
NOTE
Autorotation rpm should be set during first flight.
1. Check autorotation (rotor) rpm (figure 14).
2. If required, correct autorotation (rotor) rpm as follows:
WARNING
MAXIMUM EXPOSED THREADS SHALL NOT EXCEED 11 ON PITCH LINK

UPPER ROD END BEARING AND 8 ON LOWER ROD END BEARING.
NOTE
An airspeed of 65 KNOTS is used to set autorotation RPM.
a. If autorotation rpm is high, increase length of all pitch link assemblies an equal amount.
b. If autorotation rpm is low, decrease length of all pitch link assemblies an equal amount.
c. Remove lockwire and loosen jamnuts on pitch link. Adjust pitch link as required.
NOTE
One full turn of all four pitch link tubes will change autorotation rpm approximately
1% Nr. One full turn of all four pitch link upper rod ends will change autorotation
RPM approximately 3%.
d. Center upper rod end bearing in pitch horn clevis. Center lower rod end bearing in re-phasing lever clevis. Hold
pitch link tube and torque jamnuts 120 to 150 in-lbs (13.56 to 16.95 Nm). Secure lower jamnut to pitch link tube
insert using lockwire (C-405).
e. Test fly helicopter to confirm autorotation rpm is set correctly (E-AB412-PT6T-1).
f. After final adjustment apply corrosion preventive compound (C-101) to threads of pitch link.
8-1-1. Setting autorotation rpm - control of main rotor 2/rev
The standard accelerometer fit for RADS is adequate to monitor 2/rev levels. Main rotor 2/rev vibration results when one
pair of blades is not generating the same lift as the other pair of blades. This is normally reduced to acceptable levels by
flying the rotor as close to the ±20 mm track spread as possible. This track spread is automatically targeted by the desired
spread. When normal tracking does not reduce vibration to an acceptable level, refer to figure 15 for further corrective
action.
18-12-01
Page 28 Rev. 2
E-AB412-PT6T-2
8-1-2. Setting autorotation rpm - control of main rotor 4/rev
The next most predominant vibration (besides 1/rev) is main rotor 4/rev. This vibration is perceived by the crew and
passengers as a “buzz” in the cabin. The primary device for maintaining low 4/rev levels is the pendulum absorber assembly
on the main rotor hub. Secondary devices are instrument panel fore-and-aft struts (being delivered on new aircraft) and
instrument panel frahm absorber. These devices are designed to reduce instrument panel vibration which can blur
instruments and cause crew to perceive higher vibration levels.
Many factors can affect the 4/rev levels. These include:
1. Degradation of the pendulum absorbers.
2. Loose battery or avionics in nose.
3. Loose instrument housings in the instrument panel.
4. ow break-out friction in the elevator.
5. Cracks or looseness in the instrument panel support structure (cracks in glare shield, loose side brace attachments to
the airframe, and the sympathy of special kits to the 4/rev vibration. If 4/rev is perceived or measured to be higher than
normal, refer to module 18-12-02 "MAIN ROTOR BALANCING - TROUBLESHOOTING" for recommended
corrective action.
9. MAIN ROTOR BALANCING - RIDE QUALITY GUIDELINES
The following guidelines are provided as recommended action to be followed depending upon existing ride quality.
1. Main rotor 1/rev in flight:
a. 0 - 0.2 ips: No action required.
b. 0.2 - 0.5 ips: 1/rev levels are serviceable with no corrective action required.
c. 0.5 - 1.0: 1/rev levels higher than recommended. Corrective action should be taken as soon as possible.
d. Over 1.0 ips: 1/rev levels unacceptable for continued service. Helicopter should be removed from service as soon
as possible and corrective action taken.
2. Main rotor 2/rev: The RADS is programmed to alert the operator if 2/rev levels exceed 0.15 ips. This is only a guide
to ride quality. If 2/rev is above 0.15 ips refer to paragraph "8-1-1. Setting autorotation rpm - control of main rotor 2/
rev" for corrective action. Normally, the RADS will correct 2/rev automatically by controlling spacing between rotor
blade pairs.
3. Main rotor 4/rev: Main rotor 4/rev is dependent on kits installed and condition of nose structure. As measured on the
instrument panel, 4/rev levels at 120 knots below 1.0 ips should be considered normal. 4/Rev levels above 1.0 ips at
120 knots are above normal, refer to module 18-12-02 paragraph "1. Main rotor balance - troubleshooting" for
corrective action.
18-12-01
Rev. 2 Page 29
E-AB412-PT6T-2
NOTE:
Refer to model 412 Flight Manual for density altitude chart.
G6AB0551B
Figure 14. Autorotation descent rotor rpm chart
18-12-01
Page 30 Rev. 2
E-AB412-PT6T-2
NOTES:
1. Adjust tabs to obtain stable track readings from hover to 120 kts.
2. Plot 120 kt lateral 2/rev on chart if above .15 IPS.
3. Make indicated pitch link adjustment on one pair of blades to minimize 2/rev.
G6AB0552B
Figure 15. 2/Rev chart
18-12-01
Rev. 2 Page 31
E-AB412-PT6T-2
Table 3. Example of track change with a shifting hub
A) TRACK FOR ORIGINAL FLIGHT B) TRACK AFTER RIDE CHANGED
TEST BLADE COLOR CODE TEST BLADE COLOR CODE

ID BLU ORG RED GRN ID BLU ORG RED GRN
IDL 16 –17 11 –10 IDL 17 –17 9 –10
FPG100 12 –17 15 –10 FPG100 9 –22 20 –7
HOV 16 –18 14 –11 HOV 10 –10 19 –9
CLI 13 –15 15 –12 CLI 6 –17 22 –11
100 14 –8 11 –17 100 7 –13 21 –14
120 10 –6 16 –20 120 3 –10 24 –17
VNE 10 –7 17 –20 VNE 4 –12 26 –18
LET 11 –17 18 –20 LET 6 –19 23 –10
C) CHANGE IN TRACK Change in track is obtained by subtracting the track num-

bers obtained in the original flight from those obtained
TEST BLADE COLOR CODE after the ride changed. To determine if the hub is shifting
ID BLU ORG RED GRN on its cones, look at the change in track at idle and at 120
IDL 1 0 –2 0 knots. If the track does not change at idle, but has changed
FPG100 –3 –5 5 3 significantly at 120 knots with the blades of a pair changing
HOV –6 –8 5 2 equally and oppositely, the hub is probably shifting. This is
CLI –7 –2 7 1 an actual example of a hub shifting on the cones. Notice the
100 –7 –5 10 3 track change of the blue and red blades at 120 knots.
120 –7 –4 8 3
VNE –6 –5 9 2
LET –5 –2 5 10
18-12-01
Page 32 Rev. 2
E-AB412-PT6T-2
18-12-02
MAIN ROTOR BALANCING - TROUBLESHOOTING
1. MAIN ROTOR BALANCE - TROUBLESHOOTING
In table 1 are listed the corrective actions if problems are encountered reducing vibration to acceptable levels. Problems with
RADS are addressed in flow chart (figure 2) and table 2, table 3, table 4 and table 5.
Table 1. Troubleshooting main rotor vibration
PROBLEM SOURCE CORRECTIVE ACTION
Unworkable or sensitive lateral Soft pylon mounts If 204-031-927-105 are installed replace with
1/rev 204-031-927-107 mount.
Lead-lag dampers Replace lead lag damper pair which show

erratic trends as described in figure 1.
Degraded -107 mounts Inspect -107 pylon mounts for degradation.
Degraded skid gear supports Inspect cross tube support rubber for degrada-
tion. Replace separated supports.
Changing 1/rev Creeping tabs Check tab angles. If tab is washing out, correct
using RADS to specify corrective adjustment.
Overbend tab and set to proper position to min-
imize tab creep.
Hub shifting on the cones Check upper and lower cone torques. Refer to
table 1 for signature of hub shift.
Unworkable vertical 1/rev in Mismatched rotor blades Turn on inboard tabs (blue and orange only),
flight eliminate VNE condition when working rotor if
not required for normal missions. Replace
blades which show erratic track with airspeed.
Unworkable vertical and lateral Failed inboard spindle bearing Inspect inboard spindle bearings; replace those
1/rev beyond limits.
Main rotor 2/rev Unequal lift between blade pairs Retrack rotor to minimize change in track
between pairs with airspeed using midspan tabs
(1 = 11mm).
Use pitch links to minimize 2/rev using the

chart in figure 3.
18-12-02
Rev. 2 Page 1
E-AB412-PT6T-2
(Cont.d)
Main rotor 4/rev Degraded pendulums Grease pendulums.
Inspect pendulums for worn bearings.
Loose airframe structure Tighten battery. Tighten instruments. Repair

instrument panel support, glareshield cracks.
Install F/A panel braces.
Table 2. Troubleshooting RADS main rotor
Adjustments do not reduce 1/rev Accelerometer cables crossed Verify proper installation
CADU will not communicate with DAU not getting power Check switch, cable, and power port
DAU
Tracker cable internally shorted Disconnect cable, if CADU now com-

municates with DAU. Repair or
replace tracker cable.
TACHO failure Incorrect hook-up Connect azimuth to TACHO #1
Magnetic pickup to interrupter gap Correct gap

incorrect
Airframe wiring failed Bypass ship’s wiring and route

TACHO cable directly to sensor
Bad daylight track data Bare blade leading edge Paint leading edges
Data corrupted by sunlight Add sunshield, take data flying away

from sun.
Tracker backwards Position tracker with lens forward.
Track swaps (upper to lower) Corrupted track data Repeat. If persistent, replace tracker.
No track data at night Incorrect tracker angle Correct tracker angle
Old reflective tape Replace tape
DAU switch in wrong position Set to “Night”
Tracker bulb burned out Replace tracker
18-12-02
Page 2 Rev. 2
E-AB412-PT6T-2
NOTES:
1. Subtract the ORG lead-lag from the GRN and plot on a copy of the chart.
2. Subtract the BLUE lead-lag from the RED and plot on a copy of the chart.
3. Properly operating dampers will have a straight tread.
4. Possible faulty dampers will have a tread of changing lead-lag with the idle and letdown near the same value.
G6AB0553B
Figure 1. Lead - lag trending (sheet 1 of 2)
18-12-02
Rev. 2 Page 3
E-AB412-PT6T-2
LEAD-LAG DATA IS OBTAINED BY

SUBTRACTING RED FROM BLUE FOR
THE UPPER BLADE PAIR AND ORANGE
FROM GREEN FOR THE LOWER PAIR.
G6AB0554A
Figure 1. Lead - lag trending (sheet 2 of 2)
18-12-02
Page 4 Rev. 2
E-AB412-PT6T-2
3 4 5
G6AB0555A
Figure 2. Flow chart for troubleshooting main rotor
18-12-02
Rev. 2 Page 5
E-AB412-PT6T-2
NOTES:
1. Adjust tabs to obtain stable track readings from hover to 120 kts.
2. Plot 120 kt lateral 2/rev on chart if above .15 IPS.
3. Make indicated pitch link adjustment on one pair of blades to minimize 2/rev.
G6AB0552B
Figure 3. 2/Rev chart
18-12-02
Page 6 Rev. 2
E-AB412-PT6T-2
Table 3. Troubleshooting chart when no changes are identified
High lateral 1/rev at idle, and at 100% Hung droop stops 1. Inspect droop stops for binding and
RPM. Vibration will not respond nor- ensure correct rigging. Correct any discrep-
mally to balance moves. Vibration ancies found. (Note: RADS can be used to
could be intermittent from run to run. guide inspections. Check phase of lateral 1/
rev at idle: ORG=250, BLUE=340,
GRN=160, RED=70).
Remove all hub balance weights and rebal-
ance with RADS to verify correction of
problem.
2. If problem persists, remove droop stop

arms and operate aircraft without them for
maintenance tests only. Balance rotor using
RADS. Once rotor has been balanced, rein-
stall droop stops and rig per maintenance
manual.
High ground bounce at approx. 80% Swashplate support 1. Inspect swashplate support bearings for
rotor rpm. Idle 1/rev not excessive. proper installation and serviceability.
Excessive ground bounce only at Rotor track and balance 1. Reinstall RADS and balance rotor at
100% RPM. 100% RPM. Have flight crew position col-
lective and cyclic to minimize vibration
during normal operation.
Vertical 1/rev at 120 knots will not Cracked trim tab 1. Inspect all tabs and replace any found
respond to tab moves. cracked.
Vertical 1/rev in hover and climb, but Elastomeric failure 1. Inspect spindles for signs of elastomer
not at 120 knots. delamination. Replace any rubber bearing
delaminated beyond maintenance manual
limits. (Note: Use following hover vertical
phase as a guide: ORG=190, BLUE=280,
GRN=100, RED=10.)
Control system looseness 2. Inspect control system rod end bearings

for excessive wear. Replace any worn bear-
ing. (Note: Use following hover vertical
phase as a guide: ORG=0, BLUE=90,
GRN=180, RED=270.)
Rotor will not stay tracked. Hub shift 1. Incorporate improved hub to mast joint.
2. If above has been incorporated, retorque

rotor head cones and thru bolts.
18-12-02
Rev. 2 Page 7
E-AB412-PT6T-2
(Cont.d)
Lateral 1/rev in flight which will not Soft pylon mounts 1. Install pylon mounts
respond properly to adjustments. P/N 204-031-927-107.
Lead-lag damper loose- 1. Inspect lead-lag damper to spindle joint

ness failure for black “smoke” which would indicate
looseness. To correct, bond joint on all
dampers.
Lateral 1/rev in flight which will not Lead-lag damper loose- 2. Review lead-lag trends as defined in
respond properly to adjustments. ness/failure maintenance manual. Replace pair which
shows “problem” trend.
Lateral 1/rev in letdown which has Control system looseness 1. Inspect control system rod end bearings
appeared to degrade over time. for excessive wear. Replace any worn bear-
ing.
Vertical 1/rev in flight which Soft trim tabs 1. Inspect trim tabs and reset to previous
appeared to degrade over time. levels.
2. Replace trim tabs that are too soft and

washout or tabs that are too stiff and creep.
Table 4. Troubleshooting rotor blade problems
Excessive lateral 1/rev at idle and Main rotor blade unbalance Note: Verify droop stop rigging
higher rpms which cannot be bal- prior to conducting following steps.
anced with available hub weight
provisions.
1. Check main rotor product bal-

ance pockets to verify that blades
have proper loading. Reset blade
product balance as necessary to
return blade to proper loading.
2. If resetting product balance does

not fix balance problem, check lat-
eral 1/rev phase at idle. 245 is
BLUE heavy, 135 is ORANGE
heavy, 45 is RED heavy, 315 is
GREEN heavy. Statistically, the
heavy blade is the problem as it is
hard to make a blade lighter than
master balance.
18-12-02
Page 8 Rev. 2
E-AB412-PT6T-2
(Cont.d)
To correct problem:
A) Remove suspect blade(s) and

balance on scale balancer.
B) Replace suspect blade with

another.
Note: In an emergency when addi-

tional blades are not available it is
possible to adjust the product bal-
ance weights to balance the rotor.
This, however, will limit the ability
to product balance the rotor in
flight. To balance the blade using
product balance either add a –056
weight to the light blade’s leading
edge pocket, or remove a –056
weight from the heavy blade’s trail-
ing edge pocket. One –056 weight
is worth eleven (–11) hub weights.
Excessive track change with rpm. Blade outboard trailing edge shape Note: Verify RADS tracker, install
problem as described in flow chart.
1. Use midspan tab to help outboard

tab correct track change.
2. Observe other blades. If another

blade has similar track trend with
rpm, repair the rotor blades so that
blades with similar rpm trends are
opposite of each other.
3. Contact AgustaWestland service

rep. about bending the outboard
trailing edge of the blade to correct
rpm trend.
4. Replace blade.
Excessive vertical on first flight Inboard contour of blade 1. Inspect trim tabs to ensure that
after ground tracking which cannot they are not cracked or damaged.
be worked to an acceptable ride
with RADS and standard tab adjust-
ments.
18-12-02
Rev. 2 Page 9
E-AB412-PT6T-2
(Cont.d)
2. Use midspan tab to help outboard

tab correct/reduce vibration levels.
3. Observe track change from

FPG100 to 120 knots and from 120
knots to VNE. Repair rotor blades
to match observed track trends.
Rework rotors. If this cannot be
done or does not work, then replace
blades with abnormal track trend.
Excessive lateral in flight. Soft pylon mounts 1. Install pylon mounts

P/N 204-031-927-107.
Lateral and/or F/A 1/rev in flight. Mismatched blades 1. Observe track characteristics of
blades. Change blade(s) which do
not behave as the others.
Excessive track change from Product balance 1. Verify RADS tracker installation.
ground to hover and vibration in
hover.
2. Reset blade product balance to

nominal.
3. Replace blade(s) which do not

have sufficient product balance
capability to obtain an acceptable
ride.
Table 5. Troubleshooting main rotor hub/control system faults
High lateral 1/rev at idle, during run Hung droop stops 1. Inspect droop stops for binding
up, and at 100% RPM. Vibration and ensure correct rigging. Correct
will not respond normally to bal- any discrepancies found. (Note:
ance moves. Vibration could be RADS can be used to guide inspec-
intermittent from run to run. tions. Check phase of lateral 1/rev
at idle: ORG=250, BLUE=340,
GRN=160, RED=70.)
Remove all hub balance weights
and rebalance with RADS to verify
correction of problem.
18-12-02
Page 10 Rev. 2
E-AB412-PT6T-2
(Cont.d)
2. If problem persists, remove

droop stop arms and operate aircraft
without them for maintenance tests
only. Balance rotor using RADS.
Once rotor has been balanced, rein-
stall droop stops and rig per mainte-
nance manual.
Excessive ground bounce only at Rotor track and balance 1. Reinstall all RADS and balance
100% RPM. rotor at 100% RPM. Have flight
crew position collective and cyclic
to minimize vibration during nor-
mal operation.
Vertical 1/rev in hover and climb, Elastomeric failure 1. Inspect spindles for signs of elas-
but not at 120 knots. tomer delamination. Replace any
rubber bearing delaminated beyond
limits. (Note: use following hover
vertical phase as a guide:
ORG=190, BLUE=280,
GRN=100, RED=10.)
Rotor will not stay tracked. Hub shift 1. Incorporate improved hub to
mast joint.
2. If above has been incorporated,

retorque rotor head cones and thru
bolts.
Lateral 1/rev in flight which will Lead-lag damper looseness/failure 1. Inspect lead-lag damper to spin-
not respond properly to adjust- dle joint for black “smoke” which
ments. would indicate looseness. To cor-
rect, bond joint on all dampers.
2. Review lead-lag trends as defined

in maintenance manual. Replace
damper pair which shows “prob-
lem” trend.
High ground bounce at approx. 80% Swashplate support 1. Inspect swashplate support bear-
rotor rpm. Idle 1/rev not excessive. ings for proper installation and ser-
viceability.
18-12-02
Rev. 2 Page 11
E-AB412-PT6T-2
(Cont.d)
Vertical 1/rev in hover and/or climb, Control system looseness 1. Inspect control system rod end
but not at 120 knots. bearings for excessive wear.
Replace any worn bearing. Look at
track to note any blade that climbs
from hover to climb then dives from
climb to 120 knots. Inspect this
blade’s control system. (Note: Use
following hover vertical phase as a
guide: ORG=0, BLUE=90,
GRN=180, RED=270.)
18-12-02
Page 12 Rev. 2
E-AB412-PT6T-2
18-12-03 TAIL ROTOR BALANCING (SCIENTIFIC ATLANTA ROTOR ANALYSIS AND DIAGNOSTIC SYSTEM, MODEL AT (RADS AT))
18-12-03
TAIL ROTOR BALANCING (SCIENTIFIC ATLANTA ROTOR ANALYSIS AND
1. TAIL ROTOR BALANCING - CONTROL OF TAIL ROTOR VIBRATION
Vibration from tail rotor can be perceived as a medium to high frequency vibration in the airframe. The following procedures
should be conducted when:
1. Flight crew feels abnormal medium to high frequency vibration.
2. After any component changes in tail rotor/90 gearbox assembly.
3. After 300 hour and annual inspections.
2. TAIL ROTOR BALANCING - INSTALLATION OF THE RADS
NUMBER NOMENCLATURE
T72 ACCELEROMETER BRACKET (STIFF)
T72 212/412 OPTICAL TAIL ROTOR BRACKET

BASIC RADS OPERATING SYSTEM, 3,10AO OR GREATER
412_41 VERSION 5,22 OR GREATER FOR USE ON HELICOPTERS
WITH 204-031-927-105 PYLON MOUNTS
412_50 VERSION 5,24 OR GREATER FOR USE ON HELICOPTERS

WITH 204-031-927-107 PYLON MOUNTS
T72 ACCELEROMETER CABLE
T73 ACCELEROMETER (WILCOXU)
Install RADS to balance tail rotor as follows:
1. Locate DAU (29328200) in cabin aft of crew compartment in a convenient area.
2. Remove nut from top stud (12:00 o'clock position) on 90 gearbox. Using (29329700) accelerometer bracket (T72) (or
equivalent), install one accelerometer (T73) on stud with connector up and secure with nut. Connect accelerometer end
of 50 foot long accelerometer cable (29105600) (T72) to vertical accelerometer. Route to DAU down left side of fin
and tailboom. Secure so it can not foul tail rotor or controls. Connect to ACC #4 (figure 1).
18-12-03
Rev. 3 Page 1
E-AB412-PT6T-2
3. Attach optical rpm sensor (29314700) to tail rotor optical sensor bracket (29338500A) (T72) so wire is on flange edge
of bracket. Secure sensor to bracket with #440 self locking nuts. Remove nut from aft stud on 90 gearbox and install
sensor/bracket. Secure with gearbox nut so it is level to horizon and pointed directly aft (figure 1). Route optical sensor
cable to DAU, down left side of fin and tailboom. Secure cable so it cannot foul tail rotor or controls. Connect cable
to TACHO #2 on DAU.
4. Check the blades to determine which one does not have large balance washers on gearbox side of blade bolts. This will
be target blade. Install a full width piece of reflective tape (10605000) between two blade bolts on gearbox side of
blade (figure 1).
5. Connect 28 Vdc power cable (29104700) to 28 Vdc port on copilot side of pedestal (figure 3). Connect other end of
cable to 28 Vdc connector on DAU.
6. Connect CADU to DAU using communications cable (29325601).
7. When correctly installed, RADS should be configured as shown in figure 2.
3. TAIL ROTOR BALANCING - TESTS TO BALANCE THE TAIL ROTOR
1. Turn on CADU. From the main screen select the proper 412 program, select or define the tail number of the helicopter
and select TAIL as FLIGHT PLAN. This configures RADS to balance tail rotor. An example of a properly setup
CADU is shown in figure 4.
2. Press F1 to activate MEASUREMENT mode.
3. Operate helicopter with either or both power sections operating (operate as near 100% rpm as possible if operating
both power sections or 99% with single power section operating).
4. Once rpm and temperatures have stabilized, press DO to obtain balance data. In event any error occurs, repeat
acquisition of data up to four times before shutting down helicopter and troubleshooting system as described in
module 18-12-04 "TAIL ROTOR BALANCING - TROUBLESHOOTING".
5. Once the data has been obtained shut down the helicopter.
6. With the data taken, select DIAGNOSTICS to define what adjustments are required to balance tail rotor. Record
adjustments to be made and implement as described in paragraph "4. Tail rotor balancing - making tail rotor balance
adjustments".
7. Repeat tests until the tail rotor has been balanced. To troubleshoot balancing problems refer to
module 18-12-04 "TAIL ROTOR BALANCING - TROUBLESHOOTING".
4. TAIL ROTOR BALANCING - MAKING TAIL ROTOR BALANCE ADJUSTMENTS
RADS specifies balance adjustments required to balance the tail rotor as adjustments made only to target the blade. There
are three dynamic adjustments available: the chordwise balance bracket, inboard blade bolt, and outboard blade bolt. The
default in the RADS software is to use only chordwise balance bracket and inboard blade bolt. Should the operator need to
use the outboard bolt for balance, then from within DIAGNOSTICS, select EDIT ADJUSTABLES from DIAGNOSTICS
menu and use F1 to turn off the inboard blade bolt (by changing Y to N) and then use F1 to turn on the outboard blade bolt
on the target blade only (N to Y). Pressing DO will automatically recalculate corrections using the outboard blade bolt.
Once adjustments to target blade have been defined, determine what moves can be made. If RADS specifies to add weight
to a location where weight is on opposite blade, the proper course is to remove required amount from opposite location. If
RADS specifies to remove weight from a location that does not have weight, add weight to opposite side. Refer to figure 5
for information on making balance adjustments.
1. The target blade is the one with the reflector.
18-12-03
Page 2 Rev. 3
E-AB412-PT6T-2
2. The target chordwise balance bracket is next to the target pitch link.
3. It is acceptable to add chordwise weight on the both the blank and target balance brackets to make moves smaller than
can be made on one side only due to weight of the bolt.
5. TAIL ROTOR BALANCING - TRACKING TAIL ROTOR
The optimum tail rotor vibration in flight (within the current 1/2 turn pitch link adjustment capability) is achieved with the
pitch links set to as nearly equal lengths as possible. Therefore, tracking tail rotors is no longer required if the operator sets
both pitch links as shown in figure 6.
NOTE
Helicopters equipped with the fixed length T/R pitch change links
P/N 212-310-701-101 do not require tracking of tail rotor.
18-12-03
Rev. 3 Page 3
E-AB412-PT6T-2
G6AB0556A
Figure 1. Equipment installation, tail rotor balancing
18-12-03
Page 4 Rev. 3
E-AB412-PT6T-2
G6AB0557A
Figure 2. RADS configuration, tail rotor balancing
18-12-03
Rev. 3 Page 5
E-AB412-PT6T-2
2. Helicopter magnetic pickup receptacle
3. Power receptacle
NOTE:
Cables go to the lateral, vertical and fore-and-aft accelerometers.
G6AB0425B
18-12-03
Page 6 Rev. 3
E-AB412-PT6T-2
G6AB0558A
Figure 4. CADU screen for tail rotor balance
18-12-03
Rev. 3 Page 7
E-AB412-PT6T-2
2 3
1
4
5
14
12 7
11
6 9
8
13
12
11
10
1. Blade bolt
2. Washer
3. Tail rotor blade
4. Washer
5. Washer
6. Washer
7. Washer
8. Washer
9. Nut
10. Bolt
11. Washer
12. Washer
13. Balance bracket
14. Nut
CORROSION PREVENTIVE COMPOUND (C-104)
CORROSION PREVENTIVE COMPOUND (C-101)
60 IN-LBS
(6.7 Nm)
500 TO 550 IN-LBS

(57 TO 62 Nm)
NOTES:
1 Apply a coating of corrosion preventive compound (C-104) to the shanks of the bolts (1 and 10) prior to installation. Do not
apply corrosion preventive compound to bolt threads.
2 Apply a coating of corrosion preventive compound (C-101) to all bolt heads, washers, nuts and exposed threads after installa-
tion.
G6AB1047A
Figure 5. Tail rotor dynamic balance weight adjustment (sheet 1 of 2)
18-12-03
Page 8 Rev. 3
E-AB412-PT6T-2
BLADE BOLT SPANWISE BALANCE HARDWARE 3

ITEM NUMBER NOMENCLATURE PART NUMBER WEIGHT (GRAMS)
1 BLADE BOLT NAS1308-34 87.5
1 BLADE BOLT 20-057-8-34 84.8
1 BLADE BOLT NAS1308-36 90.7
1 BLADE BOLT 20-057-8-36 88.0
5 WASHER AN970-8 37.7
6 WASHER 212-010-764-1 11.3
7 WASHER AN960-816 3.2
7 WASHER NAS1149F0863P 5.1
8 WASHER AN960-816L 1.6
9 NUT NAS1022A8 8.9
9 NUT MS21245-L8 9.9
CHORDWISE BALANCE BRACKET HARDWARE 4

ITEM NUMBER NOMENCLATURE PART NUMBER WEIGHT (GRAMS)
10 BOLT NAS1304-1 5.4
10 BOLT NAS6604-1 5.2
10 BOLT NAS1304-2 5.8
10 BOLT NAS6604-2 5.6
10 BOLT NAS1304-3 6.2
10 BOLT NAS6604-3 5.9
10 BOLT NAS1304-4 6.5
10 BOLT NAS6604-4 6.3
10 BOLT NAS1304-6 7.3
10 BOLT NAS6604-6 7.1
10 BOLT NAS1304-8 8.0
10 BOLT NAS6604-8 7.9
10 BOLT NAS1304-10 8.7
10 BOLT NAS6604-10 8.9
10 BOLT NAS1304-12 9.4
10 BOLT NAS6604-12 9.4
10 BOLT NAS1304-14 10.2
10 BOLT NAS6604-14 10.2
11 WASHER AN960-416 1.2
12 WASHER AN970-4 7.5
14 NUT MS21042L4 1.6
NOTES:
3 To accomplish spanwise dynamic balance, use blade bolts (1) as required to accommodate balance washers (5, 6, 7 or 8). Bolts
(1) may be installed with head, inboard or outboard, but all four blade bolts must be installed the same. When change of bal-
ance washers and/or bolts is required, make sure that one washer (2) and one washer (4) are installed next to the blade as illus-
trated. Then install the heaviest balance washer next to the washer (4). Install the required combination of washers (5, 6, 7, or
8) on blade (3) or on opposite blade as required to obtain balance. After installation, make sure proper thread engagement of
two complete threads is shown on bolt.
4 To accomplish chordwise dynamic balance on balance brackets (13), use bolts (10) as required to accommodate the required
combination of balance washers (11 and 12). Use a maximum of two washers (12) and a maximum of ten washers (11) on one
bracket. Install washers (11 and 12) symmetrically. Install the required hardware on balance bracket (13) or opposite bracket
(not illustrated), as required to obtain balance. It is also acceptable to install balance hardware on both balance brackets to
make moves smaller than can be made on one bracket only due to the weight of the bolt.
Figure 5. Tail rotor dynamic balance weight adjustment (sheet 2 of 2)
18-12-03
Rev. 3 Page 9
E-AB412-PT6T-2
6.190 in (157.226 mm)

6.170 in (156.718 mm)
NOTE:
Set both pitch links to equal lengths.
(T/R Pitch link 212-011-710-1)
6.115 in (155.321 mm)
(T/R Pitch link 212-310-701-101)
G6AB0541B
Figure 6. Tail rotor pitch link rigging
18-12-03
Page 10 Rev. 3
E-AB412-PT6T-2
18-12-04
TAIL ROTOR BALANCING - TROUBLESHOOTING
1. TAIL ROTOR BALANCING - TROUBLESHOOTING
Table table 1 lists probable causes of helicopter and RADS problems encountered during balancing of the tail rotor.
Table 1. Troubleshooting tail rotor balance
No TACHO or TACHO No/dirty reflective tape Install or replace reflective tape.

out-of-bounds warnings
Optical Sensor fault Refer to figure 1 to fine tune sensor.
Acceleration saturation warning Accelerometer saturation Verify accelerometer bracket is stiff. Replace
accelerometer.
18-12-04
Page 1
E-AB412-PT6T-2
G6AB0430A
Figure 1. Troubleshooting optical pickup
18-12-04
Page 2
E-AB412-PT6T-2
18-12-05 BALANCING MAIN DRIVESHAFT (SCIENTIFIC ATLANTA ROTOR ANALYSIS AND DIAGNOSTIC SYSTEM, MODEL AT (RADS AT))
18-12-05
BALANCING MAIN DRIVESHAFT (SCIENTIFIC ATLANTA ROTOR
ANALYSIS AND DIAGNOSTIC SYSTEM, MODEL AT (RADS AT))
1. BALANCING MAIN DRIVE SHAFT - CONTROL OF MAIN DRIVESHAFT VIBRATION
NOTE
Helicopters code [D] and subsequent equipped with Main Driveshaft
P/N 412-040-005-101/-103, perform main driveshaft balancing whenever driveshaft
is removed and reinstalled.
Most Model AB412 helicopters will make a pulsating low frequency noise at flat pitch due to normal amount of freeplay in
shaft coupling and gearbox bearings. If this pulsating noise is present in hover, shaft out-of-balance is indicated. High levels
of shaft out-of-balance will be perceived as a buzz in the tail rotor pedals in addition to a pulsating noise.
Balancing the main driveshaft can minimize an out-of-balance condition. During balancing procedure, 0,2 ips or less should
be the vibration level attained to maintain the vibration levels within acceptable limits during the time in-service of the shaft.
For helicopters prior to codes [A][B][C], this procedure is optional and not required for any component life or serviceability
requirement. For helicopters code [D] and subsequent equipped with Main Driveshaft P/N 412-040-005-101/-103, refer to
table 1 for balance criteria.
Table 1. Helicopter code [D] main drive balance criteria
VIBRATION OPERATION VIBRATION LEVEL RECOMMENDED ACTION

FREQUENCY CONDITION
Main driveshaft 1/rev 100% NR on ground 0,2 ips or less Vibe. Equipment target value
0,5 ips or less No immediate action required
Greater than 0,5 ips Balance driveshaft
2. BALANCING MAIN DRIVESHAFT - INSTALLATION OF RADS
NUMBER NOMENCLATURE
T72 ACCELEROMETER BRACKETS (STIFF) (2)
T72 412 OPTICAL SENSOR TAIL ROTOR ADAPTER

BASIC RADS OPERATING SYSTEM, 3,10AO OR GREATER
412-41 VERSION 5,22 OR GREATER FOR USE ON HELICOPTER
WITH 204-031-927-105 PYLON MOUNTS.
18-12-05
Page 1
E-AB412-PT6T-2
(Cont.)
NUMBER NOMENCLATURE
412-50 VERSION 5,24 OR GREATER FOR USE ON SHIPS WITH

204-031-927-107 PYLON MOUNTS
T72 ACCELEROMETER CABLE
T73 ACCELEROMETER (WILCOXU)
1. Locate DAU (29328200) (T71) in cabin aft of crew compartment in a convenient area.
2. Install one accelerometer (T73) using bracket (29329700) (T72) (or equivalent) on right side of combining gearbox
(figure 1). Orient accelerometer and bracket in a horizontal plane with connector pointing outboard. Connect
accelerometer end of an accelerometer cable (291056000 and 29105605) (T72) to combining gearbox accelerometer.
Route to DAU so it can not foul any rotating components, and connect to ACC #3.
3. Using a 29329700 stiff accelerometer bracket (T72) (or equivalent), install one accelerometer (T73) on stud of main
driveshaft input quill (refer to figure 1) by removing Allen head screw and using a bolt to secure accelerometer. Orient
accelerometer and bracket in a horizontal plane with connector pointing outboard. Connect accelerometer end of an
accelerometer cable (291056000 and 29105605) (T72) to transmission input quill accelerometer, route to DAU so it
can not foul any rotating components and connect to ACC #4.
4. Attach optical rpm sensor (29314700) to tail rotor driveshaft optical sensor bracket (29337500A or 29338501) (T72)
so wire is opposite flange edge of bracket. Secure sensor to bracket with self locking nuts. Remove right hand inlet
cowl and install optical pickup to cowling alignment bracket using a bolt (5, figure 3), washers (1 and 6), and nut
(2). If properly installed, optics will be looking at shaft and wire will be pointed up. Route optical sensor cable up and
to right and secure to a convenient location with a tie-wrap. Route cable into cabin ensuring it can not foul any rotating
components. Connect cable to TACHO #2 on DAU.
5. With optical sensor installed, turn shaft so one shaft-to-adapter bolt is directly on top. With shaft in this position, center
a 2,0 in. by 1,0 in. piece of reflective tape on shaft with long axis of tape aligned with long axis of shaft and centered
relative to shaft-adapter bolt. The bolt aligned with reflector is #1 bolt (figure 4).
6. Connect 28 VDC power cable (29104700) to 28 VDC port on copilot side of pedestal (figure 2). Connect other end of
cable to 28 VDC connector on DAU.
7. Connect CADU (29314101 or 29481301) to DAU using communications cable (29325601).
8. The RADS is now installed and ready to balance driveshaft. When correctly installed, RADS should be configured as
shown in figure 5.
18-12-05
Page 2
E-AB412-PT6T-2
G6AB0424A
Figure 1. Equipment installation, main driveshaft balancing
18-12-05
Page 3
E-AB412-PT6T-2
G6AB0425A
18-12-05
Page 4
E-AB412-PT6T-2
G6AB0426A
Figure 3. Optical sensor and bracket
18-12-05
Page 5
E-AB412-PT6T-2
G6AB0427A
Figure 4. Reflector tape installation, main driveshaft
18-12-05
Page 6
E-AB412-PT6T-2
G6AB0428A
Figure 5. RADS configuration for balancing main driveshaft
18-12-05
Page 7
E-AB412-PT6T-2
3. BALANCING MAIN DRIVESHAFT - TESTS TO BALANCE DRIVESHAFT
1. Install RADS, paragraph "2. Balancing main driveshaft - installation of RADS".
2. Turn on CADU and, from the main screen, select proper 412 program. Select or define TAIL number of aircraft and
select D/S (for standard 412 and 412SP) or D/S-HP (412HP) as FLIGHT PLAN (figure ). This will configure the
RADS to balance main driveshaft.
3. Press F1 to activate measurement mode.
4. Operate helicopter (E-AB412-PT6T-1) with both power sections at 100% main rotor rpm.
5. Once rpm and temperatures have stabilized, press DO to obtain balance data (on initial run wait five minutes to warm
up grease).
NOTE
In case of any error, repeat acquisition of data up to four times before shutting down
helicopter and troubleshooting system (paragraph "6. Balancing main driveshaft -
troubleshooting").
6. Once data has been obtained, shut down helicopter.
7. With data taken, select DIAGNOSTICS to define what, if any, adjustments are required to balance driveshaft
(paragraph "5. Balancing main driveshaft - making adjustments").
8. Repeat tests until driveshaft has been balanced. To troubleshoot balancing problems, refer to paragraph "6. Balancing
main driveshaft - troubleshooting". Upon completion, remove RADS equipment from helicopter.
4. BALANCING MAIN DRIVESHAFT - USING DIAGNOSTICS
Once all data has been obtained and diagnostics have been entered:
1. The LIMITS screen will appear and display any vibration measurement above the 0,2 limit. As stated above, this limit
is used only as a target level for RADS diagnostics and is in no way an indicator of a level of vibration which must be
met to be serviceable. If operator chooses to improve the balance of shaft, press DO to calculate recommended.
2. When calculated, RADS will display adjustments made to aft and forward adapters of shaft. As programmed, RADS
specifies adjustments only to #1, #2 and #3 bolts. This allows adjustments also to be made to #4, #5 and #6 bolts
without editing adjustments. The definition of blade bolt locations and adjustment options is shown in figure 4.
3. With adjustments defined, record adjustments for future reference and refer to paragraph "5. Balancing main driveshaft
- making adjustments" for proper way to make adjustments.
5. BALANCING MAIN DRIVESHAFT - MAKING ADJUSTMENTS
Once adjustments have been defined by diagnostics, proceed as follows:
1. The shaft is balanced by installing or removing balance weights from shaft-to-adapter bolts (#2 and #5, figure 4).
2. Once bolt to be adjusted has been located, remove nut and bolt and using bolt/weight combination shown in table 18-2,
configure a weight package closest to weight specified by RADS.
18-12-05
Page 8
E-AB412-PT6T-2
G6AB0429A
Figure 6. Cadu screen, main driveshaft balancing
18-12-05
Page 9
E-AB412-PT6T-2
Table 2. Hardware and weight
PART NO. NAME WEIGHT

GRAMS OUNCES
AN5-12A Bolt 2,0 0,07

AN5-13A Bolt 4,00 0,14
100-106-1 Plate, Balance Weight 14,18 0,50
*100-106-4 Plate, Balance Weight 14,18 0,50
*NAS6604-6 Bolt 2,0 0,07
*NAS6604-8 Bolt 4,00 0,14
NOTE
Bolt weights are referenced to minimum bolt size used. AN513-12A (or
NAS6604-6) bolt shall be used when one weight is installed and AN513-13A (or
NAS6604-8) bolt shall be used when two weights are stacked at one location. The
maximum weight allowed at one bolt location is 1,0 ounce (28,35 g). Maximum
stack up of weight is two per bolt.
3. Install bolt/weight package with weights under the head of the bolt. Torque nuts 100 to 140 inch-pounds (11,30 to
15,82 N-m).
6. BALANCING MAIN DRIVESHAFT - TROUBLESHOOTING
The table 3 lists probable causes of helicopter and RADS problems encountered during balancing of driveshaft.
NOTE
If adjustments are edited do not turn on more than two locations at either end.
Table 3. Troubleshooting driveshaft balance
No TACHO or TACHO out-of-bounds No/dirty reflective tape Install or replace reflective tape.
warnings
Optical sensor fault Refer to figure 7 to fine tune sensor.
Shaft balance cannot be corrected Excessively out of balance Index shaft two bolt holes and repeat.
within weight limits.
Re-grease
18-12-05
Page 10
E-AB412-PT6T-2
(Cont.)
Check adapter run-out and torque.
Check shaft installation
Remove shaft inspect for correct

assembly
Erratic balance results Make single adjustment. Refer to bal-

ance charts figure 8
18-12-05
Page 11
E-AB412-PT6T-2
G6AB0430A
Figure 7. Troubleshooting optical pickup
18-12-05
Page 12
E-AB412-PT6T-2
CODES A B
G6AB0431A
Figure 8. 1/Rev driveshaft balance chart with script file 412-41 - main transmission
18-12-05
Page 13
E-AB412-PT6T-2
18-12-05
Page 14
E-AB412-PT6T-2
18-13-01 MAIN ROTOR TRACKING AND BALANCING (CHADWICK HELMUTH VIBREX EQUIPMENT, MODEL 177M OR EQUIVALENT)
18-13-01
MAIN ROTOR TRACKING AND BALANCING (CHADWICK HELMUTH
1. MAIN ROTOR TRACKING AND BALANCING - ROTOR VIBRATION

MEASUREMENT INSTRUMENTATION
The Chadwick-Helmuth Vibrex equipment is an analog system that requires all vibration and tracking data to be obtained
manually. The equipment kit includes a Strobex tracker, a balancer/phazor, a magnetic pickup, two accelerometers, and
various cables (figure 1). Model 6404 Vibrex equipment is recommended, but equivalent equipment is acceptable.
1-1. ROTOR VIBRATION MEASUREMENT INSTRUMENTATION - INSTALLATION
MATERIALS REQUIRED
NUMBER NOMENCLATURE
C-482 TAPE
NUMBER NOMENCLATURE
T65 CHADWICK-HELMUTH VIBREX KIT
NOTE
Model 412 helicopters are delivered with the following production installed
balance equipment: A magnetic pickup bracket, magnetic pickup cable and
receptacle and a 28 Vdc power receptacle. Remainder of equipment is contained in
Chadwick-Helmuth Vibrex Kit (T65).
1. Install magnetic pickup (module 18-12-01 paragraph "3. Main rotor balancing - rads at installation").
2. Connect magnetic pickup cable (7, figure 1) to helicopter magnetic pickup receptacle and to balancer (9).
3. Connect balancer (9) to power receptacle (11) with cable (10).
4. Install vertical accelerometer (module 18-12-01 paragraph "3. Main rotor balancing - rads at installation"). Connect
accelerometer cable (8, figure 1) to channel “B” of balancer.
5. Install lateral accelerometer (module 18-12-01 paragraph "3. Main rotor balancing - rads at installation"). Connect
accelerometer cable (6, figure 1) to channel “A” of balancer.
18-13-01
Page 1
E-AB412-PT6T-2
G6AB0560A
Figure 1. Chadwick - helmuth equipment hook-up
18-13-01
Page 2
E-AB412-PT6T-2
NOTE
If it is necessary to measure fore-and-aft 1/rev vibration in flight, the lateral
accelerometer can be rotated so it is oriented fore-and-aft (cable away from pilot).
6. Install reflective tape (C-482) on main rotor blades as shown on figure 2. The targets shall be located exactly the same
on each blade to ensure proper tracking.
2. MAIN ROTOR TRACKING AND BALANCING - STROBE TRACKING - MAIN ROTOR

BLADES
NUMBER NOMENCLATURE
CAUTION
USE CHADWICK-HELMUTH EQUIPMENT IN ACCORDANCE WITH

CHADWICK-HELMUTH OPERATION AND SERVICE INSTRUCTION
HANDBOOK. IF THERE ARE ANY QUESTIONS CONCERNING USE OF
THIS EQUIPMENT, CONTACT CHADWICK-HELMUTH, MONROVIA,
CALIFORNIA.
NOTE
Strobing blades to determine track variations during flight is essential when working
main rotor. Use Chadwick-Helmuth Strobex (Model 135M-11) only.
It is recommended that Chadwick-Helmuth system be used to ground track rotor. A flag may be used for ground tracking
(especially during ground track at 60%) to ensure perfect track and blade separation between blade pairs (upper and lower
1,75 in. separation).
1. Connect Strobex (1, figure 1) to balancer (9).
2. To obtain a proper track picture with the Strobex, accomplish the following:
a. Set Balance/Phazor MAGNETIC PICKUP switch to COMMON.
b. Set Balancer/Phazor INTERRUPTER LOGIC switch to SINGLE.
c. Set Strobex (1) function switch to “B”.
d. Set Strobex rpm setting to less than Nr x 4 x 40%.

EXAMPLE:If Nr = 194 (60% rotor speed)
194 x 4 x 0,40 = 310,4
Set Strobex to 300
If Nr = 324 (100% rotor speed)
324 x 4 x 0,40 = 518,4
Set Strobex to 500
3. Aim Strobex at 11:30 clock position of tip path plane. Move strobe until a single target is seen; this will be green blade
(figure 3, View A).
18-13-01
Page 3
E-AB412-PT6T-2
4. Slowly increase Strobex rpm setting. As rpm setting is raised, targets on other three blades will appear to approach
green blade’s target from the left. The Strobex is properly tuned when all four blades can be seen. View B shows how
track should appear when Strobex is properly tuned.
NOTE
At 100% Nr, all four targets can be seen at approximately 512 RPM on the Strobex
RPM selector (figure 3, View B). Tuning Strobex too high will result in the two
blade pairs merging into one target (View C).
NOTE
If Strobex does not pick up blade target at 60% Nr, slightly decrease spacing
between magnetic pickup and interrupter.
A sharper track picture may be obtained on Strobex by setting RPM selector on Strobex to twice recommended setting.
(Example: at 60% Nr, set RPM selector on Strobex to 600 rpm instead of normal 300 rpm.) Increase setting slowly from 600
rpm until picture is obtained.
Track information from Strobex is used in conjunction with move data obtained from track and balance charts. The charts
tell how much roll (pitch link adjustment) or tab is needed in each blade pair while the Strobex tells which blade of each pair
should be rolled or tabbed.
EXAMPLE: At 120 knots IAS, the vertical 1/rev is recorded to be 0,25 IPS at 12:30 clock position. As will be determined
in paragraph "3-2. Track and balance - main rotor - working main rotor", the green tab should be bent up 2 degrees or orange
tab bent down 2 degrees. The strobe information, however, shows orange climbing as a function of airspeed with respect to
other three blades. Therefore, orange blade should be tabbed down 2 degrees.
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G6AB0561A
Figure 2. Main rotor blade reflective tape installation
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G6AB0562A
Figure 3. Strobex reflector patterns
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3. MAIN ROTOR TRACKING AND BALANCING - TRACK AND BALANCE - MAIN

ROTOR
NUMBER NOMENCLATURE
T43 TAB BENDER
T44 TAB GAGE

(The -127 may be modified (figure 5))
There are four basic adjustments available to minimize main rotor 1/rev vibration. These are:
— Hub balance weights
— Pitch link length adjustment (roll)
— Blade trim tabs
— Blade product or dynamic balance
The functions of each of these adjustments are described in module 18-12-01 paragraph "6-1-1. Making adjustments - pitch
links" through module 18-12-02 "MAIN ROTOR BALANCING - TROUBLESHOOTING". The current blade designs are
shown in figure 4 with adjustments labeled in terminology used herein.
3-1. TRACK AND BALANCE - MAIN ROTOR - PREPARATION
Perform the following prior to beginning work on rotor:
1. Ensure all trailing edge blade attachment bolts (expandable bolts, if installed) are at proper locking force and are
oriented parallel to centers of blade bolts. It is extremely important that expanding bolts are all oriented the same and
orientation can be repeated when blades are unfolded.
2. If any rotating control system links have been disconnected, ensure link is reinstalled in such a way that any
elastomeric bearing has zero torsional preload at flat-pitch when swashplate is level with respect to mast. This may be
accomplished as follows:
a. Center cyclic to maintain swashplate level in respect to mast.
b. Disconnect upper end of pitch links from pitch horns.
c. Lower collective lever until down stop is reached.
d. Install link in such a way that it is within one serration on elastomeric bearing of being perpendicular (90) to
the re-phasing link.
e. Repeat step d. until all links are installed.
f. Attach upper end of pitch links to pitch horns.
3. If new blades are being installed, ensure tabs are set to zero or are set to angles called out on data sheet supplied with
blades. When replacing one or a pair of blades in a previously worked rotor, do not “zero” tabs of original blades; leave
them as a set prior to blade change. The one exception to this is when one blade is replaced, the inboard tab of mating
blade should also be zeroed, since both inboard tabs of a blade pair are always bent opposite each other.
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G6AB0563A
Figure 4. Blade configuration
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G6AB0549A
Figure 5. Tab gage for three-tab rotor blades
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3-2. TRACK AND BALANCE - MAIN ROTOR - WORKING MAIN ROTOR
The proper sequence for working the rotor on helicopters having blades which incorporate three trim tabs and product
balance is shown in figure 6. The most important phase in working the rotor is to obtain a good ground track and balance
prior to going to flight. Once in flight, track is less important, but should be recorded to provided information on which blade
of a pair should be worked to maintain the best separation between the pairs. In flight, the magnitude and clock angle of the
1/rev vibration takes precedence over the track (i.e. a good ride has higher priority than a good track). All rotor track and
balance data should be recorded on a copy of the form in figure 7.
1. Rolling into ground track at 60%: The first phase in working the rotor is to obtain a good ground track at 60% rotor
speed (Nr). To accomplish this proceed as follows:
a. Operate at approximately 60% Nr (E-AB412-PT6T-1).
b. Observe track of rotor using Strobex or flag (if Strobex is used, set initial oscillator setting at 600) and record on
rotor tracking sheet.
c. Set Balance/Phazor FUNCTION selector to TRACK. Aim Strobex at the 11:30 location. Slowly increase
Strobex setting until all four blades are seen.
d. Estimate amount of out-of-track and adjust length of pitch links as required (module 18-12-01 paragraph "6-1-1.
Making adjustments - pitch links"). The amount of blade-track change per adjustment of pitch link is as follows:
— Turning barrel one flat = 0,1 in.
— One full turn of barrel (6 flats) = 0,6 in.
— One half turn of upper rod end = 1,0 in.
— One turn of upper rod end = 2,0 in.
— One turn of lower rod end = 1,4 in.
e. Repeat steps a. through d. until rotor is in proper track. The blades are in proper track when blades of upper pair
(red and blue blades) are in same plane and blades of lower pair (orange and green blades) are in same plane
with separation between pairs being 1,75 in. (Reflectors are 1,25 in. in length and can be used to estimate gap
between blade pairs.)
f. To see track of main rotor at idle, set Balance/Phazor selector to B.
2. Obtaining 100% track and balance. Once 60% track has been obtained, rotor is ready to be tracked and balanced at
100% Nr. To accomplish this, proceed as follows:
a. Operate helicopter at, or near, 100% Nr (single power section operation is acceptable).
(1) Air Strobex to view track in front of copilot seat (11:30 position).
(2) Pull trigger and move Strobex until one target is seen.
(3) With this target in view, increase tuning of Strobex until all four targets are seen.
(4) Record position of targets and gage track by length of reflective tape.
b. Measure and record magnitude and phase of lateral and vertical 1/rev vibration and record blade track (if Strobex
is used, set oscillator to an initial setting of 500).
c. Plot lateral 1/rev vibration on Hub Balance Chart shown in figure 8. Note to which blade(s) chart calls for adding
weight. If track is close, make weight adjustment indicated. If rotor is significantly out of track, proceed to step
e. prior to balancing.
d. Repeat steps a. through c. until lateral 1/rev vibration is reduced to below 0,1 ips (preferably to 0,05 ips, or
below).
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E-AB412-PT6T-2
e. Use outboard trim tab to obtain track at 100% rpm. Bending outboard tab up causes blade to climb; bending tab
down causes blade to dive (module 18-12-01 paragraph "6-1-2. Making adjustments - trim tabs"). The sensitivity
of track to outboard tab adjustment is as follows:
— Large tab:0,25 in. per degree
f. After each tab move, repeat steps a. through e. until lateral 1/rev is below 0,1 ips and rotor is in track.
3. Working Lateral 1/Rev Vibration in a Hover.
a. Product-balancing the Rotor (-200, -111, and all -300’s). Once the rotor has been tracked and balanced on the
ground, the product-balance of the rotor is checked and adjusted, if necessary. To accomplish this proceed as
follows:
(1) Observe track of rotor at 100% flat pitch on ground and record vertical and lateral 1/rev readings (if not
already accomplished). The lateral 1/rev readings should be below 0,1 ips at this time.
(2) Lift helicopter into a hover (E-AB412-PT6T-1) and orient nose into wind. Observe and record track as well
as lateral 1/rev vibration levels (magnitude and phase).
(3) If lateral 1/rev vibration is acceptable in a hover, then helicopter is ready to go into forward flight.
(a) If lateral 1/rev vibration is higher than desired and at the same clock angle as lateral on the ground,
use balance chart (figure 8) to reduce lateral vibration in a hover as low as possible without causing
an unacceptable 1/rev ground balance. If hover is still unacceptable, go to step b.
(b) If the lateral 1/rev vibration in a hover is radically different from that measured on ground in either
magnitude or clock angle, plot 1/rev data on in flight lateral 1/Rev Chart shown in figure 9. From
chart, note which pair of blades should be product-balanced to minimize lateral 1/rev vibration in
hover. By observing track, one can distinguish which blade of the pair should be product-balanced to
maintain a proper separation between the pairs.
(c) Once blade on which the product-balance will be adjusted has been identified, remove cover of
product-balance pocket from which weight is to be removed (module 18-12-02 "MAIN ROTOR
BALANCING - TROUBLESHOOTING"). If exact amount, or significant fraction, of weight to be
removed is present, remove cover of the other product-balance pocket and make all or part of move
indicated by the chart. If insufficient weight is present in product-balance pockets of chosen blade,
the opposite blade will have to be product-balanced the remainder of the move indicated by chart.
Once product-balance move has been made, secure pocket covers on all pockets.
NOTE
If sufficient product-balance capability is not available in the product-balance
pockets, refer to step 4. below.
b. Recheck balance of rotor at 100% Nr on ground and correct if necessary.
NOTE
The mistake many make when product-balancing rotor is not rebalancing the rotor
before determining full effect of product-balance move. Remember that any mistake
made in the ratio of weights adjusted at blade tip is magnified by approximately a
factor of eleven; then the error must be countered by weight at hub balance weight
attachment locations.
c. Repeat steps a. and b. above until lateral 1/rev vibration on ground is less than 0,1 ips and in hover is less than
0,2 ips. Once this has been accomplished, the helicopter is ready to go into forward flight.
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E-AB412-PT6T-2
NOTE
As rotor is balanced it may be necessary to make slight adjustments of outboard trim
tab to maintain an acceptable track at 100% rpm.
4. Rolling the Rotor for Lateral 1/Rev Vibration in a Hover. On rotors with blades that do not have sufficient product
balance capability, the only means available to adjust lateral 1/rev vibration in a hover semi-independently of lateral
1/rev vibration on ground is roll. Roll has more effect on lateral 1/rev vibration in a hover than it does on the lateral 1/
rev vibration on ground, while hub balance weights have an equal effect on lateral 1/rev vibration on ground and in a
hover. With these characteristics known, the proper method for working lateral 1/rev vibration in a hover is to roll rotor
blades until lateral 1/rev vibration in a hover is approximately the same as it is on ground. Once this is done, hub
balance weights are used to correct both lateral 1/rev vibration on the ground and in a hover. The proper method for
working the rotor with roll is as follows:
a. Reduce lateral 1/rev vibration on the ground using Lateral 1/Rev Balance Chart shown in figure 8.
b. Measure and record lateral 1/rev vibration in a hover. Plot this information on Lateral 1/Rev in a Hover Chart
shown in figure 9 and make roll move indicated.
c. Recheck lateral 1/rev vibration on the ground and correct using hub balance weights (module 18-12-01
paragraph "6-1-3. Making adjustments - hub balance weights").
d. Repeat steps a. through c. continuing to use roll to correct lateral 1/rev vibration in a hover and hub balance
weights to correct lateral 1/rev vibration on ground until both are 0,2 ips or lower.
5. Working Vertical 1/Rev Vibration.
NOTE
Check autorotation rpm (figure 10) on the first flight and, if necessary, adjust as
required (module 18-12-01 paragraph "8. Main rotor balancing - setting autorotation
rpm"). Once lateral 1/rev vibration has been reduced to an acceptable level both on
ground and in a hover, the rotor is ready for evaluation in forward flight. To work
rotor with respect to vertical 1/rev vibration the following steps are taken.
6. Once lateral vibration in hover has been reduced, conduct an airspeed sweep where track, vertical, and lateral
information is obtained at conditions as follows:
a. 100% flat pitch on ground.
b. Hover.
c. 1000 rpm climb at 60 knots.
d. 120 knots level.
e. VNE.
f. 1000 rpm descent at 60 knots.
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G6AB0564A
Figure 6. Flow chart working model 412 rotor with three - tab blades
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G6AB0565A
Figure 7. Sample form used to record 1/rev vibration levels and rotor moves
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G6AB0566A
Figure 8. M412/Pen hub balance chart
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G6AB0567A
Figure 9. M412/Pen in flight lateral 1/rev chart
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G6AB0551A
Figure 10. Autorotation descent rotor RPM chart
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G6AB0551A
Figure 11. Vertical 1/rev chart
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E-AB412-PT6T-2
7. Review data obtained in performing step 6. to determine the vibration in the helicopter. Work helicopter as follows:
a. Reduce vertical 1/rev at speeds up to and including 20 knots.
(1) Adjust outboard trim tabs (module 18-12-01 paragraph "6-1-2. Making adjustments - trim tabs"). Plot data
on vertical 1/rev chart (figure 11). Record outboard trim tab adjustments indicated as needed to reduce 1/
rev at 120 knots. Chart provides options to bend one trim tab up or its mate down. Select option that best
maintains proper track spacing for rotor.
(2) Adjust inboard trim tabs only when vertical 1/rev at speeds above 120 knots cannot be made acceptable by
adjusting outboard trim tabs (figure 12 and module 18-12-01 paragraph "6-1-2. Making adjustments - trim
tabs").
(3) Repeat steps (1) and (2) until vertical 1/rev vibration level is acceptable.
NOTE
If primary flight condition for helicopter is 120 knots cruise, it is not necessary to
check vibration level at VNE.
b. After vertical 1/rev vibration is worked to an acceptable level, work lateral 1/rev vibration.
(1) Using hub balance weights and M412/Pen in flight Lateral 1/Rev Chart (figure 9), re-trim rotor at flat pitch
on the ground.
(2) Using hub balance weights (module 18-12-01 paragraph "6-1-3. Making adjustments - hub balance
weights"), product balance (module 18-12-02 "MAIN ROTOR BALANCING -
TROUBLESHOOTING"), and/or pitch link adjustments (module 18-12-01 paragraph "6-1-1. Making
adjustments - pitch links"), reduce lateral 1/rev in flight as follows:
(a) If lateral 1/rev is present in a hover and at high speed (and rotor was properly tracked at idle), make
product balance adjustment indicated on M412/Pen in flight Lateral 1/Rev Chart (figure 9). Repeat
this step until additional product balance adjustments cannot be made or lateral 1/rev at hover reaches
an acceptable level.
(b) Make pitch link adjustments if lateral 1/rev is not acceptable and additional product balance
adjustments cannot be made. Refer to pitch adjustment (roll) portion of M412/Pen in flight Lateral 1/
Rev Chart (figure 9). Also, refer to pitch link adjustment procedure (module 18-12-01 paragraph
"6-1-1. Making adjustments - pitch links").
(c) After lateral 1/rev in hover is acceptable, make pitch link adjustments to obtain an acceptable lateral
1/rev in forward flight. Refer to pitch adjustment (roll) portion of M412/Pen in flight Lateral 1/Rev
Chart (figure 9). Also, refer to pitch link adjustment procedure (module 18-12-01 paragraph "6-1-1.
Making adjustments - pitch links"). Make one-half indicated pitch link adjustment for 120 knots.
(d) Once lateral 1/rev in forward flight is acceptable, make small hub balance weight adjustments to
obtain an acceptable lateral 1/rev vibration level in letdown. Since lateral 1/rev in letdown is more
sensitive to hub balance weight changes than lateral 1/rev on ground and in forward flight, it is
possible to make a limited improvement in the lateral 1/rev without making a significant change in
lateral 1/rev on ground or in forward flight. Refer to M412/Pen Hub Balance Letdown Chart (figure
13) and hub balance weight procedure (module 18-12-01 paragraph "6-1-3. Making adjustments -
hub balance weights") and make adjustments to reduce lateral 1/rev in letdown (figure 14) to an
acceptable level.
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E-AB412-PT6T-2
NOTE
As adjustments are made it may be necessary to re-trim main rotor vertical and
lateral vibration by using the procedures in steps 6. and 7.
Do not change balance for letdown enough to make ground bounce unacceptable.
Since 1/rev vibration is primarily a ride quality factor, the acceptable level is up to
the operator, and must be weighed against increased maintenance time and
component replacement. Optimize ride for primary operating condition of
helicopter.
8. Lateral 1/Rev Vibration that Changes with Gross Weight. It is important to work the rotor without making radical
gross-weight changes. If lateral 1/rev vibration changes significantly when going from light to heavy gross weight,
measure lateral 1/rev throughout flight regime at the increased gross weight. Use Lateral 1/Rev in Hover Chart
(figure 9) to determine proper product balance roll move to correct this condition. To date, adjustments in roll have
been sufficient to correct for minor changes in 1/rev with gross weight changes. Significant changes in 1/rev vibration
with gross weight changes are generally caused by degradation of elastomeric bearings in the control system; therefore,
these bearings should be thoroughly inspected prior to further rotor working efforts.
9. Recording Rotor Configuration. To assist in maintaining rotor at an acceptable level of 1/rev, the chart shown in
table 1 should be filled out immediately upon completion of working the rotor. Save chart for future reference.
10. Remove all track and balance equipment from helicopter.
11. Trimming the Rotor. Once the rotor is worked, very little maintenance should be required to maintain acceptable
vibration levels. If, after maintenance or during normal operations, the ride has deteriorated, the following steps should
be taken:
a. If rotor has been folded, ensure all expandable blade bolts are torqued and aligned properly. Make any necessary
corrections.
b. Verify that idle track and tab settings are the same as documented in Rotor Configuration Log (table 1). Correct
if necessary.
c. Check hub to mast installation.
d. Remove any water from product balance pockets. Verify covers for product balance pockets (2 and 3, figure 12)
are installed and sealed (module 18-12-02 "MAIN ROTOR BALANCING - TROUBLESHOOTING").
If the rotor still exhibits higher than desired main rotor 1/rev levels, work the rotor from its present point; do not zero
everything and start over. If the rotor works successfully, log final tab settings, idle track, and weight configuration on a copy
of the Rotor Configuration Log (table 1). Assure all logs are maintained in such a way that any trend which could give
indications of degradation in the control system elastomeric can be monitored. If degradation is found later, a previous log
entry may allow rotor to be reset to original configuration; thus minimizing rotor working time.
NOTE
When reworking rotors, initial data should be taken with previous hub balance
weights and trim tab settings. Outboard trim tabs should only be zeroed on new
blades. Midspan and inboard trim tabs should be zeroed on both new blade and blade
opposite new blade.
3-3. TRACK AND BALANCE - MAIN ROTOR - MAIN ROTOR AUTOROTATION RPM ADJUSTMENT
1. Check autorotation (rotor) rpm (figure 10).
2. If required, correct autorotation (rotor) rpm (module 18-12-01 paragraph "8. Main rotor balancing - setting
autorotation rpm").
3. Recheck 1/rev vibration levels throughout and adjust as necessary.
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E-AB412-PT6T-2
G6AB0548A
Figure 12. Adjustments on 412-015-300 main rotor blade
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G6AB0569A
Figure 13. M412/pen hub balance for lateral in letdown chart
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G6AB0570A
Figure 14. Lateral 1/rev vibration letdown
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E-AB412-PT6T-2
Table 1. Rotor configuration log
HELICOPTER TYPE: _______________ DATE: ____/____

HELICOPTER S/N: ________________
TAB SETTING
BLADE S/N COLOR OUTBOARD MIDSPAN INBOARD
_____________ _____________ _____________ _____________ _____________
_____________ _____________ _____________ _____________ _____________
_____________ _____________ ____________ _____________ _____________
_____________ _____________ _____________ _____________ _____________
TRACK PICTURE AT 60%
Note Relative
Dimensions.
HUB WEIGHTS
BLADE S/N COLOR LEADING EDGE TRAILING EDGE
_________________ _________________ _________________ _________________
_________________ _________________ _________________ _________________
_________________ _________________ _________________ _________________
_________________ _________________ _________________ _________________
CHANGES TO BLADE MASTER:
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E-AB412-PT6T-2
3-4. TRACK AND BALANCE - MAIN ROTOR - WORKING MAIN ROTOR 2/REV VIBRATION
Main rotor 2/rev vibration in helicopters with pendulums is similar to main rotor 1/rev vibration. Main rotor 2/rev is
perceived by the flight crew as a roughness in ride which does not register on the Balancer when tuned to 324 rpm (1/rev).
While main rotor 1/rev vibration is caused by the variation in lift between blades within a pair, 2/rev is caused by variations
in lift between pairs. Generally maintaining proper separation between pairs will result in low 2/rev vibration levels
throughout the flight regime. If, after the main rotor 1/rev has been reduced to an acceptable level, a roughness is still felt in
the helicopter main rotor, 2/rev vibration should be checked. To check main rotor 2/rev vibration, the following procedure
should be accomplished:
1. Mount an accelerometer on the floor of the cabin directly behind the aft row of passenger seats, on the right side of
cabin near cargo door. Connect right-angle accelerometer brackets (figure 15) (or make a bracket which orients the
accelerometer perpendicular to the mounting plane). Once the two brackets have been connected, attach with a
convenient screw at indicated location. To assure that the brackets are sufficiently stiff, back up the bracket attached
to the deck with a large washer. Once brackets are installed, attach accelerometer to bracket in such a way that it is
oriented vertically with connector pointed up.
2. Connect accelerometer cable to accelerometer and Balancer/Phazor. Tune balancer to 647 rpm.
3. Measure 2/rev levels at flight conditions specified for checking main rotor 1/rev vibration.
4. Plot 2/rev levels on Vertical 2/Rev Chart (figure 16).
a. If clock angle of 2/rev vibration is generally the same but levels build with airspeed, then indicated roll move
should be sufficient to reduce 2/rev vibration.
b. If clock angle of 2/rev changes 3 hours between low speed and high speed, then roll for low speed 2/rev and use
midspan tabs for high speed 2/rev.
c. If 2/rev is present only in a letdown, then bend both outboard tabs in direction indicated by charts and counter it
with an opposite bend in midspan tabs. Once 2/rev is adjusted so that all of the data is at the same clock angle,
make a final adjustment using roll to correct.
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E-AB412-PT6T-2
G6AB0571A
Figure 15. Accelerometer support for measuring cabin 2/rev levels
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E-AB412-PT6T-2
G6AB0572A
Figure 16. Main motor 2/rev reduction chart
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E-AB412-PT6T-2
18-13-02 TAIL ROTOR HUB AND BLADE TRACKING AND BALANCING (CHADWICK-HELMUTH VIBREX EQUIPMENT, MODEL 177M OR EQUIVALENT)
18-13-02
TAIL ROTOR HUB AND BLADE TRACKING AND BALANCING
(CHADWICK-HELMUTH VIBREX EQUIPMENT, MODEL 177M OR
EQUIVALENT)
1. TAIL ROTOR HUB AND BLADE TRACKING AND BALANCING - TAIL ROTOR HUB
AND BLADE OPERATIONAL CHECK
1. Tail rotor track check by manual flag method (paragraph "3. Tail rotor hub and blade tracking and balancing - tail rotor
hub and blade flag tracking") or by VIBREX Track and Balance System (dynamic method) (paragraph "4. Tail rotor
hub and blade tracking and balancing - tail rotor tracking and balancing with chadwick-helmuth vibrex equipment
(dynamic method)").
2. Tail rotor vibration check by VIBREX Track and Balance System (dynamic method) (paragraph "4. Tail rotor hub and
blade tracking and balancing - tail rotor tracking and balancing with chadwick-helmuth vibrex equipment (dynamic
method)").
3. Tail rotor rigging check for adequate right and left anti-torque control by flight test (Chapter 64 and E-AB412-PT6T-1).
2. TAIL ROTOR HUB AND BLADE TRACKING AND BALANCING - TAIL ROTOR
TROUBLESHOOTING
Potential troubles which may occur in the tail rotor are listed in module 18-12-04 "TAIL ROTOR BALANCING -
TROUBLESHOOTING".
3. TAIL ROTOR HUB AND BLADE TRACKING AND BALANCING - TAIL ROTOR HUB
AND BLADE FLAG TRACKING
MATERIALS REQUIRED.
NUMBER NOMENCLATURE
C-438 TINTING MEDIUM
1. Attach a small piece of sponge rubber 0,125 to 0,25 in. (3 to 6 mm) thick on the tip of a 0,5 x 0,5 in. (12 x 12 mm) pine
stick or any other flexible device. Coat sponge rubber with tinting medium (C-438) or similar type of coloring thinned
with oil.
2. Start engine and run at 100% Nr, with pedals in neutral position (E-AB412-PT6T-1).
3. Brace marking device on forward side of tail fin assembly. Slowly move marking device toward tail rotor blades,
approximately 1 in. (25 mm) from the blade tip. Move marking device just far enough to touch one blade, which will
be the near blade.
4. Shut down engine and allow rotor blades to stop after marking near blade. Shorten pitch control link of unmarked blade
one-half turn.
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E-AB412-PT6T-2
5. Repeat steps 2. and 3.
CAUTION
WHEN ADJUSTING PITCH CHANGE LINK, USE WITNESS HOLE IN

BARREL TO ENSURE PROPER AMOUNT OF ROD END THREAD
ENGAGEMENT.
6. Lengthen pitch control link of marked blade if further adjustment is needed. Continue adjustments alternately on
opposite links by one-half turn increments until blades are in track.
7. Perform maintenance test flight (E-AB412-PT6T-1).
TRACKING AND BALANCING WITH CHADWICK-HELMUTH VIBREX EQUIPMENT
(DYNAMIC METHOD)
4-1. TAIL ROTOR TRACKING AND BALANCING WITH CHADWICK-HELMUTH VIBREX EQUIPMENT
(DYNAMIC METHOD) - TAIL ROTOR TRACKING
MATERIALS REQUIRED
NUMBER NOMENCLATURE
NUMBER NOMENCLATURE
CAUTION
COMPLY WITH THE CHADWICK-HELMUTH OPERATIONS AND SERVICE

INSTRUCTION HANDBOOK AND THE FOLLOWING INSTRUCTIONS
WHEN TRACKING TAIL ROTOR WITH CHADWICK-HELMUTH
EQUIPMENT.
NOTE
If there are questions concerning use of Vibrex equipment (T65), contact
Chadwick-Helmuth, Monrovia, California.
1. Inspect tail rotor hub and blades for damage and proper installation.
2. Install the Balancer/Phazor for use outside the helicopter, near the left side of the tail rotor. Connect Strobex to
Balancer.
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E-AB412-PT6T-2
NOTE
Do not connect the magnetic pickup cable. It is not required when tracking the tail
rotor.
3. Mount tail rotor balance accelerometer on the tail rotor gearbox as follows:
a. Loosen nut on tail rotor gearbox case at the 12 o’clock position.
b. Install accelerometer and bracket (#3382) between gearbox case and nut, then tighten nut.
4. Connect accelerometer cable to accelerometer and route the cable forward to, and around, the elevator and then to the
right side of the tail rotor, approximately 15 ft. (4,57 m) from the rotor disc. Connect only the tail rotor accelerometer
cable to the Balancer/Phazor at “A”. Secure cable to tailboom with masking tape.
5. Select one rotor blade as “target” blade. Place a 3/4 in. (19,05 mm) strip of reflective tape (C-483) on blade grip
between blade bolts as shown on figure 1.
6. Place a 3/4 in. (19,05 mm) strip of reflective tape (C-483) on tail rotor blade tips as shown on figure 2.
CAUTION
BEFORE PROCEEDING, ENSURE THAT ALL CABLE SLACK HAS BEEN

REMOVED BY TAPING CABLE TO THE TAILBOOM AND THAT
ADEQUATE CLEARANCE EXISTS BETWEEN CABLE AND ROTATING
COMPONENTS.
7. Operate helicopter (E-AB412-PT6T-1) at 100% Nr at flat pitch on the ground, standing approximately 15 ft. (4,57 m)
from the right side of the tail rotor. Adjust Strobex oscillator to approximately 6648 RPM (four times tail rotor rpm).
8. Face the tail rotor disc, shine the Strobex at the rotor and locate the reflection target (figure 1). Refer to operational
manual to fine tune the Balancer/Phazor and thus “stop” the reflective image from rotating. The target will appear
simultaneously at the 12, 3, 6, and 9 o’clock positions when the oscillator is properly adjusted.
9. Stand on the right side of the helicopter next to the pilot compartment. Aim the Strobex at the front of the tail rotor
while it is at normal operating rpm. Observe the track of the target. If targets form a “+” sign as shown on figure 3, the
blades are in track.
CAUTION
WHEN ADJUSTING PITCH CHANGE LINK, USE WITNESS HOLE IN

BARREL TO ENSURE PROPER AMOUNT OF ROD END THREAD
ENGAGEMENT.
10. If blades are out of track, shut down engines, adjust the length of the pitch change link on the target blade by one-half
increments to bring target blade close to other blade. Record amount of change.
11. Repeat step 8. if blades are still out of track, adjust pitch link on opposite blade to bring it closer to target blade. Record
amount of change.
12. Repeat steps 7. through 11. if required to bring blades into track.
13. Disconnect accelerometer from Balancer/Phazor. Disconnect dc power cable from balancer.
14. Remove dc power cable.
18-13-02
Page 3
E-AB412-PT6T-2
15. Remove accelerometer and bracket from tail rotor gearbox.
BALANCING
MATERIALS REQUIRED
NUMBER NOMENCLATURE
NUMBER NOMENCLATURE
T66 ACCESSORY KIT
CAUTION
COMPLY WITH THE CHADWICK-HELMUTH OPERATIONS AND SERVICE

HANDBOOK WHEN PERFORMING DYNAMIC BALANCING PROCEDURES.
1. Inspect tail rotor hub and blades for damage and proper installation.
2. Confirm that tail rotor hub and blade assembly has been statically balanced prior to starting dynamic balance
procedure.
3. Install the Balancer/Phazor for use outside the helicopter, near the left side of the tail rotor. Connect Strobex to
Balancer.
NOTE
Do not connect the magnetic pickup cable. It is not required when balancing the tail
rotor.
4. Mount tail rotor balance accelerometer on the tail rotor gearbox as follows:
a. Loosen nut on tail rotor gearbox case at the 12 o’clock position.
b. Install accelerometer and bracket (#3382) between gearbox case and nut, then tighten nut.
5. Connect accelerometer cable to accelerometer and route the cable forward to, and around, the elevator and then to the
right side of the tail rotor (approximately 15 ft. (4,57 m) from rotor disc). Connect only the tail rotor accelerometer
cable to Balancer/Phazor at “A”. Secure cable to tailboom with masking tape.
6. Place a 3/4 in. (19,05 mm) strip of reflective tape (C-483) on one blade grip between blade bolts (figure 2).
18-13-02
Page 4
E-AB412-PT6T-2
G6AB0573A
Figure 1. Tail rotor reflection target installation at tail rotor hub
18-13-02
Page 5
E-AB412-PT6T-2
G6AB0574A
Figure 2. Tail rotor reflection target installation at tail rotor tips
18-13-02
Page 6
E-AB412-PT6T-2
G6AB0575A
Figure 3. Tail rotor reflection target images for “in track” and “out of track” condition
18-13-02
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E-AB412-PT6T-2
CAUTION
BEFORE PROCEEDING, ENSURE ALL CABLE SLACK HAS BEEN

REMOVED BY TAPING CABLE TO TAILBOOM AND ENSURING
ADEQUATE CLEARANCE EXISTS BETWEEN CABLE AND ROTATING
COMPONENTS.
7. Operate helicopter (E-AB412-PT6T-1) at 100% Nr at flat pitch on the ground. Stand approximately 15 ft. (4,57 m)
from right side of tail rotor. Set Balancer/Phazor function switch to ‘A’, RPM range switch to ‘x 10’, and tune filter to
166.
8. Facing tail rotor disc, shine Strobex at rotor and locate reflective target (figure 1). Refer to operational manual to fine
tune Balancer/Phazor and thus “stop” reflective image from rotating.
9. Approximate clock position of image and note IPS level.
NOTE
Do not read IPS level when Strobex is flashing because it changes the IPS level.
10. Plot and record IPS level and position on tail rotor balance chart (4685). Shut down helicopter.
11. Determine weight, if any, and location required to balance rotor from information recorded in step 10. Determine
correct hardware required to achieve a balanced rotor from figure 4.
12. Install weights as illustrated on figure 4. Comply with applicable sections of notes 1, 2, and 3 on illustration.
13. Repeat steps 8. through 12. until an IPS level of 0,2 IPS or less is achieved.
14. Remove accelerometer and bracket from tail rotor gearbox. Torque nut on gearbox 50 to 70 in.-lbs. (5,65 to 7,91 Nm).
15. Remove Balancer and cables.
18-13-02
Page 8
E-AB412-PT6T-2
G6AB0559A
Figure 4. Tail rotor dynamic balance weight
18-13-02
Page 9
E-AB412-PT6T-2
18-13-02
Page 10
E-AB412-PT6T-2
18-13-03 BALANCING MAIN DRIVESHAFT (CHADWICK-HELMUTH VIBREX EQUIPMENT, MODEL 177M OR EQUIVALENT)
18-13-03
BALANCING MAIN DRIVESHAFT (CHADWICK-HELMUTH VIBREX
1. BALANCING MAIN DRIVESHAFT - CONTROL OF MAIN DRIVESHAFT VIBRATION
SPECIAL TOOLS
NUMBER NOMENCLATURE
CHADWICK-HELMUTH ACCELEROMETERS (2 REQ’D)
CHADWICK-HELMUTH EXTENSION CABLE (50 FT. (15,24M))
MODEL 135M-10 OR -11 STROBEX
MODEL 6A OR 7A BALANCER
100-106-1 WEIGHT, 0,50 OZ. (QTY AS REQ’D)
3300 RETRO-REFLECTIVE TARGETS
T66 ACCELEROMETER BRACKET (2 REQ’D)
NOTE
One source of high frequency vibration is the engine-to-transmission driveshaft
out-of-balance. This condition is indicated by a pulsating low frequency noise with a
period of 1.25 seconds. Most model 412 helicopters will make this noise at flat pitch
due to the normal amount of freeplay in shaft couplings and gearbox bearings.
However, if this pulsating noise is present in hover, shaft out-of balance is indicated.
High levels of shaft out-of-balance will be perceived as an annoying buzz in the
pedals in addiction to the pulsating noise.
1. Install one accelerometer bracket (6752 m) (T66) on right side of combining gearbox on stud below and forward of
right power section trim compensator control (figure 1). Position accelerometer laterally with connector pointing right.
2. Install second accelerometer bracket (6752 m) (T66) on transmission input quill at one o’clock (looking forward) stud
by removing existing Allen head screw and replacing it with a 1/4 X 28 UNF bolt (figure 2). Position accelerometer
laterally with connector pointing right.
3. Connect combining gearbox accelerometer to Channel ‘A’ and input quill accelerometer to Channel ‘B’.
4. Secure accelerometer cables to prevent fouling of rotating components.
5. Operate helicopter (both power sections) at 100% Nr, flat pitch (E-AB412-PT6T-1).
18-13-03
Page 1
E-AB412-PT6T-2
6. Tune balancer (T66) to 6600 rpm.
7. Record I.P.S. levels of Channels ‘A’ and ‘B’. A vibration level of 0,2 I.P.S., or below, is considered acceptable.
NOTE
If, when measuring Channel ‘A’ (combining gearbox accelerometer), the I.P.S.
needle is seen to oscillate significantly, the accelerometer is being saturated. To
compensate, allow both power sections to warm up for 5 minutes. If, after warm up,
the oscillation still exists, shut down right power section. This should cause the
oscillation to cease. Retune balancer, as necessary, if single power section operation
will not operate rotor at 100% Nr.
8. Shut down helicopter. Return helicopter with acceptable vibration levels to flight status.
9. If main driveshaft out-of-balance is in excess of 0,2 I.P.S. on either end of driveshaft, remove right engine air inlet
cowling.
10. Install reflective targets on outer rim of transmission input quill adapter (figure 3). Since only one third of the adapter
can be strobed from one location above roof line, three targets are placed at 120 intervals around adapter
circumference.
11. Using a soft lead pencil, mark 4 o’clock target with one broad stripe and 8 o’clock target with two narrow stripes
(figure 3).
12. The targets on forward coupling are used to obtain phase information for balancing both ends of shaft. Should
alignment of bolts between engine and transmission adapters not be the same, some reclocking of engine adapter
balance chart may be required.
13. Position work stand at side of cabin so forward coupling is sufficiently visible to Chadwick operator to strobe at least
one target.
14. Accomplish steps 5. through 7. Record I.P.S. levels on form (figure 4).
15. Using Strobex (T66), locate target visible from operator location and record clock angle on form.
16. Using strobe information from form, determine clock angle of master target. Record on form.
17. Plot I.P.S. level and master target clock angle on appropriate chart (figure 5 and figure 6).
18. Using data supplied on charts, locate proper bolt on adapter and add required balance weights (and bolts) as required
(refer to module 18-12-05 "BALANCING MAIN DRIVESHAFT (SCIENTIFIC ATLANTA ROTOR ANALYSIS
AND DIAGNOSTIC SYSTEM, MODEL AT (RADS AT))" table 2 for weights and usage).
NOTE
The combining gearbox (engine) coupling should be balanced to 0,2 I.P.S. or below
prior to balancing the transmission end coupling.
A maximum of two weights of any combination up to 1,0 oz. (28,35 g) may be

installed on a single bolt.
A maximum of 1,5 oz. (42,35 g) may be added at each coupling.
Use AN5-12A bolt when adding one weight and use AN5-13A bolt when adding
two weights.
18-13-03
Page 2
E-AB412-PT6T-2
19. Continue balancing until both couplings are balanced to 0,2 I.P.S. or below. Upon completion of balancing, replace
any nut removed with a new nut. Torque nuts in required sequence (Chapter 63).
20. When balancing either coupling, if clock angle moves from side to side and I.P.S. level change does not agree with
balance move made, the following causes are suspect:
a. Excessive freeplay in combining gearbox output shaft or support bearings.
b. Excessive freeplay in transmission input quill shaft or support bearings.
21. When balancing either coupling, if maximum allowable weight is insufficient to reduce vibration to acceptable levels,
accomplish the following:
a. Remove driveshaft and measure run out of engine output adapter or transmission input quill adapter. If run-out
is in excess of 0,004 in. (11,18 mm) reindex adapter on gearbox output shaft.
b. If adapter run out is acceptable, reindex female driveshaft coupling with respect to male coupling by 180.
18-13-03
Page 3
E-AB412-PT6T-2
G6AB0434A
Figure 1. Combining gearbox accelerometer
18-13-03
Page 4
E-AB412-PT6T-2
G6AB0435A
Figure 2. Transmission input quill accelerometer
18-13-03
Page 5
E-AB412-PT6T-2
G6AB0436A
Figure 3. Reflector positioning and bolt pattern identification
18-13-03
Page 6
E-AB412-PT6T-2
G6AB0437A
Figure 4. Balance moves recording form
18-13-03
Page 7
E-AB412-PT6T-2
G6AB0438A
Figure 5. Balance chart - combining gearbox end of engine to transmission (main drive shaft)
18-13-03
Page 8
E-AB412-PT6T-2
G6AB0439A
Figure 6. Balance chart - transmission end of engine (main drive shaft)
18-13-03
Page 9
E-AB412-PT6T-2
18-13-03
Page 10
E-AB412-PT6T-2
CHAPTER 21 - ENVIRONMENTAL CONTROL

Module Page
Number Title Number
21-00-00 ENVIRONMENTAL CONTROL
1. Environmental control - general ............................................................................................................. 1
21-21-01 AIR DISTRIBUTION SYSTEM
1. Air distribution system - ventilation blower ........................................................................................... 1

1-1. Ventilation blower - description .................................................................................................... 1
1-2. Ventilation blower - removal ......................................................................................................... 1
1-3. Ventilation blower - installation .................................................................................................... 1
2. Bleed air heating components - overhead ventilation system ................................................................. 3
2-1. Overhead ventilation system - description .................................................................................... 3
2-2. Overhead ventilation system - removal ......................................................................................... 3
2-3. Overhead ventilation system - installation .................................................................................... 4
3. Bleed air heating components - heat/vent air ducts ................................................................................ 7
3-1. Heat/vent air ducts - description .................................................................................................... 7
3-2. Heat/vent air ducts - removal ......................................................................................................... 7
3-3. Heat/vent air ducts - installation .................................................................................................... 7
3-4. Heat/vent air ducts - repair ............................................................................................................ 8
4. Bleed air heating components - bleed air shutoff valve ........................................................................ 11
4-1. Bleed air shutoff valve - description ............................................................................................ 11
4-2. Bleed air shutoff valve - removal ................................................................................................ 11
4-3. Bleed air shutoff valve - installation ............................................................................................ 11
5. Bleed air heating components - housed selector ................................................................................... 13
5-1. Housed selector - description ....................................................................................................... 13
5-2. Housed selector - removal ........................................................................................................... 13
5-3. Housed selector - installation ....................................................................................................... 13
21-41-01 HEATING SYSTEM
1. Heating system - noise suppressor .......................................................................................................... 1

1-1. Noise suppressor - description ....................................................................................................... 1
1-2. Noise suppressor - removal ........................................................................................................... 1
1-3. Noise suppressor - installation ....................................................................................................... 1
2. Heating system - heat/defrost control lever ............................................................................................ 5
2-1. Heat/defrost control lever - description ......................................................................................... 5
2-2. Heat/defrost control lever - removal .............................................................................................. 5
2-3. Heat/defrost control lever - installation ......................................................................................... 5
21-42-01 WINTERIZATION HEATER - BLEED AIR (P/N 212-706-008-103)
1. Bleed air (P/N 212-706-008-103) - description ...................................................................................... 1

2. Bleed air (P/N 212-706-008-103) - operational check ........................................................................... 1
3. Bleed air (P/N 212-706-008-103) - troubleshooting ............................................................................... 1
21-Index
Page 1
E-AB412-PT6T-2
CONTENTS - MAINTENANCE PROCEDURES (CONT)

Module Page
Number Title Number
21-61-01 TEMPERATURE CONTROL
1. Temperature control - variable control mixing valve ..............................................................................1

1-1. Variable control mixing valve - description ...................................................................................1
1-2. Variable control mixing valve - removal .......................................................................................1
1-3. Variable control mixing valve - installation ...................................................................................1
2. Temperature control - remote sensor and positioning motor .................................................................. 5
2-1. Remote sensor and positioning motor - description .......................................................................5
2-2. Remote sensor and positioning motor - removal ...........................................................................5
2-3. Remote sensor and positioning motor - installation and rigging ...................................................5
21-Index
Page 2
E-AB412-PT6T-2
FIGURES
Figure Page
Number Title Number
Figure 1. Heating and ventilation environmental control (sheet 1 of 2) ....................................................................... 2

Figure 2. Heating and ventilation environmental control schematic ............................................................................ 4
Figure 1. Ventilation/defog components....................................................................................................................... 2

Figure 2. Overhead ventilation system (sheet 1 of 2) ................................................................................................... 5
Figure 4. Bleed air shutoff valve................................................................................................................................. 12
Figure 5. Housed selector............................................................................................................................................ 14

Figure 2. Noise suppressor............................................................................................................................................ 4
Figure 3. Heat/defrost control lever .............................................................................................................................. 7

Figure 2. Variable control mixing valve ....................................................................................................................... 4
Figure 3. Remote sensor and positioning motor installation ........................................................................................ 6
21-Index
Page 3
E-AB412-PT6T-2
TABLES
Table Page
Number Title Number
Table 1. Troubleshooting - air distribution (ventilation) system ................................................................................. 5
Table 1. Bleed air troubleshooting ............................................................................................................................... 2
21-Index
Page 4
E-AB412-PT6T-2
21-0 -0 ENVIRONMENTAL CONTROL
21-00-00
ENVIRONMENTAL CONTROL
1. ENVIRONMENTAL CONTROL - GENERAL
The cabin environmental control (figure 1) includes two subsystems which provide optional use of heated or ventilated air
from separate sources. The subsystems are functionally separated by flow actuated Y-valves located under the windshield
defrost-defog nozzles. Refer to figure 2 for system schematic.
Heated air for cabin heating and defrosting windshields is provided by bleed air from engine compressors. The system
pumps air through ducking to outlets at both door posts, either side of center pedestal, each side of instrument panel, lower
forward window nozzles, and left and right windshield defrosting nozzles. Heating is controlled by switches on overhead
console, a temperature selecting dial on right side door post, and heater defrost control lever on right side of center pedestal.
Ventilating-defogging system uses ram air as source from intake grills on cabin nose, with optional use of blowers for
windshield nozzle and outlets ahead of crew stations. Air intake is controlled by actuating a cable knob. Blowers are
controlled by an overhead panel switch (figure 2).
The temperature selecting dial, through an electrical positioning motor, controls a remote sensor which is mounted on
plenum chamber in compartment on right side below engine deck. This remote sensor, using a bi-metallic element, senses
temperature in heater duct and controls mixing valve through a small tube which operates bleed port in valve.
When heater-defrost control lever on front right pedestal is moved forward to ON, valve in base of pedestal is closed by
linkage to shut off heated air flow to four air valves in pedestal base. Simultaneously, lever linkage activates a micro-switch
in base and a micro-switch closes two valves on single shaft in air distribution outlet control valve and shuts off heated air
flow to passenger compartment valves. When lever is moved aft to OFF position, reverse actions occur to open the valves.
Engine compressor air flow noise is muffled by a noise suppressor in rear of fuselage forward of mixing valve. Heated air
exits from noise suppressor into plenum chamber aft of cabin. Temperature limit switch in aft cabin prevents system
overheating. If temperature in plenum exceeds 220°F (104,4°C), the limit switch activates MASTER CAUTION light and
HEATER AIR LINE caution segment. Cycling continues until heater is turned OFF or problem is corrected.
21-00-00
Page 1
E-AB412-PT6T-2
G6AB0760A
Figure 1. Heating and ventilation environmental control (sheet 1 of 2)
21-00-00
Page 2
E-AB412-PT6T-2
G6AB0761A
21-00-00
Page 3
E-AB412-PT6T-2
G6AB0762A
Figure 2. Heating and ventilation environmental control schematic
21-00-00
Page 4
E-AB412-PT6T-2
Table 1. Troubleshooting - air distribution (ventilation) system
INDICATION OF TROUBLE PROBABLE CAUSE CORRECTIVE ACTION
1. No bleed flow to mixing Ruptured bleed air line. Find and repair line.
valve.
No voltage to bleed air Refer to Chapter 96.

valve.
Bleed air valve stuck. Replace valve.
2. No bleed air flow thru mixing No voltage to mixing valve. Refer to Chapter 96.
valve.
Inadequate air pressure. Repair leakage in line from

mixing valve to sensor.
Inoperative mixing valve. If bleed air and voltage

exists - replace mixing valve.
3. Temp of heated ventilation Faulty selector dial cable. Replace cable.

air will not modulate.
4. Ventilation air all hot. Plugged line from mixing Clear line.
valve to sensor.
5. Ventilation air all cool. Faulty temp selector dial Replace cable.
cable.
6. No air out of door post No voltage to door post Repair wiring. Refer to
outlets. outlet valve. Chapter 96.
Inoperative limit switch on Same as above.

console.
7. Unable to cut off air to door No voltage to door post Same as above.
post outlets. outlet valve.
8. HEATER AIR LINES caution Defective overheat switch or Replace switch and/or repair
segment illuminated — defective wiring. wiring. Refer to Chapter 96.
HEATER switch ON or OFF.
9. HEATER AIR LINES caution Defective overheat switch. Replace switch. Refer to
segment illuminated when Chapter 96.
HEATER switch is ON.
21-00-00
Page 5
E-AB412-PT6T-2
21-00-00
Page 6
E-AB412-PT6T-2
21-21-01
AIR DISTRIBUTION SYSTEM
1. AIR DISTRIBUTION SYSTEM - VENTILATION BLOWER
1-1. VENTILATION BLOWER - DESCRIPTION
Ventilation/defog system delivers outside air to windshield nozzles and nozzles on sides of instrument panel. Ram air intake
grills are located on cabin nose below each windshield. Each grill is connected to a plenum chamber and ducts connect
chambers to output nozzles. Air intake volume is controlled by knobs near instrument panel nozzles. When ram air is low,
outside air may be pulled in by turning on the blower which is part of the system.
1-2. VENTILATION BLOWER - REMOVAL
NOTE
Maintenance procedures for left plenum and blower is given. Maintenance
procedures for the right plenum and blower are similar.
1. Remove screws (1, figure 1) and remove grill (2) on left side of cabin nose.
2. Remove tie down wraps (28) from tubes (17, 22, and 23).
3. Remove clamps (19).
4. Remove tubes (17, 20, 22, and 23) and adapter (21) between grommet (18) and bottom of plenum assembly (24).
5. Remove clamp (25) and plenum (5).
6. Remove clamp (26) between duct (27) and plenum assembly (24). Remove clamp (11) and remove plenum assembly
(24) as a unit.
7. Remove clamps (14 and 16) and remove blower (15).
1-3. VENTILATION BLOWER - INSTALLATION
1. Position plenum assembly (24, figure 1) in cabin nose and install clamp (11), screw (9), washer (10), and spacer (12).
Thread screw (9) into threaded insert on electrical equipment shelf.
2. Install clamp (26) between plenum assembly (24) and duct (27).
3. Position clamp (25) on plenum (5) and plenum assembly (24). Install screw (8), washer (7), and nut (6).
4. If not previously accomplished, position air valve (4) on plenum (5) and install screws (3).
5. Position tubes (23, 22, and 17) and adapter (21) on plenum (24). Install clamps (19) and install tiedown wraps (28) on
tubes (23, 22, and 17).
6. If not previously accomplished, position blower (15) on plenum (24), and install clamps (14 and 16).
21-21-01
Page 1
E-AB412-PT6T-2
G6AB0763A
Figure 1. Ventilation/defog components
21-21-01
Page 2
E-AB412-PT6T-2
7. Position grill (2) on top of cabin nose left side. Install screws (1) to secure grill to plenum (24).
8. Perform functional check of blower (15).
2. BLEED AIR HEATING COMPONENTS - OVERHEAD VENTILATION SYSTEM
2-1. OVERHEAD VENTILATION SYSTEM - DESCRIPTION
[A] (P/N 212-073-100-1101)

[B] [C] (P/N 412-8500-01-101)
Overhead ventilation system takes ram air from screened opening in forward end of pylon fairing and directs it through air
valves mounted in ceiling. Two air valves are located in crew compartment, two in forward center passenger compartment,
and five along sides of passenger compartment.
NOTE
The maintenance procedures for ducts on left side is given. Maintenance procedures
for ducts on right side are similar.
2-2. OVERHEAD VENTILATION SYSTEM - REMOVAL
1. Remove insulation blankets to gain access.
2. Remove clamps (20, 16, 14, and 27, figure 2). Remove duct (15).
3. Remove ducts (7 and 15).
4. Remove two screws and washers from forward duct (19).
5. Remove ducts (19 and 21).
6. Remove nut (26) from windshield screws.
7. Remove forward duct (22).
8. Disconnect drain hose (5) from plenum (4).
9. Remove screws (2). Remove inlet duct (1) and plenum (4).
10. Remove grounding strap (39) and screws (35 and 32). Disconnect cabin light cable (40).
11. Remove plenum (28).
12. Remove screws (12) and remove plenum (13).
21-21-01
Page 3
E-AB412-PT6T-2
2-3. OVERHEAD VENTILATION SYSTEM - INSTALLATION
MATERIALS REQUIRED
NUMBER NOMENCLATURE
C-314 ADHESIVE
C-401 TAPE
1. Position plenum (13, figure 2) in helicopter and install screws (12) and washers (11). Install a maximum of two
aluminum washers (not illustrated) between plenum (13) and structure with each screw (12) to clear rivet heads.
2. Position aft end of plenum (28). Route wires L170-22 and L180-22 from cabin light (38) to TB-7 and connect to pins.
Install two screws (35) and washers (36). Install two screws (34), washers (33), and nut (32). Install grounding strap
(39).
3. Position duct (1) and plenum (4) on structure and plenum (28). Install screws (2) and washers (3). Seal mating surfaces
of duct (1) and plenum (4) with adhesive (C-314). Seal edges between plenum (4) and plenum (28) with tape (C-401).
4. Install drain hose (5). Secure hose to plenum with adhesive (C-314). Ensure grommet (6) is positioned to prevent
chafing of hose (5) seal.
5. Position duct (19) on duct (22) and install clamp (20).
6. Position assembled ducts in helicopter. Secure forward end with two windshield attaching screws and install nuts (26)
between duct and structure.
7. Secure duct (19) with washers (18) and screws (17).
8. Position duct (15) on duct (19) and plenum (13). Install clamps (14, 16, and 27).
9. Position duct (7) on plenum (13) and plenum (4). Seal edges of duct with tape (C-401).
21-21-01
Page 4
E-AB412-PT6T-2
A
IL
ETA
D
E
SE
G6AB0764A
Figure 2. Overhead ventilation system (sheet 1 of 2)
21-21-01
Page 5
E-AB412-PT6T-2
G6AB0609A
Figure 2. Overhead ventilation system (sheet 2 of 2)
21-21-01
Page 6
E-AB412-PT6T-2
3. BLEED AIR HEATING COMPONENTS - HEAT/VENT AIR DUCTS
3-1. HEAT/VENT AIR DUCTS - DESCRIPTION
The flexible air ducts throughout the heat-vent air distribution system are made from silicone impregnated fiberglass cloth.
The non-flexible air ducts are made from polycarbonate material.
3-2. HEAT/VENT AIR DUCTS - REMOVAL
NOTE
Remove individual duct sections as follows:
1. Remove tape at duct joints.
2. Remove attaching screws. Remove ducts. Cover openings to prevent entry of foreign material.
3-3. HEAT/VENT AIR DUCTS - INSTALLATION
MATERIALS REQUIRED
NUMBER NOMENCLATURE
C-300 ADHESIVE
C-403 GLASS CLOTH
C-423 ABRASIVE CLOTH OR PAPER
C-439 TAPE
1. Position duct in its proper location as shown on figure 3.
2. Install attaching screws.
3. After joining ducts in heat/vent system to other ducts or to plenums or valves, wrap joints between units as follows:
a. Prepare surface of duct about 1,0 in. (25,4 mm) from outside edge by roughing up surface with 400 grit abrasive
cloth or paper (C-423). Clean up using dry, pressurized air or clean dry cloths.
b. Brush 0,010 to 0,015 in. (0,254 to 0,381 mm) coating of adhesive (C-300) on outside surface of both ducts about
1,0 in. (25,4 mm) from their outside edges. Allow adhesive to air dry about 30 minutes, but not more than one
hour.
c. Wrap joint with three full turns of 2,0 in. (50,8 mm) wide glass cloth (C-403). Do not stretch last two turns of
tape.
d. Secure tape with two full turns of 2,0 in. (50,8 mm) tape (C-439). Tape edges of tape applied at preceding step
together and tape ends of the tape to ducts.
21-21-01
Page 7
E-AB412-PT6T-2
3-4. HEAT/VENT AIR DUCTS - REPAIR
MATERIALS REQUIRED
NUMBER NOMENCLATURE
C-306 TOLUENE
C-314 ADHESIVE
C-347 XYLENE
C-404 GLASS CLOTH
1. Repair flexible air ducts made from silicone-impregnated fiberglass cloth as follows:
a. Repair scuffs and abrasions that do not penetrate through cloth and are not more than 3,0 in. (76,2 mm) long by
1,5 in. (38,1 mm) wide. A maximum of two repairs per foot, covering up to 10 percent of surface area are
acceptable.
(1) Clean damaged area using toluene (C-306) or xylene (C-347). Allow area to air dry for at least 30 minutes.
(2) Apply brush coat of adhesive (C-314) over damaged area, with minimum of 0,50 in. (12,7 mm) overlap
beyond damage.
(3) Smooth adhesive and cure by air drying for minimum of two hours at room temperature or until dry to
touch.
b. Repair damage which penetrates fiberglass cloth as follows:
NOTE
Repairs covering up to 10% of surface area are acceptable.
(1) Clean circumference of duct damage with toluene (C-306) or xylene (C-347). Allow area to air dry for at
least 30 minutes.
(2) Cut one piece of glass cloth (C-404) to cover duct circumference with at least 1,0 in. (25,4 mm) overlap of
damaged area.
(3) Apply one thin smooth brush coat of adhesive (C-314) around duct circumference in area to be covered by
cloth.
(4) Wrap cloth around duct and smooth out.
2. Allow area to air dry at least two hours or until dry to touch, before using or handling duct.
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G6AB0760A
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G6AB0761A
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4. BLEED AIR HEATING COMPONENTS - BLEED AIR SHUTOFF VALVE
4-1. BLEED AIR SHUTOFF VALVE - DESCRIPTION
Two bleed air shut off valves (2, figure 3), installed on deck of engine compartment, control air flow to cabin heating system.
Valves are opened by 28 Vdc to actuate solenoid and are closed by air pressure.
NOTE
Maintenance procedures for both bleed air shutoff valves is the same. The following
procedures are for bleed air shutoff valve (3, figure 4).
4-2. BLEED AIR SHUTOFF VALVE - REMOVAL
1. Open engine lower cowling.
2. Disconnect electrical connector (5) and bleed air tube (2).
3. Remove "Y" circular access door from bottom of fuselage near F.S. 211 (Chapter 52).
4. Disconnect "Y" tube (11) under engine deck. Remove locknut (10) and washer (9).
5. Remove valve (3) from top of engine deck.
4-3. BLEED AIR SHUTOFF VALVE - INSTALLATION
MATERIALS REQUIRED
NUMBER NOMENCLATURE
C-405 LOCKWIRE
1. Install locknut (6) on valve (3). Install washer (7) on valve (3).
2. Secure nut (6) to valve (3) with lockwire (C-405).
3. Position valve (3) on top of engine deck (8) with electrical receptacle (4) forward.
4. Insert lower end of valve (3) through engine deck (8). Install washer (9) and locknut (10).
5. Connect "Y" tube (11) to valve (3).
6. Apply lock wire (C-405) between ends of "Y" tube (11).
7. Connect tube (2) from bleed air outlet at top of engine power section to top of valve (3). Torque nut (2) 40 to 58 ft.-lbs.
(53,4 to 77,5 Nm).
8. Install electrical connector (5) to receptacle (4).
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E-AB412-PT6T-2
G6AB0765A
Figure 4. Bleed air shutoff valve
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E-AB412-PT6T-2
5. BLEED AIR HEATING COMPONENTS - HOUSED SELECTOR
5-1. HOUSED SELECTOR - DESCRIPTION
The housed selector (10, figure 3) is electrically controlled to open and close two flappers in the air distribution outlet control
valve. The selector and valve are interconnected by a shaft adapter.
5-2. HOUSED SELECTOR - REMOVAL
1. Remove floor panel and access plate from lower fuselage near right B.L. 30,0, forward of F.S. 102,0.
NOTE
Ensure HEATER AFT OUTLET switch is OFF.
2. Disconnect electrical connector (9, figure 5) from selector (10).
3. Remove four screws (11) and remove selector (10) and adapter (5).
4. Remove adapter (5) from shaft (6) of selector (10).
5-3. HOUSED SELECTOR - INSTALLATION
1. Remove cover plate (3, figure 5) so position of flapper (4) can be visually checked through opening.
NOTE
An inspection mirror will aid viewing.
2. Manually rotate flapper (4) to horizontal (open) position.
3. Position shaft (6) as shown in figure 5, and install adapter (5) onto shaft (6).
4. Position housed selector (10) onto valve and secure with four screws (11), washers (8), and self-locking nuts (7).
5. Connect electrical connector (9) to selector (10).
6. Apply electrical power. Place HEATER AFT OUTLET switch on overhead panel to OFF and ensure flapper (4) rotates
to vertical (closed) position.
Remove electrical power.
7. Replace cover plate (3) and secure with screws (1) and washers (2).
8. Replace access plate and floor panel.
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G6AB0766A
Figure 5. Housed selector
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E-AB412-PT6T-2
21-41-01
HEATING SYSTEM
1. HEATING SYSTEM - NOISE SUPPRESSOR
1-1. NOISE SUPPRESSOR - DESCRIPTION
Air flow noise from the engine compressor is muffled by the noise suppressor (6, figure 1). Heated air exits from the noise
suppressor into a plenum chamber in aft cabin area. The noise suppressor is installed in the rear fuselage forward of the
mixing valve.
1-2. NOISE SUPPRESSOR - REMOVAL
1. Open access door on right side of fuselage below engine deck.
2. Remove clamps (1 and 3, figure 2). Remove coupling (2).
3. Remove clamp (6). Remove duct (7) from aft end of suppressor (4).
4. Remove clamps (5 and 8) and suppressor (4).
1-3. NOISE SUPPRESSOR - INSTALLATION
1. Position noise suppressor (4, figure 2) in fuselage compartment near Sta.211, with coupling (2) on suppressor (4) and
duct (not illustrated). Install clamps (1 and 3) with screws, washers, and nuts.
2. Place clamp (5) around middle of suppressor (4) and install on bracket on forward side of Sta.211 bulkhead with screw,
washer, and nut.
3. Place clamp (8) around middle of suppressor (4) and install clamp and sense tube with screw, washers, and nut.
4. Position duct (7) on suppressor (4). Install clamp (6) with screw, washer, and nut.
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G6AB0760A
21-41-01
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G6AB0761A
21-41-01
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E-AB412-PT6T-2
G6AB0771A
Figure 2. Noise suppressor
21-41-01
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E-AB412-PT6T-2
2. HEATING SYSTEM - HEAT/DEFROST CONTROL LEVER
2-1. HEAT/DEFROST CONTROL LEVER - DESCRIPTION
The heat/defrost control lever (16, figure 1) is installed on the right side of pedestal in cockpit. With lever pushed forward
to ON detent, the flapper valve in the heat-defrost duct opens and directs heated air to windshield. With lever pulled aft to
OFF detent, flapper valve closes and heated air is directed to crew and passengers.
2-2. HEAT/DEFROST CONTROL LEVER - REMOVAL
1. Remove two control panels from forward right corner of center pedestal and remoter panel on right side of pedestal.
2. Remove bolt (9, figure 3).
3. Remove pin (3) and lever (1). Pull lever upward through slot in support (7).
4. Remove nut (36) and bolt (11). Slide arm (12) off shaft (15) and remove with rod (10) attached.
5. Remove pin (38) and separate rod (10) from arm (12).
6. Remove two screws (26) and remove switch (27). Disconnect wiring from terminals on bottom of switch.
7. Remove pin (19). Separate link (30) from rod (20).
8. Remove bolt (34). Remove arm (33) and links (30 and 31) from shaft (15).
9. Hold spacer (14) and pull shaft (15) from outboard side of pedestal.
NOTE
Do not remove rod (20) unless flapper valve shown in View A is to be removed.
2-3. HEAT/DEFROST CONTROL LEVER - INSTALLATION
1. Insert shaft (15, figure 3) through right side of pedestal into riveted boss (13) and install spacer (14).
2. Position arm (33) on shaft (15) and install bolt (34), washer (32), and nut (18).
3. If not previously accomplished, assemble links (30 and 31). Install link (31) on arm (33) and install washer (17) and
cotter pin (16). Position assembled parts on rod (20) and install pin (19), washer (29), and cotter pin (28).
4. Attach wiring to terminals on switch (27). Position switch (27) on duct (21) and install screws (26) and washers (25).
5. Rotate shaft (15) forward to open flapper valve to aft outlets and install arm (12), with rod (10) attached, so arm (12)
is forward.
6. Install bolt (11), washer (37), nut (36), and cotter pin (35). Ensure pin (38), washer (40), and cotter pin (41) are properly
installed.
7. Position lever (1) through slot in support (7) with elbow of lever aft.
8. Install bolt (9), washers (8, 44, 2, and 4), nut (5), and cotter pin (6).
9. Push down on rod (10) until it presses switch (27) and hold in position.
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E-AB412-PT6T-2
10. Pivot lever (1) forward and loosen jam nuts on top and bottom ends of rod (10).
11. Adjust length of rod (10) to align with hole in lever (1). Keep exposed threads at clevis ends on rod (10).
12. Position rod (10) on lever (1) and install pin (3), washer (42), and cotter pin (43).
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E-AB412-PT6T-2
G6AB0772A
Figure 3. Heat/defrost control lever
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E-AB412-PT6T-2
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E-AB412-PT6T-2
21-42-01
WINTERIZATION HEATER - BLEED AIR (P/N 212-706-008-103)
1. BLEED AIR (P/N 212-706-008-103) - DESCRIPTION
The winterization heater is the same as the basic heater system except for a higher capacity mixing valve, the addition of a
mixing valve actuator line and control valve and aft cabin outlets with aft outlet control valve.
WARNING
DO NOT OPERATE HEATER ABOVE 21°C (70°F).
NOTE
Refer to Chapter 98 for winterization heater wiring diagram.
2. BLEED AIR (P/N 212-706-008-103) - OPERATIONAL CHECK
1. Operation check air-flow.
a. Thermostat full cold.
b. Heater switch on.
c. Increase thermostat setting and observe heated air-flow.
d. Return thermostat to full cold and observe heated air-flow shut off.
2. Operation check of the actuator line switch is as follows:
a. Turn heat switch to ON, HEATER AIR LINE CAUTION light should illuminate. Light should turn off after
engine No. 2 has started and is up above 75%Ng.
b. Repeat basic heater checkout procedure. (See module 21-00-00 "ENVIRONMENTAL CONTROL").
3. BLEED AIR (P/N 212-706-008-103) - TROUBLESHOOTING
NOTE
Remove and test the temperature control switch, 212-072-705-1, every 500 hours. If
found defective, replace.
NOTE
For identification of the parts refer to wiring diagram.
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E-AB412-PT6T-2
Table 1. Bleed air troubleshooting
No bleed air flow through mixing valve. Defective on-off actuator line Check for defective actuator valve.
valve. If defective replace valve.
Defective wiring. Check for voltage of plug 222 pin

A. If no voltage exists, check
wiring and repair as necessary.
Leaking actuator line. Check for leakage in actuator line

and repair as necessary.
No air out of aft outlet valve. Defective outlet valve. Check for defective outlet valve. If
defective, replace valve.
Defective wiring. Check for voltage at plug P187

pins B and D. If no voltage exists,
check wiring and repair as
necessary.
Defective limit switch on console. Check limit switch on console,

replace if defective.
CAUTION light does not illuminate when Defective actuator line pressure Check for defective pressure
heater switch is turned on with engines off. switch. switch. If defective, replace switch.
Defective wiring. Check for voltage at plug P223 pin

B. If no voltage exists, check
wiring and repair as necessary.
NOTE
Refer to module 21-00-00 "ENVIRONMENTAL CONTROL" for complete
troubleshooting.
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E-AB412-PT6T-2
21-61-01
TEMPERATURE CONTROL
1. TEMPERATURE CONTROL - VARIABLE CONTROL MIXING VALVE
1-1. VARIABLE CONTROL MIXING VALVE - DESCRIPTION
The variable control mixing valve (4, figure 1) is installed in the compartment on right side below engine deck. This valve
controls bleed air and ambient air flow as directed by the remote sensor. A bleed air nozzle inside the mixing valve acts as
a jet pump through a Venturi to draw in ambient air and control air flow mixture. When heated air is not at selected
temperature, the remote sensor causes the variable control mixing valve to increase or decrease engine bleed air flow and
regulate ambient air flow to correct the temperature variation. A temperature limit overheat switch (5) on mixing valve (4)
prevents structural damage in the event of an overheat. The CABIN HTR circuit breaker will open when air in mixing valve
reaches 220°F (104,4°C).
1-2. VARIABLE CONTROL MIXING VALVE - REMOVAL
1. Open aft access door at right side of fuselage below engine deck.
2. Remove switch (4, figure 2) and packing (3). Discard packing.
3. Disconnect tube (7) from valve and remove union (6).
4. Remove clamp (2) and duct (1).
5. Disconnect tube (10).
6. Disconnect electrical connector (11).
7. Remove locknut (9) and washers (8).
8. Remove mixing valve (5).
1-3. VARIABLE CONTROL MIXING VALVE - INSTALLATION
1. Position mixing valve (5, figure 2) in compartment below engine deck.
2. Install washer (8) and locknut (9).
3. Install tube (10) and torque "B" nut on tube 40 to 58 ft.-lbs. (54 to 79 Nm).
4. Install duct (1) and clamp (2).
5. Install sense tube (7) on union (6) and install union.
6. Install packing (3) and switch (4).
7. Connect electrical connector (11)
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G6AB0760A
21-61-01
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G6AB0761A
21-61-01
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E-AB412-PT6T-2
G6AB0768A
Figure 2. Variable control mixing valve
21-61-01
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E-AB412-PT6T-2
2. TEMPERATURE CONTROL - REMOTE SENSOR AND POSITIONING MOTOR
2-1. REMOTE SENSOR AND POSITIONING MOTOR - DESCRIPTION
The remote sensor (8, figure 1) is installed on top of the plenum chamber. The sensor controls the mixing valve through a
bleed air port. A bi-metallic element in the sensor activates the mixing valve through small diameter sensing tube
(7, figure 2) between mixing valve and sensor. The positioning motor is connected electrically to the temperature selecting
dial (servo-controller).
2-2. REMOTE SENSOR AND POSITIONING MOTOR - REMOVAL
1. Gain access to remote sensor (3, figure 3) by opening forward access door on right side of fuselage below engine deck.
2. Remove remote sensor as follows:
a. Disconnect sensing tube (2) and flex shaft (5) from sensor (3).
b. Remove screws (4) through spacer (15) on plenum (1) and remove sensor.
3. Gain access to positioning motor (7) by opening forward access door on right side of fuselage below engine deck.
4. Remove positioning motor as follows:
a. Disconnect electrical plug (8) from positioning motor (7).
b. Disconnect copper bonding strip (11) by removing nut (14), washer (13), and screw (12).
c. Remove screws (10) and washers (9) from bracket (6) and remove positioning motor (7) with copper bonding
strip (11) and bracket (6) as a unit.
2-3. REMOTE SENSOR AND POSITIONING MOTOR - INSTALLATION AND RIGGING
MATERIALS REQUIRED
NUMBER NOMENCLATURE
C-405 LOCK WIRE
1. Install remote sensor (3, figure 3) as follows:
a. Seat remote sensor (3) onto spacer (15) on plenum chamber (1) and secure with three screws (4).
b. Connect flex shaft (5) and sensing tube (2) to sensor (3).
c. Secure flex shaft ends with lock wire (C-405).
d. Close access door on fuselage.
2. Install positioning motor (7) as follows:
a. Position positioning motor (7) in place and secure bracket (6) with washers (9) and screws (10).
b. Connect copper bonding strip (11) with screw (12), washer (13), and nut (14).
c. Connect electrical plug (8) on positioning motor (7).
d. Close access door on fuselage.
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E-AB412-PT6T-2
G6AB0769A
Figure 3. Remote sensor and positioning motor installation
21-61-01
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E-AB412-PT6T-2
CHAPTER 25 - EQUIPMENT/FURNISHINGS

Module Page
Number Title Number
25-00-00 EQUIPMENT/FURNISHINGS
1. Equipment/furnishings - general ............................................................................................................. 1
25-11-01 CREW SEATS
1. Crew seats - description .......................................................................................................................... 1

2. Crew seats - removal ............................................................................................................................... 1
3. Crew seats - installation ........................................................................................................................... 2
4. Crew seats - inspection ........................................................................................................................... 2
5. Crew seats - repair .................................................................................................................................. 4
25-11-02 CREW SEAT RESTRAINT ASSEMBLY AND VERTICAL ADJUSTMENT CABLE
1. Crew seat restraint assembly - removal .................................................................................................. 1

2. Crew seat restraint assembly - installation ............................................................................................. 1
3. crew seat restraint assembly - check and inspection guidelines .............................................................. 2
4. Crew seat restraint assembly - inspection ............................................................................................... 3
5. Crew seat restraint assembly - repair ...................................................................................................... 6
6. Crew seat vertical adjustment cable - removal ....................................................................................... 6
7. Crew seat vertical adjustment cable - installation ................................................................................... 7
25-21-01 PASSENGER SEATS
1. Passenger seats - description ................................................................................................................... 1

2. Passenger seats - removal ....................................................................................................................... 1
3. passenger seats - installation ................................................................................................................... 1
4. Passenger seats - inspections .................................................................................................................. 2
25-23-01 LOUDSPEAKER SYSTEM (AEM-400)
1. Loudspeaker system (AEM-400) - description ....................................................................................... 1

2. Loudspeaker system (AEM-400) - operational check ............................................................................ 1
3. Loudspeaker system (AEM-400) - speakers ........................................................................................... 3
3-1. Speakers - removal ........................................................................................................................ 3
3-2. Speakers - installation .................................................................................................................... 3
4. Loudspeaker system (AEM-400) - amplifier .......................................................................................... 3
4-1. Amplifier - removal ....................................................................................................................... 3
4-2. Amplifier - installation .................................................................................................................. 3
5. Loudspeaker system (AEM-400) - control unit ...................................................................................... 3
5-1. Control unit - removal ................................................................................................................... 3
5-2. Control unit - installation ............................................................................................................... 3
25-31-01 LIGHTER (P/N 412-7716-03-101)
1. Lighter (P/N 412-7716-03-101) - description ......................................................................................... 1
25-Index
Rev. 3 Page 1
E-AB412-PT6T-2

Module Page
Number Title Number
25-33-01 NIGHT SUN SEARCHLIGHT SYSTEM (P/N 212-9000-36-101/-103)
1. Night sun searchlight system (P/N 212-9000-36-101/-103) - description ..............................................1

2. Night sun searchlight system (P/N 212-9000-36-101/-103) - operational check ....................................2
3. Night sun searchlight system (P/N 212-9000-36-101/-103) - troubleshooting .......................................4
4. Night sun searchlight system (P/N 212-9000-36-101/-103) - searchlight assembly ..............................4
4-1. Searchlight assembly - removal .....................................................................................................4
4-2. Searchlight assembly - installation .................................................................................................6
4-3. Searchlight assembly - cleaning .....................................................................................................6
5. Night sun searchlight system (P/N 212-9000-36-101/-103) - gimbal mounting ....................................6
5-1. Gimbal mounting - removal ...........................................................................................................6
5-2. Gimbal mounting - installation ......................................................................................................6
5-3. Gimbal mounting - inspection ........................................................................................................7
6. Night sun searchlight system (P/N 212-9000-36-101/-103) - junction box ............................................7
6-1. Junction box - removal ...................................................................................................................7
6-2. Junction box - installation ..............................................................................................................7
7. Night sun searchlight system (P/N 212-9000-36-101/-103) - remote control unit .................................7
7-1. Remote control unit - removal .......................................................................................................7
7-2. Remote control unit - installation ...................................................................................................7
25-33-11 INTERMITTENT LIGHTS (P/N 412-7716-02-103)
1. Intermittent lights (P/N 412-7716-02-103) - description ........................................................................1

2. Intermittent lights (P/N 412-7716-02-103) - removal .............................................................................1
3. Intermittent lights (P/N 412-7716-02-103) - installation ........................................................................1
4. Intermittent lights (P/N 412-7716-02-103) - operational check ..............................................................1
5. Intermittent lights (P/N 412-7716-02-103) - troubleshooting .................................................................3
6. Intermittent lights (P/N 412-7716-02-103) - position light flasher unit ..................................................3
6-1. Position light flasher unit - removal ...............................................................................................4
6-2. Position light flasher unit - installation ..........................................................................................4
7. Intermittent lights (P/N 412-7716-02-103) - fuselage lights ...................................................................4
7-1. Fuselage lights - removal ...............................................................................................................4
7-2. Fuselage lights - installation ...........................................................................................................4
25-51-01 CARGO RESTRAINT (P/N 205-070-507-7)
1. Cargo restraint (P/N 205-070-507-7) - description .................................................................................1

2. Cargo restraint (P/N 205-070-507-7) - removal ......................................................................................1
3. Cargo restraint (P/N 205-070-507-7) - installation .................................................................................1
4. Cargo restraint (P/N 205-070-507-7) - inspection ..................................................................................1
5. Cargo restraint (P/N 205-070-507-7) - repair or replacement .................................................................4
6. Cargo restraint (P/N 205-070-507-7) - adjustment .................................................................................4
25-60-01 LITTER INSTALLATION (3 PLACES) (P/N 205-706-047-11)
1. Litter installation (3 places) (P/N 205-706-047-11) - description ...........................................................1

2. Litter installation (3 places) (P/N 205-706-047-11) - removal ...............................................................1
3. Litter installation (3 places) (P/N 205-706-047-11) - installation ...........................................................1
4. Litter installation (3 places) (P/N 205-706-047-11) - inspection ............................................................2
5. Litter installation (3 places) (P/N 205-706-047-11) - repairing ..............................................................4
25-Index
Page 2 Rev. 3
E-AB412-PT6T-2

Module Page
Number Title Number
1. Litter installation (6 places) (P/N 212-706-002-1) - description ............................................................ 1

2. Litter installation (6 places) (P/N 212-706-002-1) - removal ................................................................. 1
3. Litter installation (6 places) (P/N 212-706-002-1) - installation ............................................................ 1
4. Litter installation (6 places) (P/N 212-706-002-1) - inspection ............................................................. 2
5. Litter installation (6 places) (P/N 212-706-002-1) - repair ..................................................................... 2
25-61-01 MAP AND DATA CASE
1. Map and data case - removal .................................................................................................................. 1

2. Map and data case - installation .............................................................................................................. 1
3. Map and data case - inspection ............................................................................................................... 1
25-61-02 FIRST AID KIT
1. First aid kit - removal .............................................................................................................................. 1

2. First aid kit - installation ......................................................................................................................... 1
3. First aid kit - inspection .......................................................................................................................... 1
4. First aid kit - repair ................................................................................................................................. 1
25-61-03 SNOW SKI (P/N 212-9000-25-1)
1. Snow ski (P/N 212-9000-25-1) - description .......................................................................................... 1

2. Snow ski (P/N 212-9000-25-1) - removal .............................................................................................. 1
3. Snow ski (P/N 212-9000-25-1) - installation .......................................................................................... 1
25-61-04 EMERGENCY FLOATS KIT (P/N 212-4600-03)
1. Emergency floats kit (P/N 212-4600-03) - description .......................................................................... 1

2. Emergency floats kit (P/N 212-4600-03) - operational check ................................................................. 3
3. Emergency floats kit (P/N 212-4600-03) - troubleshooting ................................................................... 4
4. Emergency floats kit (P/N 212-4600-03) - floats (P/N 212-4600-09) .................................................... 5
4-1. Floats (P/N 212-4600-09) - description ......................................................................................... 5
4-2. Floats (P/N 212-4600-09) - removal .............................................................................................. 5
4-3. Floats (P/N 212-4600-09) - installation ......................................................................................... 5
4-4. Floats (P/N 212-4600-09) - inspection .......................................................................................... 7
4-5. Floats (P/N 212-4600-09) - cleaning ............................................................................................. 7
4-6. Floats (P/N 212-4600-09) - repair ................................................................................................. 8
4-7. Floats (P/N 212-4600-09) - folding ............................................................................................... 9
4-8. Floats (P/N 212-4600-09) - storage instructions ........................................................................... 9
5. Emergency floats kit (P/N 212-4600-03) - floats (P/N 212-4600-26) .................................................. 12
5-1. Floats (P/N 212-4600-26) - description ....................................................................................... 12
5-2. Floats (P/N 212-4600-26) - removal ............................................................................................ 12
5-3. Floats (P/N 212-4600-26) - installation ....................................................................................... 13
5-4. Floats (P/N 212-4600-26) - inspection ........................................................................................ 13
5-5. Floats (P/N 212-4600-26) - cleaning ........................................................................................... 13
5-6. Floats (P/N 212-4600-26) - repair ............................................................................................... 13
5-7. Floats (P/N 212-4600-26) - storage ............................................................................................. 14
6. Emergency floats kit (P/N 212-4600-03) - gas generator (Kidde 894063) .......................................... 14
6-1. Gas generator (Kidde 894063) - description ................................................................................ 14
6-2. Gas generator (Kidde 894063) - inspection and test .................................................................... 14
25-Index
Rev. 3 Page 3
E-AB412-PT6T-2

Module Page
Number Title Number
6-3. Gas generator (Kidde 894063) - special instructions ...................................................................14

7. Emergency floats kit (P/N 212-4600-03) - cylinder assembly (P/N 205608)........................................15
7-1. Cylinder assembly (P/N 205608) - description ............................................................................15
7-1. Cylinder assembly (P/N 205608) - inspection and test ................................................................15
25-66-01 EXTERNAL LOUDSPEAKERS SYSTEM (P/N 412-9010-96-301)
1. External loudspeakers system (P/N 412-9010-96-301) - description .....................................................1

2. External loudspeakers system (P/N 412-9010-96-301) - maintenance ...................................................1
2-1. Maintenance - speakers ..................................................................................................................1
2-2. Maintenance - amplifier .................................................................................................................1
2-3. Maintenance - control panel ...........................................................................................................2
25-71-01 AUXILIARY FUEL TANKS (LONG RANGE) (P/N 412-706-007-109 AND 110)
1. Auxiliary fuel tanks (long range) (P/N 412-706-007-109 and 110) - description ...................................1
2. Auxiliary fuel tanks (long range) (P/N 412-706-007-109 and 110) - removal .......................................1
3. Auxiliary fuel tanks (long range) (P/N 412-706-007-109 and 110) - installation ..................................2
4. Auxiliary fuel tanks (long range) (P/N 412-706-007-109 and 110) - inspection ....................................4
5. Auxiliary fuel tanks (long range) (P/N 412-706-007-109 and 110) - repair ...........................................4
6. Auxiliary fuel tanks (long range) (P/N 412-706-007-109 and 110) - operational check .........................8
7. Auxiliary fuel tanks (long range) (p/n 412-706-007-109 and 110) - testing ...........................................8
25-71-02 AUXILIARY FUEL TANKS (SEAT TYPE) (P/N 412-706-009-107)
1. Auxiliary fuel tanks (seat type) (p/n 412-706-009-107) - description ....................................................1

2. Auxiliary fuel tanks (seat type) (p/n 412-706-009-107) - removal .........................................................1
3. Auxiliary fuel tanks (seat type) (p/n 412-706-009-107) - installation ....................................................2
4. Auxiliary fuel tanks (seat type) (p/n 412-706-009-107) - inspection ......................................................3
5. Auxiliary fuel tanks (seat type) (p/n 412-706-009-107) - operational check ..........................................3
6. Auxiliary fuel tanks (seat type) (p/n 412-706-009-107) - testing ............................................................5
25-91-00 EXTERNAL RESCUE HOIST INSTALLATION KIT (ELECTRIC)

P/N 412-8800-01-412 (BL20200-412)
1. External rescue hoist installation kit (electric) P/N 412-8800-01-412 (BL20200-412) - hoist assembly1
1-1. Hoist assembly - removal ...............................................................................................................1
1-2. Hoist assembly - installation ..........................................................................................................2
2. External rescue hoist installation kit (electric) P/N 412-8800-01-412 (BL20200-412) - wire rope
cable .........................................................................................................................................................2
3. External rescue hoist installation kit (electric) P/N 412-8800-01-412 (BL20200-412) - tension roller ..2
4. External rescue hoist installation kit (electric) P/N 412-8800-01-412 (BL20200-412) - control
pendant assembly ....................................................................................................................................2
5. External rescue hoist installation kit (electric) P/N 412-8800-01-412 (BL20200-412) - control
pendant assembly ....................................................................................................................................3
5-1. Control pendant assembly - removal ..............................................................................................4
5-2. Control pendant assembly - installation .........................................................................................4
6. External rescue hoist installation kit (electric) P/N 412-8800-01-412 (BL20200-412) - control box ....4
6-1. Control box - removal ....................................................................................................................4
6-2. Control box - installation ................................................................................................................4
7. External rescue hoist installation kit (electric) P/N 412-8800-01-412 (BL20200-412) - rescue
hoist cable handling..................................................................................................................................5
7-1. Rescue hoist cable handing - cable inspection and maintenance ...................................................5
25-Index
Page 4 Rev. 3
E-AB412-PT6T-2

Module Page
Number Title Number
8. External rescue hoist installation kit (electric) P/N 412-8800-01-412 (BL20200-412) - operating
of limit switch settings ............................................................................................................................ 5
9. External rescue hoist installation kit (electric) P/N 412-8800-01-412 (BL20200-412) - operating
of limit switch settings ............................................................................................................................ 5
10. External rescue hoist installation kit (electric) P/N 412-8800-01-412 (BL20200-412) - cable cutter .... 6
11. External rescue hoist installation kit (electric) P/N 412-8800-01-412 (BL20200-412) - cable foul
sensor ...................................................................................................................................................... 6
12. External rescue hoist installation kit (electric) P/N 412-8800-01-412 (BL20200-412) - variable
speed controller ....................................................................................................................................... 6
12-1. Variable speed controller - removal ............................................................................................... 7
12-2. Variable speed controller - installation .......................................................................................... 7
13. External rescue hoist installation kit (electric) P/N 412-8800-01-412 (BL20200-412) - hoist
maintenance and refurbishing ................................................................................................................. 7
14. External rescue hoist installation kit (electric) P/N 412-8800-01-412 (BL20200-412) - sliding
panel installation rh ................................................................................................................................. 7
14-1. Sliding panel installation RH - removal ........................................................................................ 7
14-2. Sliding panel installation RH - installation .................................................................................... 7
14-3. Sliding panel installation RH - inspection ..................................................................................... 8
15. External rescue hoist installation kit (electric) P/N 412-8800-01-412 (BL20200-412) - cable
protection ................................................................................................................................................ 8
15-1. Cable protection - removal ............................................................................................................ 8
15-2. Cable protection - installation ........................................................................................................ 8
15-3. Cable protection - inspection ......................................................................................................... 8
25-91-01 EXTERNAL RESCUE HOIST - HOOK ASSEMBLY
1. Hook assembly - disassembly ................................................................................................................. 1

2. Hook assembly - assembly ..................................................................................................................... 2
3. Hook assembly (P/N 412-8800-05-101) disassembly/assembly (post BT 412-103) ............................. 3
25-91-02 INTERNAL RESCUE HOIST (P/N 214-706-003-103)
1. Internal rescue hoist (P/N 214-706-003-103) - description .................................................................... 1

2. Internal rescue hoist (P/N 214-706-003-103) - removal ......................................................................... 1
3. Internal rescue hoist (P/N 214-706-003-103) - installation .................................................................... 2
4. Internal rescue hoist (P/N 214-706-003-103) - operational check ......................................................... 6
5. Internal rescue hoist (P/N 214-706-003-103) - troubleshooting ............................................................. 7
6. Internal rescue hoist (P/N 214-706-003-103) - cable replacement ....................................................... 11
7. Internal rescue hoist (P/N 214-706-003-103) - cable cutter refurbishment........................................... 12
8. Internal rescue hoist (P/N 214-706-003-103) - up-limit switch adjustment ......................................... 12
9. Internal rescue hoist (P/N 214-706-003-103) - lights replacement ...................................................... 12
25-92-00 EXTERNAL RESCUE HOIST [B]
1. External Rescue hoist (P/N 212-8800-01-101) [B] - description ........................................................... 1

2. External Rescue hoist (P/N 212-8800-01-101) [B] - Removal ............................................................... 1
3. External Rescue hoist (P/N 212-8800-01-101) [B] - Installation ............................................................ 2
4. External Rescue hoist (P/N 212-8800-01-101) [B] - Rescue hoist test .................................................. 2
5. External rescue hoist [B] - adjustment of the limit switches .................................................................. 7
25-92-01 EXTERNAL RESCUE CABLE CUTTING CARTRIDGE
1. External rescue cable-cutting cartridge - description ............................................................................. 1
25-Index
Rev. 3 Page 5
E-AB412-PT6T-2

Module Page
Number Title Number
2. External rescue cable-cutting cartridge - removal ...................................................................................1

3. External rescue cable-cutting cartridge - installation ..............................................................................1
25-92-02 EXTERNAL RESCUE HOIST CABLE
1. External rescue hoist cable - description .................................................................................................1

2. External rescue hoist cable - removal .....................................................................................................1
3. External rescue hoist cable - installation .................................................................................................3
4. External rescue hoist cable - inspection ..................................................................................................3
25-92-03 EXTERNAL RESCUE HOIST, HANDWHEEL AND BUMPER
1. External rescue hoist, handwheel and bumper - description ...................................................................1

2. External rescue hoist, handwheel and bumper - removal ........................................................................1
3. External rescue hoist, handwheel and bumper - installation ...................................................................1
4. External rescue hoist, handwheel and bumper - periodical inspection ...................................................2
25-92-04 EXTERNAL RESCUE HOIST - TEST BOX OF THE HOIST SHEAR CIRCUIT
1. Test box of the hoist shear circuit - description ......................................................................................1

2. Test box of the hoist shear circuit - removal ...........................................................................................1
3. Test box of the hoist shear circuit - installation ......................................................................................1
4. Test box of the hoist shear circuit - inspection ........................................................................................1
5. Test box of the hoist shear circuit - repair ...............................................................................................1
25-92-05 EXTERNAL RESCUE HOIST - NO. 3 HYDRAULIC PUMP AND ROTOR BRAKE DRIVE
QUILL P/N 212-3101-22-9
1. External rescue hoist - No.3 hydraulic pump and rotor brake drive quill P/N 212-3101-22-9 -
description ................................................................................................................................................1
removal ....................................................................................................................................................1
installation ...............................................................................................................................................1
inspection ................................................................................................................................................2
25-92-06 EXTERNAL RESCUE HOIST - UTILITY HYDRAULIC SYSTEM (FOR EXTERNAL RESCUE
HOIST) [B] [C]
1. Utility hydraulic system (for external rescue hoist) [B][C] - description ...............................................1
2. Utility hydraulic system (for external rescue hoist) [B][C] - heat exchanger .........................................1
3. Utility hydraulic system (for external rescue hoist) [B][C] - indication and test.....................................2
4. Utility hydraulic system (for external rescue hoist) [B][C] - cable shear cartridge ................................2
25-92-07 EXTERNAL RESCUE HOIST - TROUBLESHOOTING
1. Troubleshooting - description .................................................................................................................1
25-92-08 EXTERNAL RESCUE HOIST - OPERATIONAL CHECK
1. Operational check - description ...............................................................................................................1
25-Index
Page 6 Rev. 3
E-AB412-PT6T-2

Module Page
Number Title Number
25-92-09 EXTERNAL RESCUE HOIST - FLUSHING
1. Flushing - description ............................................................................................................................. 1
25-92-10 EXTERNAL RESCUE HOIST - RESERVOIR
1. Reservoir - description ............................................................................................................................ 1

2. Reservoir - removal ................................................................................................................................ 1
3. Reservoir - inspection ............................................................................................................................. 1
4. Reservoir - installation ............................................................................................................................ 1
5. Reservoir - pressure test........................................................................................................................... 2
25-92-11 EXTERNAL RESCUE HOIST - RESERVOIR FILTER
1. Reservoir filter - description ................................................................................................................... 1

2. Reservoir filter - removal ........................................................................................................................ 1
3. Reservoir filter - installation ................................................................................................................... 1
4. Reservoir filter - inspection .................................................................................................................... 1
25-92-12 EXTERNAL RESCUE HOIST - RESERVOIR VENT FILTER
1. Reservoir vent filter - description ........................................................................................................... 1

2. Reservoir vent filter - removal ................................................................................................................ 1
3. Reservoir vent filter - installation ........................................................................................................... 1
4. Reservoir vent filter - inspection ............................................................................................................ 1
25-92-13 EXTERNAL RESCUE HOIST - PUMP
1. Pump - description .................................................................................................................................. 1

2. Pump - removal ....................................................................................................................................... 1
3. Pump - installation ................................................................................................................................... 2
4. Pump - inspection ................................................................................................................................... 2
5. Pump - lubrication .................................................................................................................................. 3
25-92-14 EXTERNAL RESCUE HOIST - ELECTRO VALVE
1. Electro valve - description ...................................................................................................................... 1

2. Electro valve - removal ........................................................................................................................... 1
3. Electro valve - installation ...................................................................................................................... 1
4. Electro valve - inspection ....................................................................................................................... 1
25-92-15 EXTERNAL RESCUE HOIST - CHECK VALVES
1. Check valves - description ...................................................................................................................... 1

2. Check valves - removal ........................................................................................................................... 1
3. Check valves - installation ...................................................................................................................... 1
4. Check valves - inspection ....................................................................................................................... 1
25-92-16 EXTERNAL RESCUE HOIST - FILTER
1. Filter - description ................................................................................................................................... 1

2. Filter - removal ....................................................................................................................................... 1
25-Index
Rev. 3 Page 7
E-AB412-PT6T-2

Module Page
Number Title Number
3. Filter - removal of the cartridge ..............................................................................................................1

4. Filter - inspection ....................................................................................................................................1
5. Filter - installation of the cartridge ..........................................................................................................1
6. Filter - installation of filter ......................................................................................................................1
25-92-17 EXTERNAL RESCUE HOIST - PRESSURE SWITCH
1. Pressure switch - description ...................................................................................................................1

2. Pressure switch - removal .......................................................................................................................1
3. Pressure switch - installation ...................................................................................................................1
4. Pressure switch - inspection and test .......................................................................................................1
25-92-18 EXTERNAL RESCUE HOIST - PRESSURE TRANSMITTER
1. Pressure transmitter - description ............................................................................................................1

2. Pressure transmitter - removal .................................................................................................................1
3. Pressure transmitter - installation ............................................................................................................1
4. Pressure transmitter - inspection .............................................................................................................1
25-92-19 EXTERNAL RESCUE HOIST - TEMPERATURE TRANSMITTER
1. Temperature transmitter - description .....................................................................................................1

2. Temperature transmitter - removal ..........................................................................................................1
3. Temperature transmitter - installation .....................................................................................................1
4. Temperature transmitter - inspection ......................................................................................................1
25-92-20 EXTERNAL RESCUE HOIST - FLOW VALVE
1. Flow valve - description ..........................................................................................................................1

2. Flow valve - removal ...............................................................................................................................1
3. Flow valve - installation ..........................................................................................................................1
4. Flow valve - inspection ...........................................................................................................................1
25-92-21 EXTERNAL RESCUE HOIST - FLOW GOVERNOR (LOW SPEED)
1. Flow governor (low speed) - description ................................................................................................1

2. Flow governor (low speed) - removal .....................................................................................................1
3. Flow governor (low speed) - installation ................................................................................................1
4. Flow governor (low speed) - inspection ..................................................................................................1
25-92-22 EXTERNAL RESCUE HOIST - FLOW GOVERNOR (HIGH SPEED)
1. Flow governor (high speed) - description ...............................................................................................1

2. Flow governor (high speed) - removal ....................................................................................................1
3. Flow governor (high speed) - installation ...............................................................................................1
4. Flow governor (high speed) - inspection .................................................................................................1
25-92-23 EXTERNAL RESCUE HOIST - SHUT-OFF VALVE
1. Shut-off valve - description .....................................................................................................................1

2. Shut-off valve - removal .........................................................................................................................1
3. Shut-off valve - installation .....................................................................................................................1
4. Shut-off valve - inspection ......................................................................................................................1
25-Index
Page 8 Rev. 3
E-AB412-PT6T-2

Module Page
Number Title Number
25-92-24 EXTERNAL RESCUE HOIST - MANUAL SELECTOR VALVE
1. Manual selector valve - description ........................................................................................................ 1

2. Manual selector valve - removal ............................................................................................................. 1
3. Manual selector valve - installation ........................................................................................................ 1
4. Manual selector valve - inspection ......................................................................................................... 1
25-92-25 EXTERNAL RESCUE HOIST - DIRECTIONAL CONTROL VALVE
1. Directional control valve - description ................................................................................................... 1

2. Directional control valve - removal ........................................................................................................ 1
3. Directional control valve - installation ................................................................................................... 1
4. Directional control valve - inspection ..................................................................................................... 1
25-92-26 EXTERNAL RESCUE HOIST - PRESET SAFETY VALVE
1. Preset safety valve - description ............................................................................................................. 1

2. Preset safety valve - removal .................................................................................................................. 1
3. Preset safety valve - installation ............................................................................................................. 1
4. Preset safety valve - inspection ............................................................................................................... 1
25-92-27 EXTERNAL RESCUE HOIST - PRESSURE RELIEF VALVE
1. Pressure relief valve - description ........................................................................................................... 1

2. Pressure relief valve - removal ............................................................................................................... 1
3. Pressure relief valve - installation ........................................................................................................... 1
4. Pressure relief valve - inspection ............................................................................................................ 1
25-92-28 EXTERNAL RESCUE HOIST - HEAT EXCHANGER
1. Heat exchanger - description .................................................................................................................. 1

2. Heat exchanger - removal ....................................................................................................................... 1
3. Heat exchanger - installation .................................................................................................................. 1
4. Heat exchanger - inspect and test ........................................................................................................... 1
25-92-29 EXTERNAL RESCUE HOIST - ACCUMULATOR
1. Accumulator - description ...................................................................................................................... 1

2. Accumulator - removal ........................................................................................................................... 1
3. Accumulator - installation ...................................................................................................................... 1
4. Accumulator - inspection ........................................................................................................................ 1
25-92-30 EXTERNAL RESCUE HOIST - UTILITY HYDRAULIC SYSTEM
1. Utility hydraulic system - servicing ........................................................................................................ 1
25-92-31 EXTERNAL RESCUE HOIST - SUPPORTS
1. Supports - description ............................................................................................................................. 1

2. Supports - inspection (12 months) .......................................................................................................... 1
25-Index
Rev. 3 Page 9
E-AB412-PT6T-2

Module Page
Number Title Number
25-93-00 TRANSMISSION SYSTEM COMPONENTS - ROTOR BRAKE KIT
1. Rotor brake kit - description ....................................................................................................................1

2. Rotor brake kit - operational check .........................................................................................................1
3. Rotor brake kit - troubleshooting .............................................................................................................2
4. Rotor brake kit - master cylinder (pump) ................................................................................................3
4-1. Master cylinder (pump) - removal .................................................................................................3
4-2. Master cylinder (pump) - installation .............................................................................................5
4-3. Master cylinder (pump) - test .........................................................................................................5
5. Rotor break kit - brake units ....................................................................................................................5
5-1. Brake units - removal .....................................................................................................................5
5-2. Brake units - installation ................................................................................................................5
5-3. Brake units - pucks replacement ....................................................................................................6
6. Rotor brake kit - disc ...............................................................................................................................7
6-1. Disc - removal ................................................................................................................................7
6-2. Disc - installation ...........................................................................................................................7
6-3. Disc - inspection .............................................................................................................................7
7. Rotor brake kit - pressure switch .............................................................................................................8
25-94-00 EXTERNAL CARGO SUSPENSION HOOK (P/N 212-706-103-101)
1. External cargo suspension hook (P/N 212-706-103-101) - description ..................................................1

2. External cargo suspension hook (P/N 212-706-103-101) - operational check .......................................1
3. External cargo suspension hook (P/N 212-706-103-101) - emergency release control cable
adjustment ................................................................................................................................................1
4. External cargo suspension hook (P/N 212-706-103-101) - cargo release electrical system ...................2
25-94-01 EXTERNAL CARGO SUSPENSION HOOK - SUSPENSION UNIT AND EMERGENCY

RELEASE MECHANISM
1. Suspension unit and emergency release mechanism - removal ..............................................................1

2. Suspension unit and emergency release mechanism - installation ..........................................................1
3. Suspension unit and emergency release mechanism - inspection ...........................................................2
25-94-02 EXTERNAL CARGO SUSPENSION HOOK - REAR VIEW MIRROR (P/N 204-070-526-7)
1. Rear view mirror (P/N 204-070-526-7) - description .............................................................................1

2. Rear view mirror (P/N 204-070-526-7) - removal ..................................................................................1
3. Rear view mirror (P/N 204-070-526-7) - installation .............................................................................1
4. Rear view mirror (P/N 204-070-526-7) - adjustment ..............................................................................1
25-94-03 EXTERNAL CARGO SUSPENSION HOOK - CARGO RESTRAINT NET (CARGO HOOK)
(P/N 204-0900-08-1)
1. Cargo restraint net (cargo hook) (P/N 204-0900-08-1) - description ......................................................1
25-Index
Page 10 Rev. 3
E-AB412-PT6T-2
FIGURES
Figure Page
Number Title Number
25-11-01 CREW SEATS
Figure 1. Crew seats....................................................................................................................................................... 3

Figure 2. Copilot seat (sheet 1 of 2)............................................................................................................................... 5
Figure 3. Crew seat attenuator (sheet 1 of 2) ................................................................................................................. 9
Figure 4. Crew seat assembly ...................................................................................................................................... 11
25-11-02 CREW SEAT RESTRAINT ASSEMBLY AND VERTICAL ADJUSTMENT CABLE
Figure 1. Crew seat restraint (sheet 1 of 2) .................................................................................................................... 4

Figure 2. Passenger seats ............................................................................................................................................... 8
Figure 1. Passenger seats ............................................................................................................................................... 3
25-23-01 LOUDSPEAKER SYSTEM (AEM-400)
Figure 1. Loudspeaker installation................................................................................................................................. 2
Figure 1. Night sun searchlight installation ................................................................................................................... 3

Figure 2. Remote control unit ........................................................................................................................................ 5
Figure 1. Intermittent lights installation......................................................................................................................... 2
Figure 1. Cargo restraint installation.............................................................................................................................. 2

Figure 2. Cargo net......................................................................................................................................................... 3
Figure 1. Litter installation (3 places) ............................................................................................................................ 3
Figure 1. Litter installation (6 places) ............................................................................................................................ 3
Figure 1. Map and data case........................................................................................................................................... 2
25-61-03 SNOW SKI (P/N 212-9000-25-1)
Figure 1. Snow ski installation....................................................................................................................................... 2
25-Index
Rev. 3 Page 11
E-AB412-PT6T-2
FIGURES (CONT.D)
Figure Page
Number Title Number
Figure 1. Emergency floats (P/N 212-4600-09) .............................................................................................................2

Figure 2. Emergency floats (P/N 212-4600-26) .............................................................................................................6
Figure 3. Gas generator (P/N 894063) (sheet 1 of 2) ...................................................................................................10
25-66-01 EXTERNAL LOUDSPEAKERS SYSTEM (P/N 412-9010-96-301)
Figure 1. External loudspeakers system .........................................................................................................................3
25-71-01 AUXILIARY FUEL TANKS (LONG RANGE) (P/N 412-706-007-109 AND 110)
Figure 1. Auxiliary fuel tanks (82 U.S. gallons) (long range) (sheet 1 of 2)..................................................................6
Figure 1. Auxiliary fuel tanks (37 U.S. gallons) (seat type)...........................................................................................4
25-91-00 EXTERNAL RESCUE HOIST INSTALLATION KIT (ELECTRIC) P/N 412-8800-01-412

(BL20200-412)
Figure 1. External electrical rescue hoist installation.....................................................................................................9

Figure 2. Limit switch actuation...................................................................................................................................10
25-91-01 EXTERNAL RESCUE HOIST - HOOK ASSEMBLY
Figure 1. Hook assembly ................................................................................................................................................4

Figure 2. Hook assembly (P/N 412-8800-05-101) .........................................................................................................5
Figure 1. Internal hoist control panel..............................................................................................................................2

Figure 2. Hoist installation .............................................................................................................................................4
Figure 3. Hoist locations.................................................................................................................................................5
Figure 4. Cable replacement and instruction plate .......................................................................................................13
Figure 5. Up-limit switch adjustment ...........................................................................................................................14
Figure 1. External rescue hoist (sheet 1 of 3) .................................................................................................................4

Figure 2. Rescue hoist assembly.....................................................................................................................................8
Figure 3. Rescue hoist, handwheel and bumper .............................................................................................................9

Figure 2. Hoist cable installation....................................................................................................................................4
25-Index
Page 12 Rev. 3
E-AB412-PT6T-2
FIGURES (CONT.D)
Figure Page
Number Title Number
Figure 3. Hoist cable check............................................................................................................................................ 5
Figure 1. Rescue hoist, handwheel and bumper............................................................................................................. 3
25-92-05 EXTERNAL RESCUE HOIST - NO. 3 HYDRAULIC PUMP AND ROTOR BRAKE DRIVE
QUILL P/N 212-3101-22-9
Figure 1. No.3 hydraulic pump and rotor brake disc drive quill.................................................................................... 3
25-92-06 EXTERNAL RESCUE HOIST - UTILITY HYDRAULIC SYSTEM (FOR EXTERNAL RESCUE
HOIST) [B] [C]
Figure 1. Utility hydraulic system (No. 3) ..................................................................................................................... 3

Figure 2. Utility hydraulic system (No. 3) schematic .................................................................................................... 4
Figure 1. Utility hydraulic system (No. 3) schematic .................................................................................................... 3
Figure 1. Rotor brake installation .................................................................................................................................. 1

Figure 2. Rotor brake system ......................................................................................................................................... 4
Figure 1. Cargo suspension provisions .......................................................................................................................... 3

Figure 2. Cargo suspension assembly ............................................................................................................................ 4
25-94-01 EXTERNAL CARGO SUSPENSION HOOK - SUSPENSION UNIT AND EMERGENCY

RELEASE MECHANISM
Figure 1. Cargo suspension provisions .......................................................................................................................... 3
Figure 1. Cargo hook mirror installation ....................................................................................................................... 2
25-Index
Rev. 3 Page 13
E-AB412-PT6T-2
TABLES
Table Page
Number Title Number
Table 1. Night sun searchlight system troubleshooting ................................................................................................4
Table 1. Intermittent lights troubleshooting..................................................................................................................3
Table 1. Emergency floats kit (P/N 212-4600-03)........................................................................................................4
Table 1. Internal rescue hoist troubleshooting ..............................................................................................................7
Table 1. External rescue hoist - troubleshooting...........................................................................................................1
Table 1. Rotor brake kit - troubleshooting ....................................................................................................................2
25-Index
Page 14 Rev. 3
E-AB412-PT6T-2
25-0 -0 EQUIPMENT/FURNISHINGS
25-00-00
EQUIPMENT/FURNISHINGS
1. EQUIPMENT/FURNISHINGS - GENERAL
This chapter contains maintenance information for crew and passenger seats, map and data case, and the first aid kit.
Miscellaneous furnishings consist of the map and data case and first aid kit.
25-00-00
Page 1
E-AB412-PT6T-2
25-00-00
Page 2
E-AB412-PT6T-2
25-1 -01 CREW SEATS
25-11-01
CREW SEATS
1. CREW SEATS - DESCRIPTION
The pilot and copilot (crew) seats (figure 1) are energy-attenuating, bucket-type seats upholstered with flame-retardant
materials. The seats are mounted on tracks and are adjustable in fore-and-aft and vertical directions. Each seat is equipped
with a restraint assembly (2) which consists of inertia reel (3), shoulder harness (11), and seat belt (9). The inertia reel
incorporates an automatic locking mechanism to prevent seat occupant from pitching forward in the event of rapid
deceleration. The attenuator (4) is designed to absorb energy and thereby protect the seat occupant in event of a hard landing.
NOTE
Maintenance procedures for both pilot and copilot seats are similar.
2. CREW SEATS - REMOVAL
NOTE
Crew seats may be removed/installed after removing screws (8, figure 2) on forward
or aft end of tracks (9 and 11), depending on passenger seat configuration.
1. Remove nut (5), washers (6 and 7), screw (8) and forward stop screws (17) from track (9). Remove similar screw and
forward stop screws from track (11).
WARNING
SEAT HAS HELPER SPRING TO AID VERTICAL ADJUSTMENT. SEAT WILL

MOVE RAPIDLY UPWARD FROM FULL DOWN POSITION IF NO WEIGHT
IS ON SEAT.
2. Lift fore and aft adjustment lever (12) on seat assembly (1) and slide seat off tracks.
3. Remove seat assembly (1) from helicopter.
25-11-01
Rev. 1 Page 1
E-AB412-PT6T-2
3. CREW SEATS - INSTALLATION
1. Position copilot seat assembly (1) on tracks (9 and 11).
WARNING

IS ON SEAT.
2. Move fore and aft adjustment lever (12) up and push seat assembly (1) onto tracks (9 and 11).
3. Install screw (8), washers (6), nut (5), and forward stop screws (17) on track (9). Install similar screw and forward stop
screws (not illustrated) on track (11).
4. CREW SEATS - INSPECTION
1. Inspect seat assemblies (1, figure 2) for secure installation.
2. Inspect fore and aft adjustment mechanism (12) for proper operation.
WARNING

IS ON SEAT.
3. Inspect vertical adjustment mechanism (13) for proper operation and verify cable adjustment pin (27, figure 3) is
properly engaged into tube (5) by removing plug (4) and viewing through top of tube (detail B). If pin is not properly
engaged refer to module 25-11-02 paragraph "6. Crew seat vertical adjustment cable - removal".
4. Inspect seat cushions (10 and 14, figure 2) for tears, cuts, and security of upholstery at bonding areas.
5. Inspect restraint assembly (2) (module 25-11-02 paragraph "4. Crew seat restraint assembly - inspection").
6. Inspect seat structure for obvious damage.
7. Inspect attenuator assembly (16, figure 3) for compression as follows:
a. If the attenuator assembly is provided with the white witness stripe on the guide tube assembly (12), it is enough
to verify if the stripe is visible at the top of the attenuator. If the stripe is not visible, refer to paragraph "5. Crew
seats - repair" for adjustment.
b. If the attenuator assembly is not provided with the white paint witness stripe on the tube assembly (12) or if it is
not proved the existence of the stripe, measure attenuator length as per figure 3 to verify if the attenuator has
been compressed or not. If the attenuator has compressed (i.e. fails to meet minimum extension dimension per
figure 3), refer to paragraph "5. Crew seats - repair" for adjustment. If the attenuator has not compressed beyond
criteria identified above and it is confirmed the absence of the witness stripe, paint the witness line on the
attenuator as per paragraph "5. Crew seats - repair".
25-11-01
Page 2 Rev. 1
E-AB412-PT6T-2
1. Crew seat assembly

2. Restraint assembly
3. Inertia reel
4. Attenuator (energy absorption device)
5. Track (left)
6. Bottom cushion
7. Fore and aft adjustment lever
8. Vertical adjustment button
9. Adjustable seat belt
10. Back cushion
11. Shoulder harness
12. Inertia reel control
G6AB0034B
Figure 1. Crew seats
25-11-01
Rev. 1 Page 3
E-AB412-PT6T-2
5. CREW SEATS - REPAIR
MATERIALS REQUIRED
NUMBER NOMENCLATURE
C-317 ADHESIVE
C-326 ALCOHOL
C-331 ADHESIVE
1. For repair procedure for restraint assembly (inertia reel, shoulder harness and seat belt) module 25-11-02
paragraph "5. Crew seat restraint assembly - repair".
2. For replacement of vertical adjustment cable, refer to module 25-11-02 paragraph "6. Crew seat vertical adjustment
cable - removal".
NOTE
Only limited structural repairs to bucket assembly are permitted. Contact Product
Support Engineering.
3. Replace cushions as follows:
a. Remove two screws (6, figure 4).
b. Remove bottom seat cushion (7).
c. Remove back seat cushion (8).
d. Position back seat cushion (8) in seat.
e. Position bottom seat cushion (7) in seat.
f. Install screws (6).
NOTE
Only limited structural repairs to bucket assembly are permitted. Contact Product
Support Engineering.
g. Adjust attenuator assembly (16, figure 3) as follows:
h. Remove seat assembly (paragraph "2. Crew seats - removal")from helicopter and place on clean work bench
with bucket face down.
WARNING
ENSURE THAT SEAT ADJUSTMENT IS FULLY EXTENDED TO AVOID

INJURY WHEN REMOVING CONTROL CABLE FROM GUIDE TUBE
ASSEMBLY.
25-11-01
Page 4 Rev. 1
E-AB412-PT6T-2
1. Copilot seat assembly

3. Inertia reel assembly
4. Attenuator (energy absorption device)
5. Nut
6. Washer (AN960C10)
8. Screw
9. Track (left)
10. Bottom seat cushion
11. Track (right)
12. Fore and aft adjustment lever
13. Vertical adjustment lever
14. Back seat cushion
15. Screw
16. Guide (restraint assembly)
17. Screw
G6AB0035B
Figure 2. Copilot seat (sheet 1 of 2)
25-11-01
Rev. 1 Page 5
E-AB412-PT6T-2
G6AB0036A
Figure 2. Copilot seat (sheet 2 of 2)
25-11-01
Page 6 Rev. 1
E-AB412-PT6T-2
i. Loosen nut (31, figure 3) on control cable (32). Slowly extract control cable with retainer (30), washer (29),
spring (28) and pin (27) from guide tube assembly (12). Save parts for re-use.
j. Remove attenuator assembly (16), guide tube assembly (12) and adjustment tube (5) as a unit from seat as
follows:
CAUTION
RETAIN TAPERED SHIMS AND STRUTS IN THEIR RESPECTIVE LOCATION

DURING REMOVAL OF SUPPORT FROM SEAT FRAME. MIXING OR LOSS
OF SHIM ORIENTATION COULD AFFECT SEAT FRAME ALIGNMENT
DURING REASSEMBLY.
(1) Remove four nuts (26), washers (25) from screws (21) securing support assembly (17), shims (24), and
strut (23) to left and right lower seat frame (22).
(2) Remove two screws (3) and washers (2) securing pin (1) to seat back.
k. Remove guide pin (10) and washer (11) from guide tube assembly (12). This guide pin is securing adjustment
tube (5) and once removed will allow tube to fully extend.
l. Remove adjustment tube (5) and spring (9) from guide tube assembly (12).
CAUTION
DO NOT REMOVE ROD (18) THROUGH LOWER SUPPORT ASSEMBLY (17).

RETAINERS (13 AND 14) ARE BONDED IN PLACE AND CONTAIN
LOCKING FASTENERS THAT COULD BE DAMAGED.
m. Remove lower nut (20) and washer (19) from rod (18). Remove rod (18) from guide tube assembly end only, by
pushing rod up through guide tube assembly (12).
n. Separate guide tube assembly (12) from support assembly (17). Remove and inspect attenuator (15) for
deterioration at the bevelled end. If the bevel is worn flat or deteriorated, measure tube to confirm overall length
of 9,05 to 9,20 in (229,87 to 233,68 mm) is present. Replace tube if dimension is not met.
o. Inspect lower internal surface of support assembly (17) for damaged bonded washer (34, detail D). If damaged
replace as follows:
(1) Clean washer and lower internal surface of attenuator support assembly (17) with a cloth moistened with
alcohol (C-326).
(2) Apply a thin bead of adhesive (C-317) to the washer (34) and carefully position washer into the support
(17), taking care not to get any adhesive on the inside diameter of attenuator assembly (16).
p. Install attenuator (15) into support assembly (17) with bevel edge down.
q. If retainers (13 and 14) are loose, install replacement fasteners (33, Detail C) into retainers. Bond retainers into
guide tube assembly (12) with adhesive (C-331).
CAUTION
TAKE CARE IN POSITIONING ROD (18) AS FASTENERS (33) INSTALLED

INTO RETAINERS (13 AND 14) MAY BE DAMAGED.
25-11-01
Rev. 1 Page 7
E-AB412-PT6T-2
r. Thread nut (20) onto rod (18) to allow approximately one thread to be exposed. Position washer (19) on rod and
install rod through support assembly (17) lower end up through guide tube assembly (12). Ensure sufficient
threads on rod (18) are present to allow installation of nut (7) and washers (8) at guide assembly (12) end. Torque
nut (7) 15 to 25 lbf·in (1,69 to 2,82 Nm).
s. Install spring (9) into guide tube assembly (12) and position spring guide (6) onto spring.
t. Position adjustment tube (5) into the guide tube assembly (12) and align first hole on the adjustment tube (5) to
enable installation of the guide pin (10). Insert guide pin (10) with washer (11) and secure in place.
u. Check dimension of attenuator assembly (16) per figure 3. If the attenuator has not already been provided with
a white paint witness stripe, paint a witness line in accordance with figure 3 detail A using any white epoxy
polyamide primer, epoxy paint or acrylic lacquer.
v. Position attenuator assembly (16) on seat back and install two screws (3) with washers (2) through pin (1). Install
four screws (21) through strut (23), seat frame (22), shims (24) and support assembly (17) with washers (25) and
nuts (26). Tighten screws (3 and 21).
w. Install guide pin (10) with washer (11) into tube assembly (12).
x. Position control cable (32) with retainer (30), washer (29), spring (28), and pin (27) assembled. Tighten nut (31).
y. Install seat into helicopter (paragraph "3. Crew seats - installation").
25-11-01
Page 8 Rev. 1
E-AB412-PT6T-2
G6AB0038A
Figure 3. Crew seat attenuator (sheet 1 of 2)
25-11-01
Rev. 1 Page 9
E-AB412-PT6T-2
1. Pin 18. Rod

2. Washer 19. Washer
3. Screw 20. Nut
4. Plug 21. Screw
5. Adjustment tube 22. Seat frame
6. Spring guide 23. Strut
7. Nut 24. Shim
8. Washer 25. Washer
9. Spring 26. Nut
10. Guide pin 27. Pin
11. Washer 28. Spring
12. Guide tube assembly 29. Washer
13. Retainer 30. Retainer
14. Retainer 31. Nut
15. Attenuator 32. Control Cable
16. Attenuator assembly 33. Fasteneres
17. Support assembly 34. Washer
G6AB0039B
Figure 3. Crew seat attenuator (sheet 2 of 2)
25-11-01
Page 10 Rev. 1
E-AB412-PT6T-2
2. Crew seat assembly
3. Inertia reel assembly
4. Shoulder harness assembly
5. Seat belt assembly
6. Screw
7. Bottom seat cushion
8. Back seat cushion
G6AB0040B
Figure 4. Crew seat assembly
25-11-01
Rev. 1 Page 11
E-AB412-PT6T-2
25-11-01
Page 12 Rev. 1
E-AB412-PT6T-2
25-1 -02 CREW SEAT RESTRAINT ASSEMBLY AND VERTICAL ADJUSTMENT CABLE
25-11-02
CREW SEAT RESTRAINT ASSEMBLY AND VERTICAL ADJUSTMENT
CABLE
1. CREW SEAT RESTRAINT ASSEMBLY - REMOVAL
NOTE
Maintenance procedures for pilot and copilot restraint assemblies are identical. The
following procedures are keyed to the copilot assembly.
1. Unfasten buckle (8, figure 1) and separate shoulder harness (5) om seat belt (7).
2. Disengage shoulder harness (5) from slot in guide (1).
3. For helicopters codes [A] [B], remove four screws (4) and remove shoulder harness (5) and inertia reel (3) as an
assembly.
4. For helicopters code [C], remove four screws (9, detail D), two nuts (20, detail E), four washers (21), two spacers (22),
and two screws (23). Remove shoulder harness (5, detail A) and inertia reel (3) as an assembly.
5. Remove cotter pin (18). Remove pin (13) and remove one-half of seat belt (7). Remove opposite half of seat belt in
same manner.
2. CREW SEAT RESTRAINT ASSEMBLY - INSTALLATION
NOTE
1. Position seat belt (7, figure 1) on seat (2). Install pin (13), washer (19), and cotter pin (18).
2. Install opposite half of seat belt (7) in the same manner outlined in preceding step.
3. For helicopters codes [A] [B], position shoulder harness (5) and inertia reel (3) on seat (2). Install four screws (4).
4. For helicopters code [C], position shoulder harness (5), inertia reel (3, detail D), and inertia reel control (23, detail E)
on seat (2, detail A). Install two screws (24, detail E), four washers (21), two spacers (22), and two nuts (20). Install
four screws (9, detail D).
5. Install shoulder harness strap (5) in slot in guide (1).
25-11-02
Page 1
E-AB412-PT6T-2
3. CREW SEAT RESTRAINT ASSEMBLY - CHECK AND INSPECTION GUIDELINES
1. Make sure that the restraint system is clean and does not contain dirt, oil or grease, or other unwanted particles or
substances.
2. Make sure that all the parts are satisfactorily attached.
NOTE
Slight wear of the webbing is permitted. However, excessive web wear that has
progressed to cut or worn edges must be replaced per the following step.
3. Inspect webbing for:
— Cut or worn edges
— Damaged stitching
— Broken fabric threads
— Tears
— Excessive chafe marks
— Excessive wear
— Excessive fushing
a. Replace webbing if any of the following are observed:
— A limited amount of frayed webbing will retain sufficient strength necessary to meet the required strength.
Frayed webbing is defined as broken filaments from either the warp (longitudinal) yarns or the filler (transverse)
yarns. The number of broken filaments should not be sufficient to obscure the identity of any yarn when viewed
from a distance of about 8 inches.
— Any web that is cut or torn on the edge.
— The amount of fray should be limited to an amount that is less than 10% of the width of the webbing and is not
exceed 8 inches in length.
— Webbing with more than 15 broken yarns in locations other than the edge.
— Webbing that is frayed or distorted sufficiently to cause improper operation of any portion of the restraint system.
— A total of 15 stitches can be torn in a stitch pattern before the webbing needs replacement.
b. Make sure that you can read the markings.
NOTE
Burrs, nicks and scratches is material raised above the normal surface. This material
must be removed to make sure that the parts will fit together correctly.
Dents must not damage the finish or functional operation of any part
4. Examine fittings for:
— Burrs, nicks or scratches
— Cracks
— Dents
— Corrosion
25-11-02
Page 2
E-AB412-PT6T-2
5. Examine buckle and connector for:
— Cracks
— Dents
— Corrosion
6. Examine reel assembly for:
— Cracks
— Dents
— Corrosion
a. Make sure that movable parts operate correctly.
4. CREW SEAT RESTRAINT ASSEMBLY - INSPECTION
NOTE
1. Inspect seat belt buckle (8, figure 1) for proper operation and damage. Examine buckle for burrs, nicks, scratches,
cracks, dents and corrosion. Burrs, nicks, and scratches are material that is raised above the normal surface. This
material must be removed to make sure the parts will fit together correctly. Dents must not damage the finish or
functional operation of any part.
2. Inspect seat belt (7) shoulder harness (5) for wear, damage, and secure installation. Examine belts and harness for cut
or worn edges, damaged stitching, fray, tears, chafe marks, wear. Slight wear of the webbing is permitted. However, a
belt or shoulder harness that has excessive wear that has progressed to cut or worn edges must be replaced. Any belt
or harness that is cut or torn deeper than 0,10 inch (2,54 mm) on the edge shall be replaced. Fray is defined as broken
filaments from either the warp (longitudinal) yarns or the filler (transverse) yarns. The number of broken filaments
should not be sufficient to obscure the identity of any yarn when viewed from a distance of about 8 inches (203,2 mm).
3. The amount of fray shall be limited till 10% of the width of the belt or harness, not to exceed 8 inches (203,2 mm) or
a maximum of 15 broken yarns in locations other than edges. Replace any belt or harness that is frayed or distorted
sufficiently to cause improper operation of any portion of the restraint assembly. A maximum of 15 torn stitches is
permitted in a stitch pattern.
4. Inspect inertia reel assembly (3) for secure installation and smooth operation.
25-11-02
Page 3
E-AB412-PT6T-2
CODES A AND B
CODES C AND D
CODES C AND D
G6AB0041A
Figure 1. Crew seat restraint (sheet 1 of 2)
25-11-02
Page 4
E-AB412-PT6T-2
G6AB0042A
Figure 1. Crew seat restraint (sheet 2 of 2)
25-11-02
Page 5
E-AB412-PT6T-2
5. CREW SEAT RESTRAINT ASSEMBLY - REPAIR
NOTE
NOTE
Repair of crew seat restraint assembly is limited to replacement of unserviceable
parts (paragraph "4. Crew seat restraint assembly - inspection").
6. CREW SEAT VERTICAL ADJUSTMENT CABLE - REMOVAL
1. Remove nut (25, figure 1, detail F) holding top of vertical adjustment cable (26) on seat back.
2. Remove two screws securing seat bottom cushion (10, figure 2) in place and remove cushion (10).
3. Remove two retaining clips holding vertical adjustment cable (26, figure 1) in place on support assembly (34).
4. Remove cotter pin (31), washer (30), and pin (33) securing seat height adjustment handle (32) located on bottom of
seat (2).
5. Remove three screws (29) and washers (28) holding support assembly (34) located on right bottom side of seat (2).
6. Disconnect vertical adjustment cable (26) from seat height adjustment handle (32) located on bottom of seat (2).
7. Remove two retainer clips holding vertical adjustment cable (26) on support assembly (34).
NOTE
Note how cable is routed prior to removal.
8. Disconnect vertical adjustment cable (26) from vertical adjustment locking pin and pull cable from back of seat.
25-11-02
Page 6
E-AB412-PT6T-2
7. CREW SEAT VERTICAL ADJUSTMENT CABLE - INSTALLATION
1. Connect top of cable (26) to vertical adjustment lock pin located on seat back inside of nut (25).
2. Screw nut (25) in two turns to secure cable (26).
3. Secure support assembly (34) to bottom of seat (2) with three screws (29) and washers (28).
4. Insert handle (32) inside of support assembly (34) and attach vertical adjustment cable (26).
5. Attach handle (32) to support assembly (34) with pin (33), washer (30), and cotter pin (31).
6. Secure vertical adjustment cable assembly (26) to support assembly (34) with two retainer clips.
7. Tighten nut (25).
8. Adjust screw (27) to remove all slack from vertical adjustment cable (26). After all slack has been removed from
vertical adjustment cable (26), turn screw (27) 1/2 additional turn or bottom out screw, which ever occurs first.
9. Position cushion (10, figure 2) on seat (2, figure 1) and secure with two screws.
25-11-02
Page 7
E-AB412-PT6T-2
G6AB0043A
Figure 2. Passenger seats
25-11-02
Page 8
E-AB412-PT6T-2
25-21-01
PASSENGER SEATS
1. PASSENGER SEATS - DESCRIPTION
The helicopter is provided with seating for 13 passengers. One four-man seat (4, figure 1) is located just aft of the crew
station facing aft. Facing forward and in line with the forward bulkhead of the pylon support structure is a five-man seat
consisting of three seat sections. the center seat section (1) is for use of a medical attendant, hoist operator or crewman.
Outboard of the center seat are a left and right single two place seat (2) attached to the pylon support structure. Two seats
for two persons (3) each facing outboard are attached to each side wall of the pylon support structure. All seats are provided
with safety belts for the occupants.
2. PASSENGER SEATS - REMOVAL
1. Unhook seat back support straps from upper support tubes. Remove nuts, bolts, attachment fittings and support tubes
from side walls of pylon support structure, and between stanchions and pylon support.
2. Slide collar of floor attachment fittings upward on each of forward legs of seats and release legs from floor studs.
3. Remove hardware (nuts, fitting and bolts) attacching rear of seat to pylon support structure. Remove cross tubes
between stanchions and pylon supporting rear of each two man seat (facing forward), by piling pip pins attaching tube
to stanchions.
4. Remove seats, stanchions and hardware from helicopter.
5. Slide collars of floor attachment fitting upward on each leg of four man seat, located aft of pilot, co-pilot station, and
remove four man seat from helicopter.
3. PASSENGER SEATS - INSTALLATION
NOTE
The one man seat (1) attached to the front of pylon support structure and the two, 2
man seats (3) attached to each side, may be folded, stowed and strapped to side of
structure.
1. Install one man seat (1) as follow:
a. Unfold on man seat and position (facing forward) against front of pylon support structure.
b. Attach rear of seat bottom to pylon structure by use of tube assembly fittings and attaching hardware.
c. Position and secure seat back support tube on forward structure with fittings, bolts and nuts.
d. Position forward seat support legs on floor studs. Secure legs to floor by sliding attachment fitting collar up on
the leg and then down until it locks.
2. Install two man seats (2) as follow:
a. Install a stanchion on each outboard side of cabin in line with forward edge of pylon support structure in aft
ceiling fitting.
25-21-01
Page 1
E-AB412-PT6T-2
b. Attach inboard ends support tube and seat back support tube to the pylon support structure with fitting and
attacching hardware. Attach outboard tube ends to stanchions by inserting pins through fittings and support tube.
c. Hook seat back support straps around upper seat back support tubes.
d. Attach forward seat legs to floor studs by sliding attachment fitting up on seat leg, pressing seat leg down on
floor stud, and sliding attachment collar down on leg as far as possible, to lock.
e. Adjust seat back tension by means of buckles on seat back support straps.
3. Install two man seats (3) a follows:
a. Position a two man seat on either side of pylon support structure. Attach seat rear and upper support tubes to
pylon support structure with fittings and attachment hardware.
b. Position forward seat support legs on floor studs. Secure legs to floor by sliding attachment fitting collar up on
leg, then down it locks leg to the floor stud.
4. Install four man seat (4) as follows:
a. Position four man seat in cabin area aft of pilot and co-pilot seat (facing aft) with legs over floor studs.
b. Slide collar or floor fitting upward on each seat leg; press leg down on floor stud. Secure legs to floor by sliding
floor attachment collar down as far as possible on each leg.
4. PASSENGER SEATS - INSPECTIONS
1. Inspect seat webbing and blacks for rips, tears, fraying and loose or missing snap fasteners.
2. Inspect seat support and cross tubes for deformation, dents, cracks, excessive elongation of attachment bolt holes and
missing snap receptacles.
25-21-01
Page 2
E-AB412-PT6T-2
G6AB0809A
Figure 1. Passenger seats
25-21-01
Page 3
E-AB412-PT6T-2
25-21-01
Page 4
E-AB412-PT6T-2
25-23-01 LOUDSPEAKER SYSTEM (AEM-40 )
25-23-01
LOUDSPEAKER SYSTEM (AEM-400)
1. LOUDSPEAKER SYSTEM (AEM-400) - DESCRIPTION
The system (see figure 1) comprises a 250 Watt support mounted amplifier, a hand microphone with card and connector from
direct coupling into a control unit located on a support secured of the LH side of the central pedestal, and (on code [A]
helicopters) a compact set of two support mounted speakers installed on the upper LH and RH side of the central cabin.
On code [B] helicopters the compact set of four support mounted speakers may be installed either on the lower LH side of
the forward cabin, or in the cargo hook bay.
The system is powered by 28 V dc through the EXT SPKR circuit breaker on the overhead console.
The audio amplifier is a 250 Watt completely transistorized unit. Indicators and controls are located on three panels. The
amplifier monitor panel mounts the AUDIO POWER level meter, MONITOR jack and the PUSH-TO-TEST indicator lamp.
The control panel contains the GAIN control, the MICrophone, input connector and the RECORDER input connector.
The power panel contains the ON-OFF switch, the power input/speaker output connector, and the REMOTE connector. The
microphone is a noise cancelling dynamic type with an output impedance of 50 ohms.
The speaker unit includes two (or four) speaker equipped with drivers and 8 ohms voice coils. They are electrically
connected in parallel, to furnish a nominal 2 ohm load.
The remote control unit and signal source contains the GAIN control, the ON switch, the POWER light, the OUT-PUT level
meter, the SIREN and TRILL push buttons and the REC LINE, MIT and CONTR CBL connectors.
Refer to Chapter 98 for Loudspeaker wiring diagram.
2. LOUDSPEAKER SYSTEM (AEM-400) - OPERATIONAL CHECK
1. Energize DC electrical system then close EXT SPKR circuit breaker.
2. Set amplifier POWER switch to ON. Check amplifier POWER light on.
3. Set remote control unit POWER switch to ON.
4. Speak into microphone.
5. While speaking in steady tone, turn first amplifier, then control unit, GAIN control knob (clockwise) until AUDIO
POWER meter reading begins to decrease to medium scale position with momentary peaks.
6. Check quality of sound with the help of a ground assistant.
7. For the transmission of a signal supplied by a recorder, the amplifier and control unit GAIN control knobs should be
turned counterclockwise.
8. To select the siren or the trill the GAIN control knob should be turned counterclockwise and the SIREN or TRILL
button pressed.
25-23-01
Page 1
E-AB412-PT6T-2
G6AB0994A
Figure 1. Loudspeaker installation
25-23-01
Page 2
E-AB412-PT6T-2
3. LOUDSPEAKER SYSTEM (AEM-400) - SPEAKERS
3-1. SPEAKERS - REMOVAL
1. Disconnect electrical connector from speaker unit.
2. Remove speaker unit by acting on relative hardware.
3-2. SPEAKERS - INSTALLATION
1. Install speaker unit using relative hardware.
2. Connect electrical connector to the unit.
4. LOUDSPEAKER SYSTEM (AEM-400) - AMPLIFIER
4-1. AMPLIFIER - REMOVAL
1. Disconnect electrical connectors from amplifier.
2. Remove amplifier by acting on relative hardware.
NOTE
Loudspeaker may be installed in either the two positions as shown.
4-2. AMPLIFIER - INSTALLATION
1. Secure amplifier to its support using relative hardware.
2. Connect electrical connectors to amplifier.
5. LOUDSPEAKER SYSTEM (AEM-400) - CONTROL UNIT
5-1. CONTROL UNIT - REMOVAL
1. Disconnect power cable and microphone connectors from unit.
2. Remove unit from its support by acting on relative hardware.
5-2. CONTROL UNIT - INSTALLATION
1. Secure unit to its support using relative hardware.
2. Connect power cable and microphone connector to unit.
25-23-01
Page 3
E-AB412-PT6T-2
25-23-01
Page 4
E-AB412-PT6T-2
25-31-01 LIGHTER (P/N 412-7716-03-101)
25-31-01
LIGHTER (P/N 412-7716-03-101)
1. LIGHTER (P/N 412-7716-03-101) - DESCRIPTION
The kit consists of an electrical lighter installed on the panel instrument, one of each pilot.
Two ashtrays fixed on the lower edge of the panel instruments, one for each pilot, are furnished as part of the standard
configuration. Power is supplied by the 28 V dc bus and the circuit protected by three circuit breakers, one is on the overhead
panel and the other two are situated over each lighter.
NOTE
Refer to Chapter 98 for Lighter wiring diagram.
25-31-01
Page 1
E-AB412-PT6T-2
25-31-01
Page 2
E-AB412-PT6T-2
25-3 -01 NIGHT SUN SEARCHLIGHT SYSTEM (P/N 212-9000-36-101/-103)
25-33-01
NIGHT SUN SEARCHLIGHT SYSTEM (P/N 212-9000-36-101/-103)
1. NIGHT SUN SEARCHLIGHT SYSTEM (P/N 212-9000-36-101/-103) - DESCRIPTION
The Night sun Model SH-16C Searchlight System has been designed for the purpose of providing the helicopter with a high
intensity light source particularly useful for rescue operations search and surveillance duties, observation etc. By means of
an accessory filter which blocks visible light, the Nightsun Searchlight may be used in conjunction with infrared equipment
to provide covert observation in total darkness.
The installation comprises a searchlight assembly, a gimbal mount, a junction box and a remote control unit. (See figure 1).
The system provides means for remote manual control of direction and angle and focus of the light beam.
28 V dc power to the system is provided by the non essential bus and protected by a 70 ampere circuit breaker, entitled
NIGHT SUN CRT-BRK, installed on the cabin roof.
The searchlight assembly consists of a cylindrical housing within which are mounted the arc lamp bulb, the reflector, a
cooling fan, a focusing rotor, together with various electrical components used in the starting circuit of the lamp. The front
window or lens of the light is made of specially tempered glass capable of withstanding both mechanical stresses and high
temperatures.
The gimbal mounting assembly consists of a ”U” shaped yoke and two small DC motor actuators. One motor is mounted at
the base of the ”U” and serves to rotate the ”U” through the arc in azimuth.
NOTE
Stop pins are provided in the yoke bearing housing to limit the searchlight rotation in
azimuth.
A mechanical safety cable, secured to the gimbal yoke, is arranged for quick connection to, and separation from the
searchlight. In the event of accidental dislocation of the light assembly from the gimbal, the safety cable will prevent the
light assembly from falling free of the aircraft.
The second motor is mounted on one leg of the ”U” and serves to drive the trunnion mounting for the searchlight in a rotation
at right angles to the yoke for elevation.
Reversing the direction of rotation for either motor is accomplished in the control unit by reversing the DC polarity of the
28 V power supplied to the motors.
The junction box consists of a rectangular metal box containing relay and terminal connections for power distribution to the
functional components of the SH-16 searchlight equipment. Cables connect the junction box to the gimbal motors and to the
searchlight, while another cable connects with the remote control unit.
The control unit consists of a rectangular metal case designed for mounting in the pilot's compartment (see figure 1).
The control panel contains a circuit breaker (ON-OFF master) which closes a relay circuit to power circuit for the lamp
starter, power to the gimbal drive motors power to the focusing drive motor circuit and power to a cooling fan located in the
lamp housing assembly.
Opening of the MASTER switch circuit removes power from all subsidiary circuits of the system.
25-33-01
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A second switch of the momentarily contact type used to control the initial start circuit for the xenon arc lamp. A third switch
of the two-position momentary contact toggle type controls the motor which drives the focus mechanism to change the beam
of light from 6.5 degrees to 10 degrees.
Movement of the searchlight in azimuth and elevation is controlled by a four way switch of the toggle type which controls
the power to two small DC motor actuators mounted in the gimbal assembly.
NOTE
Refer to Chapter 98 for Night Sun Searchlight for wiring diagram.
2. NIGHT SUN SEARCHLIGHT SYSTEM (P/N 212-9000-36-101/-103) - OPERATIONAL

CHECK
WARNING
BEFORE TURNING THE SEARCHLIGHT ON, MAKE SURE THE AREA

AROUND THE HELICOPTER IS FREE OF FLAMMABLE MATERIALS.
POINT THE SEARCHLIGHT TOWARD A CLEAR AREA. DO NOT STAND IN
FRONT OF THE SEARCHLIGHT.
1. Make sure the NIGHT SUN CRT BRK circuit breaker is in the OFF position.
2. Start helicopter engine in normal start up procedure. Energize the non-essential bus bar.
3. Reset the NIGHT SUN CRT BRK circuit breaker and also turn ON the master switch located on the control box.
Ensure that the two circuit breakers located on the junction box, are closed. Check for operation of the cooling fan in
the searchlight.
4. Operate gimbal drive switches up/down and left/right. Observe lamp assembly and cabling to ensure freedom of
movement over total travel.
5. Operate focus switch and observe movement of artlamp reflector. Reflector travel should be approximately 0,3 in (7,6
mm).
6. Press and hold the lamp start switch for several seconds. Arc lamp should ignite. Release start switch. If lamp flashes
but does not stay lit, continue to hold start switch down.
7. Observe the electrical loadmeter. Reading on main generator should not exceed 0,7 after lamp is warmed up (1 minute).
8. Turn off lamp using the control box switch.
9. Allow the three-minute cool down period before restarting the lamp.
10. Pull the NIGHT SUN CRT BRK circuit breaker.
11. Shut off the engine.
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1. Searchlight assy
2. Gimbal assy
3. Box assy, junction
4. Box assy, control
G6AB0998B
Figure 1. Night sun searchlight installation
25-33-01
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E-AB412-PT6T-2
3. NIGHT SUN SEARCHLIGHT SYSTEM (P/N 212-9000-36-101/-103) -

TROUBLESHOOTING
Table 1. Night sun searchlight system troubleshooting
INDICATION OF TROUBLE PROBABLE CAUSE ISOLATION PROCEDURE
Light will not start. Defective NIGHT SUN CRT BRK. Replace circuit breaker.
Junction box circuit breakers, tripped Close circuit breakers and replace
or defective, junction box.
Defective controls on remote control Replace remote control unit.

unit.
Defective light assembly. Replace light assembly.
Defective lamp. Replace light assembly.
Arc lamp ignites but will not remain Defective power supply circuit. Troubleshoot and repair as
lighted for more than a minute. necessary.
Defective light assembly. Replace light assembly.
Defective junction box. Replace junction box.
Cooling fan will not operate. Defective motor. Replace light assembly.
Defective control panel. Replace control panel.
Gimbal mounting assembly does not work Defective gimbal mounting. Replace gimbal mounting.
properly.
Defective control. Replace remote control.
Defective wiring, Repair wiring as necessary (See

Chapter 98).
4. NIGHT SUN SEARCHLIGHT SYSTEM (P/N 212-9000-36-101/-103) - SEARCHLIGHT

ASSEMBLY
4-1. SEARCHLIGHT ASSEMBLY - REMOVAL
1. Remove the light assembly from the gimbal mounting.
2. Disconnect the connector from the receptacle on the helicopter.
3. Remove securing hardware and disconnect the gimbal mounting from the support. Remove the gimbal mounting.
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E-AB412-PT6T-2
G6AB0999A
Figure 2. Remote control unit
25-33-01
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E-AB412-PT6T-2
4-2. SEARCHLIGHT ASSEMBLY - INSTALLATION
1. Position the searchlight in place and secure it with relative wingbolts to the gimbal arms. Make sure the travel stop is
installed on the right side between the searchlight and the gimbal arm.
2. Connect the safety cable to the gimbal mounting.
3. Connect the electrical connector to the receptacle on the searchlight.
4-3. SEARCHLIGHT ASSEMBLY - CLEANING
The SX-16 Night sun Searchlight is air cooled. The transfer of heat from certain components to the surrounding air is most
important. A thin film of dirt will alter the exchange of heat energy with the air.
Periodic cleaning will lengthen the life of the entire searchlight. The cleanliness of the tempered glass window, the xenon
arc lamp, the collector and the air filter affects the efficiency of the searchlight. Moisture and sand or dust are hazards to be
avoided. To clean the searchlight, proceed as follows:
1. Use a soft dusting brush to remove loose dust from the searchlight housing. Begin at the top and work down and around
the searchlight assembly.
2. Use soft lint-free chamois or fabric, moistened but not wet, to remove mud spatters or similar foreign matter residue
from exterior surfaces of the searchlight and mountings.
CAUTION
DO NOT DIRECT A HOSE OR WATER SPRAY OVER OR AROUND THE

SEARCHLIGHT ASSEMBLY.
3. If oil or grease deposits or films are evident on the searchlight, work these off locally with a soft rag and minimum use
of solvent. Do not use abrasive cleaners or sandpaper.
5. NIGHT SUN SEARCHLIGHT SYSTEM (P/N 212-9000-36-101/-103) - GIMBAL

MOUNTING
5-1. GIMBAL MOUNTING - REMOVAL
1. Remove the light assembly from the gimbal mounting.
2. Disconnect the connector from the receptacle on the helicopter.
3. Remove securing hardware and disconnect the gimbal mounting from the support. Remove the gimbal mounting.
5-2. GIMBAL MOUNTING - INSTALLATION
1. Position the gimbal mounting in place and secure it to the support.
2. Install the light assembly on the gimbal mounting..
3. Connect the connector to the receptacle on the helicopter
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E-AB412-PT6T-2
5-3. GIMBAL MOUNTING - INSPECTION
1. Inspect for cleanless, wear, damage, loose parts and binding.
2. Inspect wirings and motors for general condition and insulation.
3. Make sure the stop pins are located to permit searchlight travel forward to 105° left of forward.
6. NIGHT SUN SEARCHLIGHT SYSTEM (P/N 212-9000-36-101/-103) - JUNCTION BOX
6-1. JUNCTION BOX - REMOVAL
1. Disconnect the connector from the box.
2. Remove securing hardware and remove the box from the helicopter.
6-2. JUNCTION BOX - INSTALLATION
1. Position the box in place and secure it with mounting hardware.
2. Connect the electrical connector to the box.
7. NIGHT SUN SEARCHLIGHT SYSTEM (P/N 212-9000-36-101/-103) - REMOTE

CONTROL UNIT
7-1. REMOTE CONTROL UNIT - REMOVAL
1. Disconnect the electrical connector from the control unit.
2. Remove securing hardware and remove the control unit from the helicopter.
7-2. REMOTE CONTROL UNIT - INSTALLATION
1. Position the control unit in place and secure it with mounting hardware.
2. Connect the electrical connector to the control unit.
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E-AB412-PT6T-2
25-3 -1 INTERMITTENT LIGHTS (P/N 412-7 16-02-103)
25-33-11
INTERMITTENT LIGHTS (P/N 412-7716-02-103)
1. INTERMITTENT LIGHTS (P/N 412-7716-02-103) - DESCRIPTION
The position lights (figure 1), used for navigation, consists of two red lights on the helicopter LH side, two green lights on
the helicopter RH side and two white lights on the tail fin, one on either side. The electrical circuit is controlled by the
EXTERIOR LIGHT POSITION STEADY-OFF-FLASH and DIM-BRT switches on the upper control panel. When the
STEADY-OFF-FLASH switch is positioned to FLASH all position lights flash on and off; when the switch is positioned to
STEADY all position lights remain illuminated. The DIM-BRT switch allows all position lights to be dimmed. Power is
supplied by the 28 V dc bus and the circuit is protected by the LT POSN circuit breaker on the upper control panel. A flasher
unit and a resistor group provide light flashing and dimming.
NOTE
Refer to Chapter 98 for Intermittent Lights wiring diagram.
2. INTERMITTENT LIGHTS (P/N 412-7716-02-103) - REMOVAL
1. Be sure all electrical power is off.
2. Remove screw, lens and lamp.
3. Remove two securing screws and withdraw light assembly. Disconnect electrical wiring.
3. INTERMITTENT LIGHTS (P/N 412-7716-02-103) - INSTALLATION
2. Connect electrical wiring and secure light assembly to helicopter fuselage.
3. Install lamp.
4. Secure lens with screw.
4. INTERMITTENT LIGHTS (P/N 412-7716-02-103) - OPERATIONAL CHECK
1. Close all circuit breakers in external light circuits.
2. Connect a 28 V dc external power supply to helicopter external DC power receptacle.
3. Place the POSITION STEADY-FLASH switch to STEADY.
4. Place the POSITION DIM-BRT switch to DIM.
5. Check the navigation lights are illuminated.
6. Place the POSITION DIM-BRT switch to BRT.
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E-AB412-PT6T-2
G6AB0995A
Figure 1. Intermittent lights installation
25-33-11
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E-AB412-PT6T-2
7. Check that navigation lights increase in brightness.
8. Place the POSITION STEADY-FLASH switch to FLASH.
9. Check that fuselage lights are steady bright, with position lights are flashing bright.
10. Place the POSITION DIM-BRT switch to DIM.
11. Check that fuselage lights are steady dim, while position lights are flashing dim.
12. Place the POSITION STEADY-FLASH switch to OFF.
13. Check that navigation lights are extinguished.
5. INTERMITTENT LIGHTS (P/N 412-7716-02-103) - TROUBLESHOOTING
Table 1. Intermittent lights troubleshooting
Lights of one system only fail to illuminate

when:
circuit breakers are closed, control switch Circuit breaker defective. Replace circuit breaker.
on STEADY and rheostat on BRT.
Control switch defective. Replace control switch.
Electrical wiring defective. Repair electrical wiring.
One or more lamps fail to illuminate. Lamp defective. Replace lamp.
Lamp ground connection defective. Check ground conditions.
When rheostat is operated, navigation lights Rheostat defective. Replace rheostat.

do not dim or are extinguished.
Resistor defective or short-circuited. Replace resistor.
Flashing box defective. Replace the box.
6. INTERMITTENT LIGHTS (P/N 412-7716-02-103) - POSITION LIGHT FLASHER UNIT
The position light flasher unit type MS24577-2A is installed in the helicopter LH side equipment compartment. It consists
of a housing containing a power transistor operating as a switch and controlled by a square wave oscillating circuit. The
flashing frequency is 80 to 90 Hz, and the on/off ratio is 2.16/1 to 2.64/1.
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E-AB412-PT6T-2
CAUTION
THE OUTPUT TRANSISTOR MAY BE DAMAGED BY A SHORT CIRCUIT

BEFORE THE CIRCUIT BREAKER OPENS.
6-1. POSITION LIGHT FLASHER UNIT - REMOVAL
2. Remove lockwire and disconnect connector.
3. Remove four screws and washers, and remove flasher unit.
6-2. POSITION LIGHT FLASHER UNIT - INSTALLATION
2. Position flasher unit and secure with four screws and washers.
3. Connect connector and lockwire.
7. INTERMITTENT LIGHTS (P/N 412-7716-02-103) - FUSELAGE LIGHTS
The fuselage lights (figure 1) consists of white lights and are installed on the RH and LH sides of the upper fuselage and on
the lower fuselage of the helicopter. The fuselage light electrical circuit is controlled by the switches used in the position
lights circuit. The fuselage lights do not flash but can be dimmed. When the DIM-BRT switch is positioned to BRT, the
bright lamps are powered; when on DIM, the dim lamps are powered. Power is supplied by the 28 V dc bus and the circuit
is protected by the LT FSL circuit breaker.
7-1. FUSELAGE LIGHTS - REMOVAL
2. Remove screw, lens and lamps.
3. Remove two mounting screws and pull-out lamp assembly. Disconnect electrical wiring.
7-2. FUSELAGE LIGHTS - INSTALLATION
2. Connect electrical wiring and secure lamp assembly to helicopter fuselage.
3. Install lamps.
4. Secure lens with screws.
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E-AB412-PT6T-2
25-51-01
CARGO RESTRAINT (P/N 205-070-507-7)
1. CARGO RESTRAINT (P/N 205-070-507-7) - DESCRIPTION
The cargo net and ring assembly consists of a three section prefabricated net and 16 threaded tie down rings. Each net is
composed of web straps, reefing rings and adjustable hooks for attaching the net to the tie down rings.
2. CARGO RESTRAINT (P/N 205-070-507-7) - REMOVAL
1. Loosen the reefing hooks along the bottom and sides of the cargo net (3, figure 2) to provide slack in net.
2. Disconnect all adjustable hooks (2) from rings in the deck, aft firewall and transmission support structure.
3. CARGO RESTRAINT (P/N 205-070-507-7) - INSTALLATION
1. Install 16 rings (1, figure 1) in cabin aft firewall and transmission support structure approximately 84 cm (33.0 in)
above cabin deck.
2. Place cargo net in install position in aft end of passenger compartment.
NOTE
Net sections are identified as INBD; AFT LH; CENTER AFT; or AFT RH INBD
stenciled in 12.7 mm (1/2 in) letters with orange or yellow paint.
3. Attach two adjustable hooks (2) on CENTER AFT of net (3) to forward bulkhead of transmission structure support (5).
4. Attach three inboard adjustable hooks (2) on CENTER AFT of net (3) area marked AFT RH INBD, to ring assemblies
(1) on right side of transmission support (5), and four remaining aft hooks to ring assemblies in right aft cabin
firewall (6).
5. Attach three inboard adjustable hooks (2) of net (3), area marked INBD AFT LH, to ring assemblies (1) on left side of
transmission support (5) and four remaining aft hooks to ring assemblies inleft firewall (6).
6. Loosen reefing hooks (1, figure 2) in net assembly (3) and extend net strap to full length.
7. Attach adjustable hooks (2) to tie down rings (4, figure 1) on cabin deck as shown.
4. CARGO RESTRAINT (P/N 205-070-507-7) - INSPECTION
1. Inspect webbing for damage or excessive wear.
2. Inspect hooks for deformation and security of attachment.
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E-AB412-PT6T-2
G6AB1000A
Figure 1. Cargo restraint installation
25-51-01
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E-AB412-PT6T-2
G6AB1001A
Figure 2. Cargo net
25-51-01
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E-AB412-PT6T-2
5. CARGO RESTRAINT (P/N 205-070-507-7) - REPAIR OR REPLACEMENT
1. Replace cargo net if damaged or excessively worn.
2. Replace cargo net if hooks are deformed or not securely attached.
3. Replace any malformed rings or rings with damaged threads.
6. CARGO RESTRAINT (P/N 205-070-507-7) - ADJUSTMENT
Shorten the cargo net to prevent cargo movement by tightening web straps through each reefing hook (1, figure 2) and each
adjustable hook (2) of net (3) and make certain all hooks are tight (closed on straps).
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E-AB412-PT6T-2
25-60-01 LITTER INSTALLATION (3 PLACES) (P/N 205-706-047-1 )
25-60-01
LITTER INSTALLATION (3 PLACES) (P/N 205-706-047-11)
1. LITTER INSTALLATION (3 PLACES) (P/N 205-706-047-11) - DESCRIPTION
The litter installation (figure 1) accommodates three litters, one above the other, parallel to, and just forward of the aft cabin
passenger compartment aft bulkhead, and one man attendant's seat located forward of the litters.
The installation consists of two stanchions and two strap assemblies, secured to the cabin floor and roof. Support brackets
on stanchions and fittings on strap assemblies provide seat for litters. Litters can be quickly installed for transporting
patients, or rapidly removed for carrying cargo or personnel.
2. LITTER INSTALLATION (3 PLACES) (P/N 205-706-047-11) - REMOVAL
1. Litter racks.
a. Detach lower ends of straps from corresponding tie-down fittings in cabin deck.
b. Detach upper ends of strap from each suspension fitting.
c. Loosen nut on adapter end of stanchion assembly enough to allow to slide in tube.
d. Pull back collars on both ends of stanchion to open locking lugs.
e. Apply enough downward pressure to top of stanchion to permit upper end of stanchion to clear cabin roof
fitting. Remove stanchion assembly from helicopter.
f. Remove litter support bracket from stanchion by removal of securing hardware.
2. One-man attendant's seat.
a. Pull back collar on bottom of seat legs to unlock locking lugs.
b. Remove seat from helicopter.
3. LITTER INSTALLATION (3 PLACES) (P/N 205-706-047-11) - INSTALLATION
1. Install two stanchion assemblies (6, figure 1) as follows:
a. Loosen nut on slip joint end of stanchion assembly enough to allow fitting to slide in tube.
b. Locate studs (one each side) in cabin roof 674.70 mm (25.50 in) outboard and approximately 50.80 mm (2 in)
aft of forward corners of transmission island.
c. Position slip joint end of stanchion assembly toward cabin roof. Open locking lugs by pushing down on collar.
Position stanchion on ceiling stud, and push collar upward to lock lugs on stud.
d. Pull back collar on lower end of stanchion to open locking lugs. Position stanchion on stud in floor, and push
collar downward to lock lugs on stud.
e. Tighten nut loosened in step a. to secure slip joint.
2. Attach three bracket assemblies (4) on each stanchion with litter support forward.
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E-AB412-PT6T-2
3. Install two strap assemblies (8), as follows:
a. Locate two suspension fittings (one each side) in cabin roof, located approximately 558.80 mm (22.00 in)
forward of transmission pylon and 1003.30 mm (39.50 in) to left and right side of centerline.
b. Attach one strap to each suspension fitting.
c. Attach lower end of straps to corresponding tie-down fittings in cabin floor.
4. Install three litter cots (7), as follows:
a. Loosen straps at cabin floor fitting as necessary to allow litter cot installation.
b. Install litter cot in upper position. Secure aft rail of litter cot in upper stanchion support brackets and forward rail
in upper brackets on straps.
c. Install litter cots in center and lower positions by securing respective aft rails in their stanchion brackets and
forward rails in their brackets on straps.
d. Adjust brackets on straps as necessary to level litter cots.
e. After leveling litter cots, tighten straps at floor tiedown fittings to remove all slack.
f. Install two safety belts (9) on each litter cot.
NOTE
One attendant set is provided in this installation. Fixtures are provided for
installation of attendant seat on either left or right side. Installation instructions are
similar for either position.
5. Install seat assembly (1), as follows:
a. Loosen locking lug collars (10) on legs of attendant seat.
b. Position seat over four existing studs (11) on cabin floor.
c. Pull back collar on bottom of set legs to unlock locking lugs.
d. Lower seat in position.
e. Torque locking lug collars 0 to 22.8 kg/cm (0 to 150 in/lb).
6. Adjust seat hold down tubular braces until taut.
4. LITTER INSTALLATION (3 PLACES) (P/N 205-706-047-11) - INSPECTION
1. Check visually for abrasion, tears, and/or worn spots on litter fabric. Remove and replace that material which cannot
be restored to its original weight load capacity by repair techniques.
2. Inspect belts and straps carefully for abrasions, tears, and overall serviceability. Check for condition of adjustable
buckles, security rings, and fittings or each belt or strap. Remove and replace any defective part wherever necessary.
3. Visually inspect stanchions, backets, and tube assemblies for cracks and bending. Remove and replace those parts
which cannot be repaired adequately to ensure continued normal usage.
4. Check stanchions and tubes for proper fitting at end attachment points. Assure that attachments on studs are rigid.
5. Repeat instructions outlined in steps 3. and 4. above with regard to attendant set legs.
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E-AB412-PT6T-2
G6AB1002A
Figure 1. Litter installation (3 places)
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E-AB412-PT6T-2
5. LITTER INSTALLATION (3 PLACES) (P/N 205-706-047-11) - REPAIRING
1. Make prompt repairs to seat fabric to prolong service life. Inspect for damage immediately after use and make repairs
as follows:
a. Repair punctured, snagged, or torn areas by sewing in place a patch of material equal to basic material in weight,
quality, and color.
b. Reinforce and darn punctures and small holes 12.7 mm (1/2 in or less).
c. Trim and turn under frayed edges to make a neat and durable repair.
d. Use circular patches on small holes and rectangular patches on larger holes, irregular snags, or tears.
e. Mend a cluster of holes with one suitable patch, after first removing damaged area and turning under all edges.
f. Do not extend patches over more than one section of cover (seam to seam).
g. Restitch all open seams. Stitch pattern and type thread will follow as near as possible the type stitch and thread
used in original construction of item being repaired.
h. Repair damaged areas along edge of covers where attaching points are located, by folding a piece of material
equal to the basic material over damaged area and sewing in place.
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E-AB412-PT6T-2
25-60-02 LITTER INSTALLATION (6 PLACES) (P/N 212-706-0 2-1)
25-60-02
LITTER INSTALLATION (6 PLACES) (P/N 212-706-002-1)
1. LITTER INSTALLATION (6 PLACES) (P/N 212-706-002-1) - DESCRIPTION
The litter installation (figure 1) provides capability for installing six litters. It consists of strap assemblies, shelf assemblies
and plates, safety belts, brackets and attaching hardware. Two stanchions and the one-man seat from the troop seat are also
used with the litter equipment kit. Plates are provided on right and left walls of the pylon supports for attachment of brackets,
and threaded inserts are provided on the cabin aft bulkhead for attachment of litter shelf plates.
2. LITTER INSTALLATION (6 PLACES) (P/N 212-706-002-1) - REMOVAL
1. Remove and store safety belts (7, figure 1) when litters are removed.
2. Release tension on each strap assembly (6). Unhook strap fitting from cargo tie-down ring, loosen upper fitting and
detach strap from roof stud.
3. Release locks and remove brackets (4) from studs on pylon support walls, and brackets (11) from stanchions (3).
4. Release stanchion attachments from roof and deck studs. Remove stanchions and one-man seat for storage with troop
seat.
5. Remove bolts and washers to detach shelf assemblies with plates (5) from cabin aft bulkhead.
3. LITTER INSTALLATION (6 PLACES) (P/N 212-706-002-1) - INSTALLATION
1. Attach two strap assemblies (6, figure 1) to roofstuds and cargo tie-down rings in floor at locations shown. Apply
tension to strap at floor fittings.
2. Install four shelf assemblies with plates (5) on cabin aft bulkhead at locations provided with threaded inserts at W:L:
1041 mm (41.0 in) and 1435 mm (56.51 in). (Plates are interchangeable. Shelf assemblies P/N 212-070-189-1 are for
left side, and 212-070-189-2 for right side). Use two bolts in each shelf and plate, with one washer under bolt head and
one washer next to bulkhead.
NOTE
It may be necessary to temporarily remove pins securing shelf straps to supports in
order to install bolts in step 2.
3. Install bracket assemblies (4) on right and left sidewalls of pylon support, on plates located at Station 4026 mm (158.5
in), W:L: 730 mm (28.75 in), 1090 mm (42.91 in), and 1450 mm (57.07 in). Attach each bracket by positioning four
studs in upper ends of plate slots, then pressing downward to force studs into narrow ends of slots. Be sure lock is
engaged.
4. Install two stanchions (3), from troop seat kit, between roof studs and deck fittings at Station 2083 mm (82 in), W.L.
279 mm (11 in).
5. Secure brackets (11) on each stanchion in same manner used to secure brackets to wall plates in preceding step. Center
bracket goes in lower set of holes.
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E-AB412-PT6T-2
6. Install one-man seat from troop seat between two groups of litters.
7. Check that two safety belts (7) are provided for each litter to be installed.
4. LITTER INSTALLATION (6 PLACES) (P/N 212-706-002-1) - INSPECTION
1. Check visually for abrasion, tears, and/or worn spots on litter fabric. Remove and replace that material which cannot
be restored to its original weight load capacity by repair techniques.
2. Inspect belts and straps carefully for abrasions, tears, and overall serviceability. Check for condition of adjustable
buckles, security rings, and fittings or each belt or strap. Remove and replace any defective part whenever necessary.
3. Visually inspect stanchions, brackets, and tube assemblies for cracks and bending. Remove and replace those parts
which cannot be repaired adequately to ensure continued normal usage.
4. Check stanchions and tubes for proper fitting at end attachment points. Assure that attachments on studs are rigid.
5. Repeat instructions outlined in steps 3. and 4. above with regard to legs of attendant seat.
5. LITTER INSTALLATION (6 PLACES) (P/N 212-706-002-1) - REPAIR
1. Make prompt repairs to seat fabric to prolong service life. Inspect for damage immediately after use and make repairs
as follows:
a. Repair punctured, snagged, or torn areas by sewing in place a patch of material equal to basic material in weight,
quality and color.
b. Reinforce and darn punctures and small holes 12.7 mm (1/2 in or less).
c. Trim and turn under frayed edges to make a neat and durable repair.
d. Use circular patches on small holes and rectangular patches on larger holes, irregular snags, or tears.
e. Mend a cluster of holes with one suitable patch, after first removing damaged area and turning under all edges.
f. Do not extend patches over more than one section of cover (seam to seam).
g. Restitch all open seams. Stitch pattern and type thread will follow as near as possible the type stitch and thread
used in original construction of item being repaired.
h. Repair damaged areas along edge of covers where attaching points are located, by folding a piece of material
equal to the basic material over damaged area and sewing in place.
25-60-02
Page 2
E-AB412-PT6T-2
G6AB1003A
Figure 1. Litter installation (6 places)
25-60-02
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E-AB412-PT6T-2
25-60-02
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E-AB412-PT6T-2
25-61-01
MAP AND DATA CASE
Map and data case is a plastic box with a hinged cover. The case is inserted in top of pilot pedestal on right side and is secured
by four turn lock fasteners.
1. MAP AND DATA CASE - REMOVAL
1. Unlock four fasteners (2, figure 1) and remove case (1).
2. MAP AND DATA CASE - INSTALLATION
1. Insert case (1, figure 1) into top of pedestal and secure with four fasteners (2).
3. MAP AND DATA CASE - INSPECTION
1. Inspect case (1, figure 1) for loose or damaged fasteners (2).
2. Inspect case (1) and hinge (3) for cracks and loose or missing rivets.
25-61-01
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E-AB412-PT6T-2
G6AB0045A
Figure 1. Map and data case
25-61-01
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E-AB412-PT6T-2
25-61-02 FIRST AID KIT
25-61-02
FIRST AID KIT
The first aid kit is located on the pedestal between the pilot and copilot seats. The kit is held in place by three strips of pile
(two at top and one at bottom center of the case).
1. FIRST AID KIT - REMOVAL
1. Pull kit from pile strips.
2. FIRST AID KIT - INSTALLATION
1. Push kit onto pile strips.
3. FIRST AID KIT - INSPECTION
1. Inspect kit for completeness and coverage of contents.
2. Inspect contents for condition.
3. Inspect kit for security of installation.
4. FIRST AID KIT - REPAIR
1. Replace damaged or missing pile strips.
2. Replace damaged or missing components.
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25-61-03 SNOW SKI (P/N 212-900 -25-1)
25-61-03
SNOW SKI (P/N 212-9000-25-1)
1. SNOW SKI (P/N 212-9000-25-1) - DESCRIPTION
The snow ski allow the helicopter to take-off and land on snow covered ground; with this installation the helicopter weight
is distributed over a larger surface.
The installation consist of two metal surfaces, suitably shaped, each mounted on the forward section of each landing ski
(figure 1) and two metal surfaces, each mounted on the aft section of the landing gear.
2. SNOW SKI (P/N 212-9000-25-1) - REMOVAL
Remove attaching hardware and remove skid from landing gear.
3. SNOW SKI (P/N 212-9000-25-1) - INSTALLATION
Position skid on landing gear and secure with attaching hardware.
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G6AB0810A
Figure 1. Snow ski installation
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25-61-04
EMERGENCY FLOATS KIT (P/N 212-4600-03)
1. EMERGENCY FLOATS KIT (P/N 212-4600-03) - DESCRIPTION
The emergency flotation gear (figure 1 and figure 2) enables the helicopter to alight on water during an emergency. During
normal flight conditions the floats are deflated and folded to minimize the helicopter's aerodynamic drag.
Two pair of float switches, located on the helicopter lower side, will cause inflation of floats at the time of contact with water.
The gas required for float inflation is provided by gas generators attached to the float longitudinal support tubes. Ignition of
the explosive charge is initiated by a resistance situated in the charge and connected to the helicopter electrical system.
The electrical circuit is powered by 28 V dc and protected by four circuit breakers titled EMERGENCY FLOATS CIRCUIT
BREAKERS, which are located on the right hand side of the cockpit pedestal; two circuit breakers supply power to the
resistance located in the explosive charge or to the fuse disc (post SB 412-84), one supplies the inflation control circuit and
the other supplies the inflation control circuit test system.
A control panel is located on the central pedestal. The panel incorporates two switches, both protected by a guard cover. The
FLOATS INFLATE/ARM-SAFETY switch is used as a preset switch when placed to ARM position and to prevent
accidental inflation if placed to SAFETY position.
The MANUAL FLOATS switch will be used if inflation of floats does not occur at the time of contact with water.
The test circuit is operated by a switch on a test box located in the forward electrical compartment, and must only be operated
during ground testing; when preset on TEST the EMER FLOAT light located on the advisory panel will illuminate.
CAUTION
IF THE TEST SWITCH IS INADVERTENTLY LEFT ON TEST POSITION, IT

WILL BE IMPOSSIBLE TO INFLATE THE FLOATS DURING FLIGHT.
CAUTION
DO NOT STAND ON FLOAT SHEATH WHEN ENTERING OR LEAVING

HELICOPTER.
NOTE
Refer to Chapter 98 for emergency floats wiring diagram.
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G6AB1004A
Figure 1. Emergency floats (P/N 212-4600-09)
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2. EMERGENCY FLOATS KIT (P/N 212-4600-03) - OPERATIONAL CHECK
CAUTION
THE OPERATIONS DESCRIBED IN THIS PARAGRAPH MUST BE

RIGOROUSLY PERFORMED IN THE SEQUENCE INDICATED BELOW. IF
THE LIGHT SEQUENCE DOES NOT CONFORM WITH THAT INDICATED IN
THE APPROPRIATE PARAGRAPH STOP THE PROCEDURE. TURN POWER
OFF, DISCONNECT THE CARTRIDGE ELECTRICAL CONNECTOR AND
LOCATE AND RECTIFY THE FAULT.
WARNING
DURING TESTING PROCEDURE, ALL PERSONNEL NOT CONCERNED

WITH THE TEST, ARE TO REMAIN CLEAR OF THE FLOATS IN CASE OF
ACCIDENTAL FLOAT INFLATION AND POSSIBLE INJURY.
1. Check that all the switches and circuit breakers are in normal, off or safety position.
2. Check that the battery connector is connected.
3. Insert the four EMERGENCY FLOATS CIRCUIT BREAKERS.
4. Check that the five lights (four green and one amber) on test box, are off. Check the functioning of the lights by
depressing the relative lamp holders.
5. Move the BATTERY switch to the ON position.
6. Insert the MASTER CAUTION circuit breaker.
7. Check that the EMER FLOATS light on advisory panel is extinguished.
8. Place NORMAL/TEST switch on test box, to TEST position and check that the amber light on test box and EMER
FLOAT light on advisory panel are illuminated.
9. On control panel lift the protection guard and position preset switch FLOATS INFLATE, to ARM.
10. Press the MANUAL FLOATS switch on control panel check that the four green lamps on test box illuminate; release
the switch and check that lights extinguish.
11. With FLOATS INFLATION switch on ARM check the operation of automatic floats inflation proceeding as follows:
a. Fill two cans with water and immerse the two forward float switches. The four green lamps on the test box should
illuminate.
b. Remove one can of water from either float switch. The lights should extinguish.
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NOTE
Two float switches must be immersed at one time before the system activates, and
the two must be paired as follows:
a. Two forward switches.
b. Two aft switches.
c. Left forward and right rear.
d. Right forward and left rear.
Any other combinations will not activate the system. This can be tested by
immersing the two switches on left side at one time or by immersing the right side
switches in one pair.
NOTE
If the light indications are correct, the electrical system regarding the cartridge
primer is serviceable.
12. Position the FLOATS INFLATE preset switch on SAFETY and lower the protection guard.
13. Position the NORMAL/TEST switch on test box on NORMAL and check that amber light on test box and EMER
FLOAT lights on advisory panel are extinguished.
14. Position BATTERY switch on OFF and disengage circuit breakers previously inserted.
3. EMERGENCY FLOATS KIT (P/N 212-4600-03) - TROUBLESHOOTING
Table 1. Emergency floats kit (P/N 212-4600-03)
CAUTION
A DEFECTIVE CABLE MUST BE REPLACED; REPAIRING OF CABLE IS

NOT ALLOWED.
NOTE
It is assumed that the appropriate circuit breakers are closed.
Four green lights not illuminating during Defective test box. Replace test box.
circuit test.
Defective wiring. Replace wiring.
Defective preset switch. Replace preset switch.
Defective inflate switch. Replace inflate switch.
Defective float switch(es). Replace defective switch.
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(Cont.)
One or more green light not illuminating Explosive cartridge supply cable Replace cable.
during test. defective.
Replace explosive cartridge.
Relative explosive cartridge
defective.
4. EMERGENCY FLOATS KIT (P/N 212-4600-03) - FLOATS (P/N 212-4600-09)
4-1. FLOATS (P/N 212-4600-09) - DESCRIPTION
The emergency floats consists of two neoprene impregnated nylon fabric bags with rounded ends. Each float is normally
folded and enclosed in a waterlight cover with a zip fastener and attached to a longitudinal tube by a number or rubberized
fabric straps. Installed in each float is a connection and flexible pipe for the passage of inflation gas from a gas generator.
The inflated floats have the following dimensions:
— Length - 3.21 m (126.37 in) ± 2%.
— Diameter - 0.90 m (35.43 in) ± 2%.
— Weight - 13 kg approx. (28.6 lb).
Refer to figure 1 for installation and removal procedures.
4-2. FLOATS (P/N 212-4600-09) - REMOVAL
1. Disconnect electrical connectors from gas generators.
2. Disconnect longitudinal tubes connecting floats to landing gear cross tubes by removing securing hardware, and
remove each float complete with generator and longitudinal tube.
3. Remove thermal protection from gas generators.
4. Disconnect flexible lines connecting gas generators to floats.
5. Install threaded plugs on gas generator discharge fittings.
6. Slacken clamps securing gas generators to longitudinal tubes and remove gas generators.
4-3. FLOATS (P/N 212-4600-09) - INSTALLATION
1. Position gas generators and supports on longitudinal tubes and tighten support clamps.
2. Remove threaded plugs from gas generator discharge fittings and connect flexible lines.
3. Install thermal protection on gas generators.
4. Position floats and secure longitudinal tubes to landing gear cross tubes.
5. Connect electrical connectors to gas generators.
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G6AB1005A
Figure 2. Emergency floats (P/N 212-4600-26)
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4-4. FLOATS (P/N 212-4600-09) - INSPECTION
1. Inspect emergency flotation gear as follows:
a. Check attachment to landing gear and all metallic parts for security and condition.
b. Check all metallic parts of float for security and condition.
c. Check gas generator for security of generator and supports.
d. Check all line connections for security and condition.
e. Check igniter cartridge control electrical wiring for security and condition.
f. Check float for condition and security of zip closure.
g. Check charging point cap lockwire for security.
2. Inspect float covers for abrasion, cuts and grease spots. If damage is found, remove floats, open covers, and inspect
floats. If repair is necessary, refer to paragraph "4-6. Floats (P/N 212-4600-09) - repair".
3. Inflate each float to a pressure of 100 cm of water (0.1 kg/cm² or 1.4 psi), leave for five minutes and stabilize pressure.
Leave float pressurized for 24 hours and check that pressure has not fallen below 70 cm of water (0.07 kg/cm² or 1 psi).
NOTE
It is important when calculating float pressure to take into account any variation in
temperature. Each degree of temperature above or below initial charging
temperature corresponds to 3.8 cm of water.
If pressure falls below required value, inspect float for holes and bonding separation.
For repair refer to paragraph "4-6. Floats (P/N 212-4600-09) - repair".
4. Remove gas generators and check weight, referring to that stamped on the gas generator data plate.
NOTE
During weighing, gas generator must have threaded plugs fitted to the charge and
discharge connections. The igniter cartridge is included in the weight. If weight is
less than weight stamped on data plate by more than 100 gr (0.22 lb), generator must
be overhauled.
5. Remove igniter cartridges and propellant containers and immerse gas generator cylinder in water. Check for leaks from
charge and discharge fittings and propellant container housing. If leaks are found dispatch gas generator for overhaul.
6. Inspect test box mounted in helicopter nose for security and condition.
7. Inspect electrical wiring for general condition.
CAUTION
ANY CABLE FOUND DAMAGED MUST BE REPLACED. INSULATION

TAPE AND OTHER FORMS OF REPAIR ARE NOT RECOMMENDED.
4-5. FLOATS (P/N 212-4600-09) - CLEANING
1. General.
Work on floats in a clean room.
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2. Cleaning.
If during service floats are found stained with oil, grease, rust, etc., eliminate these stains without delay using a suitable
detergent that is not harmful to rubber. The following paragraphs contain suggestions for cleaning off some of the
substances to which floats may be exposed:
Fresh water - Completely wipe dry, especially metallic parts. The rubberized fabric must be abundantly covered with
talcum powder to prevent mould especially in less accessible areas, e.g. the attaching support straps.
Salt water - Thoroughly wash with fresh water and proceed as above.
Oil and grease - Use aviation gasoline in minimum quantity. Immediately after cleaning, cover threaded area with
abundant talcum powder.
Corrosive substance - Washer area immediately after contamination: allow a waiting period then inspect to ascertain
that corrosion has been eliminated. Test resistance of affected area. If there is any doubt about reliability, dispatch float
for overhaul.
Mould - The action of mould if particularly dangerous to rubberized fabric. All traces must immediately be eliminated
by thoroughly washing the affected area with neutral soap and water. After drying, cover treated area with abundant
talcum powder.
3. Conservation.
Every time float is removed, thoroughly inspect for bonding separation or light tearing. Wash the metallic parts in fresh
water and dry. Wash and dry the float and lay out flat on a wooden shelf or cabinet, cover the float with talcum powder.
The storeroom must be clean and well ventilated with fresh but dry air and disinfected, so as to be free of insects and
rodents. Do not place float on bare ground or area saturated with oil, grease on fuel; always place the float on a clean
canvas cover.
4-6. FLOATS (P/N 212-4600-09) - REPAIR
Personnel responsible for float maintenance must be able to carry out simple small cold patch repairs using self vulcanizing
solution. (The patch must be of the same material as the float). For repair proceed as follows:
1. All repairs must be carried out with float deflated.
2. Roughen surface to be patched using (fine grade) sandpaper, remove dust deposits.
3. Clean the roughened surface with aviation gasoline.
4. Mix the vulcanizing solution with its acceleration just prior to use; mix thoroughly 5 gr (0.011 lb) of acceleration for
each 100 gr (0.22 lb) of solution.
5. Smear the solution uniformly onto the patch and the area being repaired.
6. Wait 5 to 10 minutes and apply second coat of solution to both surfaces.
7. Wait 5 to 10 minutes then join the two treated parts together checking that no air is trapped between the mating
surfaces.
8. Press the two parts together using a flat piece of wood or metal (free of sharp corners). Cover the treated area with
talcum powder.
9. Wait 1 to 2 days before inflating or using the repaired float.
NOTE
For small surface abrasions which do not compromise the sealing of the float there
are two methods of repair.
a. Repair using only a mixture of solution and acceleration (see steps 3., 4., 5. and 6.). Apply mixture to affected
area only.
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b. Apply a self adhesive patch of trim fabric in accordance with the above procedure (Float repair). Do not apply
solution to the patch as it is self adhesive; it is sufficient to clean the affected area with aviation gasoline and
apply a coat of solution.
CAUTION
TEARS THAT ARE LONGER THAN 2 CM (7.90 IN) CANNOT BE REPAIRED,

EXCEPT BY THE MANUFACTURER, WHO WILL DECIDE IF THE FLOAT
CAN BE REPAIRED OR HAS TO BE REPLACED.
4-7. FLOATS (P/N 212-4600-09) - FOLDING
1. Inflate the float to operational pressure.
2. Apply talc powder to float fabric, as necessary to prevent mould.
3. Place a polythene sheet 0.15x2320x3210 mm (0.006x91x126 in) under float cover and secure with adhesive tape. Cut
holes in polythene sheet to allow access of flexible pipe connections and attaching trunnion pins. Reinforce area
around the holes with adhesive tape.
NOTE
To wrap a pair of floats utilize a sheet of polythene 7.5 m (295.3 in) by 3.5 m
(137.8 in).
4. Cover the float in polythene sheeting and secure polythene to float with strips of adhesive tape.
NOTE
The polythene sheet must be of sufficient length to allow covering of end caps.
5. Carefully deflate float. Do not break polythene sheet.
6. Double fold ends of float to obtain same float and cover length.
7. Fold float (concertina style) and insert into cover.
8. Close zipper of cover. If a float has been used it is necessary to remove existing cover and fit new item.
4-8. FLOATS (P/N 212-4600-09) - STORAGE INSTRUCTIONS
Use utmost care when storing floats so as to prolong storage and service life; direct or indirect sunlight and heat are harmful
to rubberized fabric.
The floats must be placed on a shelf or cabinet in a clean, fresh ventilated but dry room, disinfected so as to be free of insects
and rodents. Floats must not be stored folded for a period exceeding two months. When period is longer than two months,
floats must be unfolded and ventilated for at last 24 hours.
For long term storage float must be inspected at intervals laid down by director of stores. Interval time can be reduced if
required by particular conditions (climatic, accidental, etc.).
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G6AB1006A
Figure 3. Gas generator (P/N 894063) (sheet 1 of 2)
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G6AB1007A
Figure 3. Gas generator (P/N 894063) (sheet 2 of 2)
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5. EMERGENCY FLOATS KIT (P/N 212-4600-03) - FLOATS (P/N 212-4600-26)
5-1. FLOATS (P/N 212-4600-26) - DESCRIPTION
The emergency floats, made of polyamide fabric coated on both sides with polyurethane cylindrical in shape. They are
closed at both ends by flat end pieces, globe-shaped when inflated.
The float assembly is divided into three sealed buoyancy chambers of equal volume, separated by means of two internal
round dividers made of the same fabric as the balloon body.
The fabric panels making up the balloon are assembled by the “edge to edge” technique and glued inside and outside by high
strength sealing strips which overlap the seam edges.
Two attaching girts are glued to the balloon. The purposes of these girts is to transmit all the loads produced on the balloon
during a ditching to the resistant metal structure of the helicopter and more particularly to the metallic traverse tubes.
The attaching girts are made of fabric and are provided with load absorbing loops.
The two opposite buoyancy chambers of the balloon are each equipped with:
— one outlet connector with gas valve connected to the inflation system by means of a flexible supply hose assembly
located between the attaching girts and the balloon.
— one manual inflating/deflating valve designed to inflate or deflate the balloon externally from a source of de-oiled
compressed air or a bellows.
The balloon central buoyancy chamber is equipped with:

— one feeding connector with nonreturn valve externally connected to the cylinder inflation valve by means a flexible
feed hose assembly.
— one manual inflating/deflating valve
The two floats, cylindrical in shape, are symmetrical and have the following dimensional characteristics, at a relative
pressure of 140 mb and a temperature of 15°C:
— Constant diameter 870 ± 20 mm,
— Overall length 3210 ± 65 mm,
— Nominal volume 1,780 dm3
— Balloon weight (equipped) 7.9 kg
— Balloon weight (unequipped) 7.12 kg
For further information refer to Manufacturer Manual.
5-2. FLOATS (P/N 212-4600-26) - REMOVAL
1. Disconnect electrical connectors from gas generators.
2. Disconnect longitudinal tubes connecting floats to landing gear cross tubes by removing securing hardware, and
remove each float complete with generator and longitudinal tube.
3. Disconnect flexible lines connecting gas generators to floats by removing retention ring (11, figure 2) and banyo fitting
(13).
4. Slacken clamps securing gas generators to longitudinal tubes and remove gas generators.
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5-3. FLOATS (P/N 212-4600-26) - INSTALLATION
1. Position gas generators and supports on longitudinal tubes and tighten support clamps.
2. Remove retention ring (11, figure 2) located on the gas generator valve. Lubrificate packings (12) with grease.
3. Position banyo fitting (13) on gas generator valve and press into seat. Install the retention ring.
4. Install elbow (14) of flexible tube (15) on that feeding connector (16). Torque to 305 kg.cm (234 in-lb).
5. Position floats and secure longitudinal tubes to landing gear cross tubes.
6. Connect electrical connectors to gas generators.
5-4. FLOATS (P/N 212-4600-26) - INSPECTION
1. Inspect emergency flotation gear as follows:
a. Check attachment to landing gear and all metallic parts for security and condition.
b. Check all metallic parts of float for security and condition.
c. Check gas generator for security of generator and supports.
d. Check all line connections for security and condition.
e. Check igniter cartridge control electrical wiring for security and condition.
f. Check charging point cap lockwire for security.
2. Inspect floats in accordance with Manufacturer’s manual procedures.
3. Remove gas generators and check weight, referring to that stamped on the gas generator data plate.
4. Inspect test box mounted in helicopter nose for security and condition.
5. Inspect electrical wiring for general condition.
CAUTION
ANY CABLE FOUND DAMAGED MUST BE REPLACED. INSULATION

TAPE AND OTHER FORMS OF REPAIR ARE NOT RECOMMENDED.
6. Using the test box check inflation circuit as described at paragraph "2. Emergency floats kit (P/N 212-4600-03) -
operational check".
5-5. FLOATS (P/N 212-4600-26) - CLEANING
Refer to Manufacturer Manual.
5-6. FLOATS (P/N 212-4600-26) - REPAIR
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5-7. FLOATS (P/N 212-4600-26) - STORAGE
6. EMERGENCY FLOATS KIT (P/N 212-4600-03) - GAS GENERATOR (KIDDE 894063)
6-1. GAS GENERATOR (KIDDE 894063) - DESCRIPTION
The gas required for emergency float inflation is provided by two gas generators (figure 3) fixed to the float longitudinal
supports. Each generator consists of a cylinder containing carbon dioxide, a propellant located in a container inserted into
the cylinder and an explosive igniter that when exploded causes a chemical reaction between the carbon dioxide and the
propellant which produces the gas necessary to inflate the float. Ignition of the explosive charge is initiated by a resistance
situated in the charge and connected to the helicopter electrical system.
6-2. GAS GENERATOR (KIDDE 894063) - INSPECTION AND TEST
1. Weigh the cylinder complete with threaded plugs installed in charge and discharge unions: the igniter cartridge is
include in the weight. If the weight is 100 gr (0.22 lb) less than indicated on the data plate, despatch cylinder for
overhaul.
2. Check that pins on electrical connector are not broken or bent.
3. Check all anodised parts for damage to anodic protection.
4. Check cylinder for dents, scratches, bulges, distortion and corrosion.
5. Check cylinder-to-float flexible hose for leakage.
6. Check all openings for obstruction and all joints for damage. Examine all threaded parts for damage, replacing any
item that has more than two threads damaged at any one location.
7. Inspect electrical connector and perform continuity check of wiring and cartridge.
NOTE
The threaded plug (1, figure 3) is installed when hose is disconnected.
6-3. GAS GENERATOR (KIDDE 894063) - SPECIAL INSTRUCTIONS
1. When gas generator is not connected to the floats threaded plug must be fitted to discharge union. It is also
recommended that igniter cartridge be removed. When gas generator is despatched to or from storage or retained in
storage, cartridge removal is compulsory.
2. As soon as possible after gas generator has been discharged, carefully wash out cylinder with hot water and dry.
Register washing operation and discharge condition on gas generator document and despatch gas generator to overhaul
for recharge.
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7. EMERGENCY FLOATS KIT (P/N 212-4600-03) - CYLINDER ASSEMBLY (P/N 205608)
7-1. CYLINDER ASSEMBLY (P/N 205608) - DESCRIPTION
The gas cylinder assembly, installed on the floats longitudinal supports is equipped with an inflation valve assembly, a
removable outlet banjo fitted with a non-return valve and a restrictor for connection to the float supply hose.
The inflation valve assembly allows:

— Storage under pressure of the gas required for inflation of the flotation gear:
— Filling and slow discharge of the cylinder assembly.
Inflation of the emergency flotation gear by the actuation system. The inflation valve is of the differential pressure type.
Sudden release of the pressure in rear chamber of the inflation valve unbalances the piston which instantly moves back to
release the gas contained in the cylinder.
For further information refer to manufacturer Manual.
7-1. CYLINDER ASSEMBLY (P/N 205608) - INSPECTION AND TEST
Refer to manufacturer Manual.
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25-66-01
25-66-01
EXTERNAL LOUDSPEAKERS SYSTEM (P/N 412-9010-96-301)
1. EXTERNAL LOUDSPEAKERS SYSTEM (P/N 412-9010-96-301) - DESCRIPTION
The external loudspeakers system (figure 1), comprises one amplifier, a control panel located on central pedestal and two
couples of speakers installed on the LH and RH crosstube of the landing gear.
The system is powered by 28 V dc through the EXT SPKR circuit breakers on the overhead console.
2. EXTERNAL LOUDSPEAKERS SYSTEM (P/N 412-9010-96-301) - MAINTENANCE
WARNING
ENSURE ELECTRICAL POWER IS OFF.
2-1. MAINTENANCE - SPEAKERS
2-1-1. Speakers - removal
1. Disconnect electrical connector from speaker unit (1, figure 1).
2. Cap open end of connector for protection.
3. Remove speaker unit (1) by acting on relative fasteners.
2-1-2. Speakers - installation
1. Install speaker unit (1) using relative fasteners.
2. Remove protective cap from electrical connector.
3. Connect electrical connector to the speaker unit (1).
2-1-3. Speakers - inspection
1. Inspect speakers for completeness, proper installation, cleanliness and secure mounting of each component.
2. Inspect electrical connections for corroded or bent pins and proper mating, and interconnecting cable for frayed or
broken insulation.
2-2. MAINTENANCE - AMPLIFIER
2-2-1. Amplifier - removal
1. Disconnect electrical connector (4) from the amplifier (3).
2. Cap open end of connectors for protection.
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3. Remove screws (6) and washers (5).
4. Remove the amplifier (3) from the support.
2-2-2. Amplifier - installation
1. Position the amplifier (3) on the support.
2. Secure with screws (6) and washers (5).
3. Remove protective caps from electrical connector (4).
4. Connect electrical connector (4) to the amplifier (3).
2-3. MAINTENANCE - CONTROL PANEL
2-3-1. Control panel - removal
1. Loosen spring lock fasteners that secure control panel mounting plate assembly to pedestal assembly.
2. Lift control panel mounting plate assembly and control unit far enough out of pedestal assembly to reach and
disconnect electrical connectors at back of the unit.
3. Lift control panel mounting plate assembly and control unit free of pedestal assembly.
4. Loosen screws and nuts that secure control unit to control panel mounting plate assembly.
5. Lift control unit free of control panel mounting plate assembly.
2-3-2. Control Panel - installation
1. Position control unit in control panel mounting plate assembly and secure with mounting screws and nuts.
2. Connect electrical connectors to back of the control unit.
3. Position control panel mounting plate assembly and control unit in place on pedestal and secure with spring lock
fasteners.
2-3-3. Control Panel - inspection
1. Inspect switches and controls on control panel for proper mechanical action.
2. Inspect electrical connections for corroded or bent pins and proper mating, interconnecting cable for frayed or broken
insulation and circuit breakers for proper operation.
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C
A
B
A A
C 3
6
5
1. Speaker 4. Electrical connector

2. Control panel 5. Washer
3. Amplifier 6. Screw
G6AB1045A
Figure 1. External loudspeakers system
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25-71-01 AUXILIARY FUEL TANKS (LONG RANGE) (P/N 412-706-007-109 AND 1 0)
25-71-01
AUXILIARY FUEL TANKS (LONG RANGE) (P/N 412-706-007-109 AND 110)
1. AUXILIARY FUEL TANKS (LONG RANGE) (P/N 412-706-007-109 AND 110) -

DESCRIPTION
Two 312 liters (82 U.S. gallons) capacity auxiliary fuel tanks may be installed in the passenger cargo compartment for
extended distance and ferry missions. The rigid tanks are located at the intersection of the aft cabin bulkhead and the
transmission support structure, one on each side of cabin, and are fixed with retainers. Fuel from the tanks is gravity fed into
the main fuel system.
NOTE
Refer to Chapter 98 for capacitance simulator wiring diagram.

REMOVAL
2. Drain fuel from auxiliary tanks.
3. Remove cover assembly on top of tank left side as follows:
a. Remove sensitive hook fasteners around top of tank.
b. Remove cover assembly (12, figure 1) on top of tank.
c. Right side procedures same as left side.
4. Remove cable assembly (15) left side as follow:
a. Disconnect cable assembly to probe.
b. Remove cable assembly from clamps.
c. Right side procedures same as left side.
5. Remove tank vent hose left side as follows:
a. Disconnect reducer (20) and hose assembly (10) to tube and reducer.
b. Install plug on tube.
c. Right side, procedure same as left side.
6. Remove fuel tanks, left side as follows:
a. Remove tube assembly (7) from grommet (8) under floor.
b. Remove connector (6) to existing fuel system crossover under floor.
c. Remove tank from island and bulkhead by removing bolts and washers at inboard fitting and bolt and washer at
outboard fitting.
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NOTE
Carefully remove tank from bottom coupling through hole in floor, and upper fitting
through hole in main beam panel (side of pylon island).
d. Remove seal (9) over vent valve at upper inboard edge of tank assembly (1).
e. Install auxiliary fuel vent cover from left side of pylon island.
f. Install cap from hose under floor.
g. Install auxiliary fuel floor cover in aft part of cabin.
h. Install right side thank as left side.
7. Remove sound proofing blankets from bulkhead, and from left side of pylon island.
8. Install existing sound proofing blankets stowed.
9. Install cargo door.
10. Install seat fittings.
11. Install seats and seat belts (if installed).

INSTALLATION
1. Disconnect battery and any external power source.
2. Prepare helicopter for safe fuel system maintenance.
3. Refer to Chapter 98 for general fuel system precautions and procedures.
4. Remove all seats and seat belts, if installed, from aft cabin area.
5. Remove seats attach fitting from bulkhead and beams around pylon island.
6. Remove cargo doors.
7. Remove applicable access doors on lower skin for access to existing fuel hoses aft forward fuel thanks.
8. Remove existing soundproofing blankets from aft cabin bulkhead, and left side of pylon island. Stow with loose
equipment.
9. Install blanket (18, figure 1) on aft cabin bulkhead.
10. Install blanket (19) on left side of pylon island.
11. Install blankets, right side, same as left side.
12. Remove auxiliary fuel floor cover (3), in aft part of cabin. Stow cover for future use.
13. Disconnect cap from hose under floor.
14. Remove auxiliary fuel vent cover (2) from left side of pylon island.
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CAUTION
ENSURE PROTECTIVE CAPS REMAIN ON VENT AND DRAIN FITTINGS

UNTIL TANK IS IN POSITION ON AIR-CRAFT.
15. Position tank assembly (1), on cabin floor.
16. Install seal (9) over vent valve at upper inboard edge of tank assembly.
17. Carefully positional thank, with bottom, with bottom coupling through hole in floor, and upper fitting through hole in
floor, and upper fitting through hole in main beam panel (side of pylon island).
NOTE
Shims (4) may be peeled to obtain proper alignment between bolt holes and fittings.
18. Secure thank to island and bulkhead by installing bolts and washers (4) at inboard fitting, and bolt and washer (4) at
outboard fitting.
19. Secure connector (5) to existing fuel crossover (6) under floor.
20. Install grommet (8) in hole of outer skin locate at FS 4036 mm (158.90 in) and LBL 622 mm (24.50 in) and insert tube
assembly (7) through grommet; connect rube assembly to tank.
21. Install right side tank same as left side.
22. Remove plug from previously installed tube assembly (21).
23. Connect reducer (20) to tube assembly (21).
24. Connect hose assembly (10) to tank down as shown.
25. Connect other end of hose assembly, right side, same as left side.
26. Ruote cable assembly (15) down ceiling area on the pylon bulkhead. Secure cable assembly (1) as follows:
a. Ruote cable assembly (15) down ceiling area on the pylon bulkhead. Secure cable assembly (15) with two
clamps (14) at locations shown; use existing fasteners.
b. Secure cable assembly (15) at location shown with clamp, bolt and washer (14).
c. Secure cable assembly (15) to the top of tank assembly with clamp.
d. Connect cable assembly (15) to probe (13).
CAUTION
IN THE EVENT THAT ONE OR BOTH OF THE AUXILIARY FUEL TANKS

ARE REMOVED, OR IF ONE FUEL TANK KIT IS INSTALLED, IT IS
MANDATORY TO DISCONNECT THE CABLE ASSEMBLY (212-075-611-109)
FROM THE AUXILIARY FUEL TANK PROBE AND CONNECT IT TO THE
CAPACITANCE SIMULATOR (384304-006). WHEN THE CABLE ASSEMBLY
IS CONNECTED TO THE CAPACITANCE SIMULATOR(S), THE FUEL
QUANTITY GAGE WILL REVERT BACK TO BASIC FUEL QUANTITY
SYSTEM.
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27. Position cover assembly (12) on top of tank.
28. Attach pressure sensitive hook fastener around top of tank.
29. Right side, procedures same as left side.
30. Replace sliding doors, tight and/or left side helicopter.
31. Replace right and left pylon access door assemblies.
32. Replace access panel(s) under mid-fuselage area.
33. Refuel helicopter.
34. Connect battery.

INSPECTION
1. Inspect fuel cell visually for deterioration, evidence of seepage and mechanical or structural damage.
2. Inspect fuel cell for leaks after installation as outlined in preceding paragraph "3. Auxiliary fuel tanks (long range) (P/
N 412-706-007-109 and 110) - installation".
5. AUXILIARY FUEL TANKS (LONG RANGE) (P/N 412-706-007-109 AND 110) - REPAIR
MATERIALS REQUIRED
NUMBER NOMENCLATURE
C-309 METHYL-ETHYL-KETONE (MEK)
1. Auxiliary fuel tank kit.
a. Defuel and remove leaking fuel tank assembly.
b. Dismantle and repair inner cell of tank assembly as follows:
(1) Remove two screws, NAS1189-3P6, from vent fitting, 214-066-061-1.
(2) Remove four bolts, AN4-5A, and four washers AN960PD416L, from applicable adapter assembly on
bottom of fuel tank assembly. Remove four screws, MS27039-1-25, and four washers, AN960PD10L,
from cell fitting.
(3) Remove four bolts, MS20004-6, retainer, 214-066-065, from probe, and remove transmitter from fuel tank.
(4) Remove cover assembly, by removing 69 screws.
(5) Unlace nylon cord securing rubber cell to tank assembly and lift cell from tank.
2. Repair outside surface of fuel cell as follows:
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CAUTION
FIELDS REPAIRS TO ANY RADIUS, ANY FITTING AREA, OR ANY CUT OR

TEAR LONGER THAN 25 MM (1 IN) ARE PROHIBITED. CELLS WITH SUCH
DAMAGE SHOULD BE RETURNED TO THE FACTORY FOR REPAIR.
a. Cut a patch of synthetic rubber-coated fabric (U.S. Rubber Company, P/N 5200 outside repair material) large
enough to cover damage with a 50.8 mm (2 in) overlap in any direction.
WARNING
METHYL-ETHYL-KETONE IS TOXIC AND FLAMMABLE. USE ONLY IN

WELL VENTILATED AREA. DO NOT USE NEAR OPEN FLAME.
b. Buff parch and cell area to be repaired with garnet abrasive paper. Wash with C-309 (U.S. Rubber Company
P/N 3339 solution) to remove buffing dust.
c. Apply two coats of cements (U.S. Rubber Company P/N 3230 or Minnesota Mining Company P/N EC-678) to
buffed area of fuel cell and patch. Allow each coat to dry 10 to 15 minutes.
d. Freshen cemented area of fuel cell and patch with C-309 (U.S. Rubber Company P/N 3339 solution). While still
tacky, apply edge of patch to edge of cemented area; hold opposite edge of patch off fuel cell. Roll the patch
down in 32 mm (1/2 in) wide strip increments to avoid trapping air between fuel cell and patch. Use a roller or
blunt instrument to press patch down. place a fifty pound shot bag on patch with a piece of holland cloth or
cellophane between shot bag and fuel cell. do not disturb for six hours.
e. Seal coat 32 mm (1/2 in) wide strip around edge of patch with one coat of cement (U.S. Rubber Company
P/N 3230 or Minnesota Mining Company P/N EC-678). Allow to dry thoroughly.
f. Repair inside surfaces of fuel cell only after damaged area outside surface has been repaired.
g. Cut a patch of synthetic rubber nylon sandwich material (U.S. Rubber Company P/N 5200/5187) large enough
to cover damage with a 50.8 mm (2 in) overlap in any direction. Apply patch in same manner as described for
outside patch in steps 2. through 4.
h. Seal coat patch and 32 mm (1/2 in) wide strip overlapping patch with two coats of cement (U.S. Rubber
Company P/N 3230 or Minnesota Mining Company P/N EC-678). Allow first coat to dry one hour or more. After
second coat is dry, wipe patch and cemented area with lubricating oil (C-009), to prevent patch from sticking to
other parts of the cell.
i. To repair scuffed fabric on fuel cell, buff area of scuff damage with garnet abrasive paper. Wash with C-309 (U.S.
Rubber Company P/N 3339 solution) to remove buffing dust.
j. Apply two coats of cement (U.S. Rubber Company P/N EC-678) to buffed area. Allow ten minutes Drying time
between coats.
k. Replace cell and lace to tank with existing nylon cord.
l. Replace retainer, probe, and fittings, 214-066-061-1.
m. Install fuel tank assembly and test in accordance with preceding installation and test procedures.
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G6AB0811A
Figure 1. Auxiliary fuel tanks (82 U.S. gallons) (long range) (sheet 1 of 2)
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G6AB0812A
Figure 1. Auxiliary fuel tanks (82 U.S. gallons) (long range) (sheet 2 of 2)
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OPERATIONAL CHECK
The check of the Auxiliary Fuel System consists of refilling the main fuel system after use. Auxiliary fuel is gravity fed,
therefore, controls are not required.
7. AUXILIARY FUEL TANKS (LONG RANGE) (P/N 412-706-007-109 AND 110) - TESTING
1. Visually inspect the ratcheted connector to ensure positive engagement of the locking ratchets.
2. Cap main fuel line vent connections.
3. Use regulated low-pressure, filtered, compressed air source with a manometer or accurate pressure gage and shutoff
valve.
CAUTION
DO NOT APPLY EXCESSIVE PRESSURE, AS DAMAGE TO CELL AND

STRUCTURE MAY RESULT.
4. Apply pressure until gage indicates 0.5 psig in cells and crossover tubes. Shut off air source. Cell should hold this
pressure for 15 minutes.
5. Locate and correct any leakage indicated by loss of pressure, and repeat tests until results are satisfactory.
6. Remove all caps and plugs used to close off system being tested when test result prove satisfactory.
7. Fuel the helicopter to capacity and visually inspect connection for leaks prior to installing and securing the access
covers.
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AUXILIARY FUEL TANKS (SEAT TYPE) (P/N 412-706-009-107)
1. AUXILIARY FUEL TANKS (SEAT TYPE) (P/N 412-706-009-107) - DESCRIPTION
Two 70 liters (18.5 gallons) capacity auxiliary fuel tanks may be installed in the passenger cargo compartment for extended
distance and ferry missions. The tanks are located at the intersection of the aft cabin bulkhead and the transmission support
structure, one on each side of cabin, and are fixed with retainers. Fuel from the tanks is gravity fed into the main fuel system.
2. AUXILIARY FUEL TANKS (SEAT TYPE) (P/N 412-706-009-107) - REMOVAL
2. Drain fuel auxiliary tanks.
3. Remove fitting and safety belts.
4. Disconnect hose assembly (9, figure 1).
5. Disconnect hose assembly (9) to union T (12).
6. Install plug (11) to union T (12).
7. Remove tank vent hose assembly, right side same as left side.
8. Remove tube assembly (6) from tank.
9. Remove connector (4) from existing fuel system crossover (5) under floor.
10. Remove tank by removing attaching parts fitting and shim (3).
11. Remove seal (8) over vent valve at upper inboard edge of tank assembly (13).
12. Remove tank assembly (13) from cabin floor.
NOTE
Carefully remove tank from bottom coupling through hole in the floor, and upper
fitting through hole in main beam panel (side of pylon island).
13. Install auxiliary fuel vent cover (2) on pylon island.
14. Connect caps to hose under floor.
15. Install auxiliary fuel floor covers (1).
16. Remove blanket (P/N 412-070-606-103 and -104) (16) from pylon island.
17. Remove blanket (P/N 412-070-607-103 and -104) (15)from cabin bulkheads.
18. Install soundproofing blanket (P/N 212-070-604) and (P/N 212-070-605) to aft cabin bulkhead and pylon island.
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19. Install access doors.
20. Install cargo doors.
21. Install seat attach fittings to bulkhead and beam around pylon island.
22. Install seats and belts (if installed).
3. AUXILIARY FUEL TANKS (SEAT TYPE) (P/N 412-706-009-107) - INSTALLATION
1. Disconnect battery and any external power source.
2. Prepare helicopter for safe fuel system maintenance.
3. Refer to Chapter 28 fro general fuel system precautions and procedures.
4. Remove seats and seat belts, if installed, from aft cabin area.
5. Remove seat attach fittings from bulkhead and beams around pylon island.
6. Remove cargo doors.
7. Remove applicable access doors on lower skin for access to existing fuel hoses aft of forward fuel tanks.
8. Remove existing soundproofing blankets (15, figure 1) (P/N 212-070-604) from aft cabin bulkhead, and from left side
of pylon island (16) (P/N 212-070-605). Stow with loose equipment.
9. Install blanket (15) (P/N 412-070-607-103 and -104) on aft cabin bulkhead.
10. Install blanket (16) (P/N 412-070-060-103 and -104) on left side of pylon island.
11. Install blankets, right side, same as left side.
12. Remove auxiliary fuel floor cover (3) in aft part of cabin. Stow cover for future use.
13. Disconnect cap from hose under floor.
14. Remove auxiliary fuel vent cover (2) from left side of pylon island.
CAUTION
ENSURE PROTECTIVE CAPS REMAIN ON VENT AND DRAIN FITTINGS

UNTIL THANK IS IN POSITION ON AIR-CRAFT.
15. Position tank assembly (14) on cabin floor.
16. Install seal (8) over vent valve at upper inboard edge of tank assembly.
17. Carefully position tank, with bottom coupling through hole in floor, and upper fitting through hole in main beam panel
(side of pylon island).
NOTE
Shims (3) may be peeled to obtain proper alignment between bolt holes and fittings.
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18. Secure tank to island and bulkhead by installing blots and washers (3) at inboard fitting, and bolt and washer at
outboard fitting.
19. Secure connector (4) to existing fuel system crossover (5) under floor.
20. Install grommet (7) in hole of outer skin located at FS 4036 mm (158.90 in) and LBL 622 mm (24.50 in) and insert
tube assembly (6) through grommet (7); connect tube assembly to tank.
21. Install right side tank same as left side.
22. Remove plug (11) from previously installed hose assembly (9).
23. Connect hose assembly (9) to tank as required.
24. Install tank vent hose assembly, right side, same as left side.
25. Install and secure fitting and safety belts.
26. Refuel helicopter.
27. Connect battery.
4. AUXILIARY FUEL TANKS (SEAT TYPE) (P/N 412-706-009-107) - INSPECTION
1. Inspect fuel cell visually for deterioration, evidence of seepage and mechanical or structural damage.
2. Inspect fuel cell for leaks after installation as outlined in preceding paragraph.
5. AUXILIARY FUEL TANKS (SEAT TYPE) (P/N 412-706-009-107) - OPERATIONAL

CHECK
The check of the Auxiliary Fuel System consist of refilling the main fuel system after use. Auxiliary fuel is gravity fed,
therefore controls are not required.
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G6AB0839A
Figure 1. Auxiliary fuel tanks (37 U.S. gallons) (seat type)
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6. AUXILIARY FUEL TANKS (SEAT TYPE) (P/N 412-706-009-107) - TESTING
1. Visually inspect the ratched connector to ensure positive engagement of the locking ratchets.
2. Cap main fuel line and vent connections.
3. Use a regulated low-pressure, filtered, compressed air source with a manometer or accurate pressure gage and a shutoff
valve.
CAUTION
DO NOT APPLY EXCESSIVE PRESSURE, AS SEVERE DAMAGE TO CELL

AND STRUCTURE MAY RESULT.
4. Apply pressure until gage indicates 0.035 kg/cm² (0.5 psig) in cells and crossover tubes. Shut off air source. Cells
should hold this pressure for 15 minutes.
5. Locate and correct any leakage indicated by loss of pressure, and repeat tests until results are satisfactory.
6. Remove all caps and plugs used to close off system being tested when test results prove satisfactory.
7. Fuel the helicopter to capacity and visually inspect connection for leaks prior to installing and securing the access
covers and cushion assy.
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25-91-00
EXTERNAL RESCUE HOIST INSTALLATION KIT (ELECTRIC)
P/N 412-8800-01-412 (BL20200-412)
1. EXTERNAL RESCUE HOIST INSTALLATION KIT (ELECTRIC) P/N 412-8800-01-412

(BL20200-412) - HOIST ASSEMBLY
The Rescue Hoist System (see figure 1) provides a means for lowering and raising personnel from an airborne helicopter. It
can be operated from the pilot station or the crew station. The Rescue Hoist System is secured to a support installed on the
RH side of the helicopter roof. It is comprised of a hoist assembly, pressure cartridge kit, pendant control assembly, hook
assembly, electronic variable speed controller, interconnection electrical control pendant cable, adapter link cable assembly,
and cable protection. The hoist assembly, is a multiple layered type drum design with a cable capacity of 245 feet/75 meters
of 3/16dia. 19 x 7 construction (spin resistant type). The reduction gearing is of the planetary type. The drive train includes
a fail safe mechanically actuated load brake. The hoist is driven with a 28 Vdc electric motor which includes totally enclosed
fan cooling and an integral motor brake. Limit switches are directly coupled to the hoist drum to control cable fully extended
and intermediate cable positions (hook approach to aircraft and approach to cable fully-extended switch). The cable
fully-retracted switch is built into the cable level wind nut assembly to assure proper homing of the hook when hoist is not
in service. Redundant switches are used and the mechanical mounting techniques employed ensure fail safe operation.
NOTE
If the operation of the hoist, the cable rate is automatically slowed to a safe speed
whenever the hoist is operated in the cable zone controlled by the fail safe redundant
intermediate switch.
The hoist assembly is equipped with electrical connectors to facilitate rapid interfacing with the controller assembly. The
variable speed controller is a highly efficient speed control which incorporates the latest (PWM) pulse width modulated
speed control techniques. Hoist speed control is accomplished by a speed command applied to the controller from either the
variable speed operator control or the constant speed priority override pilot’s control switch. Internal power switching
elements control the amount of average dc voltage applied to the hoist motor. The greater the deflection of the thumb wheel
on the hoist operator’s pendant control assembly, the greater average DC voltage applied to the motor, hence, faster hoisting
speeds. Full deflection of the thumb wheel on the pendant control assembly applies maximum voltage to the dc motor, hence,
maximum cable speed. The controller assembly being greater than 95% efficient dissipates minimal power. The heat skin
on the side of the controller is used to remove heat from the controller and installation must be either horizontal with heat
skin facing up or vertical. The controller incorporates digital electronics which process the hoist limit switch information
and limits the hoist speed if an intermediate switch is actuated and inhibits further hoist movement if a stop switch is
actuated. The controller’s digital electronics also control the priority of the control inputs from the hoist operator or the pilot
control. The pilot has complete priority over the hoist operator and the hoist is automatically set to the 600 lb/273 Kg mode.
The pilot’s command is fixed speed with automatic slow downs and stops when the cable extremes are reached.
1-1. HOIST ASSEMBLY - REMOVAL
1. Disconnect the electrical power and remove the hoist cowling (3, figure 1).
WARNING
OBEY ALL SAFETY PROCEDURES WHEN YOU DO THIS OPERATION AND

MAKE SURE ALL ELECTRICAL SOURCES ARE OFF. THIS PREVENTS
ACCIDENTAL DETONATION OF THE CABLE-CUTTING CARTRIDGE.
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2. Disconnect the electrical connectors from the hoist.
3. Remove the bolts and nuts that keep the hoist (2) in position and remove it.
1-2. HOIST ASSEMBLY - INSTALLATION
1. Put the hoist in position and attach it to the structure with its bolts and nuts.
WARNING
OBEY ALL SAFETY PROCEDURES WHEN TO THIS OPERATION AND

MAKE SURE ALL ELECTRICAL SOURCES ARE OFF. THIS PREVENTS
ACCIDENTAL DETONATION OF THE CABLE-CUTTING CARTRIDGE.
2. Connect the electrical connectors to the hoist.

(BL20200-412) - WIRE ROPE CABLE
The load cable for the rescue hoist has a wire rope with a swaged stainless steel ball/shank fitting. The wire rope is a 0.1875
in (4.76 mm) diameter, corrosion resistant, preformed spin resistant type. It is also proof tested. During its fabrication, an
inert gas shielded electric arc process cuts off and bonds the drum end of the load cable, such that the cable end is sealed,
and made correct for attachment at the drum anchor point.

(BL20200-412) - TENSION ROLLER
The rescue hoist uses a tension roller system located between the cable guide and drum. The tension roller is driven by the
drum gear through an overrunning clutch, such that when reeling out, the tangential speed of the tension roller is faster than
the tangential speed of the drum, and maintains a “pull” force on the cable, also with no load. The tangential speed of the
tension roller is slower than the tangential speed of the drum when reeling in, gives a drag force on the cable and ensure that
the cable wraps on the drum are tight under all conditions.

(BL20200-412) - CONTROL PENDANT ASSEMBLY
The control pendant assembly provides the crewman with freedom of movement while utilizing the following control
features:
— Load mode select.
— Direction/speed control.
— ICS.
— Warning light.
— Cable payout display
— The direction/speed control thumb wheel is centrally located on the shrouded upper portion of the handgrip. Except
for the ICS switch, all controls are partially guarded to reduce the possibility of inadvertent operation. A bracket is
provided on the handgrip to facilitate stowing the pendant in the aircraft. The pendant is equipped with an electrical
connector for interfacing with the controller.
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— The 250 lb/600 lb (114/273 Kg) control is a two-position (maintained) toggle switch used to signal the system for either
the 250 lb/114 Kg mode or 600 lb/273 Kg mode.
— The heart of the control pendant is the direction/speed control mechanism containing and actuating two switches and
a potentiometer. Two of the switches (one for either direction) provide an on-off signal. The potentiometer is rotated
by the control thumb wheel to provide a speed command signal to the controller assembly.
The ICS control is a snap action switch provided for connection to the aircraft intercom system. The switch is operated by
an auxiliary actuator which protrudes from the back of the handgrip.
The cable payout display provides the hoist operator with a visual indication on the pendant of how much cable is extended
from the hoist in feet (on Control P/N CP700-1) or in meters (on Control P/N CP-700-2). The display is sunlight readable
and NVG compatible.
An Anvis green warning light provides the hoist operator with a visual indication of two fault conditions:
— Motor over temperature - Steady light.
— 250 lb/273 Kg overload - Blinking light.
Control pendant cable assembly, is supplied with the hoist system to interconnect the control pendant, and controller.
Adapter link cable assembly, is also supplied with the system to interconnect the controller with the aircraft’s dc power
supply.

(BL20200-412) - CONTROL PENDANT ASSEMBLY
The control pendant assembly provides the crewman with freedom of movement while utilizing the following control
features:
— Digital readout to indicate the quantity of cable paid out from the hoist.
— Direction/speed control.
— ICS (Inter Communication System).
— Warning light.
— SX-16 power controls (on Control P/N CP1500-6 and Control CP1500-16).
— The direction/speed control thumb wheel is centrally located on the shrouded upper part of the handgrip. A bracket on
the handgrip facilitates stowage of the pendant in the aircraft. The pendant includes an electrical connector and a digital
cable pay out to interface with the speed controller.
— The heart of the control pendant is the direction/speed control mechanism that contains and operates two switches and
a potentiometer. Two of the switches (one for either direction) provide an on-off signal. The potentiometer is rotated
by the control thumb wheel to provide a speed command signal to the controller assembly.
The ICS control is a snap action switch provided for connection to the helicopter intercom system. The switch is operated
by an auxiliary actuator which comes out from the back of the handgrip.
The cable payout display provides the hoist operator with a visual indication on the pendant of how much cable is extended
from the hoist. The display is sunlight readable and NVG compatible.
A green warning light gives to the hoist operator a visual indication of two fault conditions:
— Motor over temperature - Steady light.
— 250 lb (113 Kg) overload blinking light. This display is sunlight readable and NVG compatible. The NVG mode is set
by the pilot or hoist operator through a switch input to the control box.
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The control pendant assembly has searchlight controls that comprise an on/off/stow selector, and a direction control switch.
The on/off/stow switch applies power to the searchlight, and brings back the searchlight to the stowed position. The
four-position searchlight control switch permits to the hoist operator to control the searchlight to the right, left, extend or
return positions.
Control pendant cable assembly, is supplied with the hoist system to interconnect the control pendant, and controller.
Adapter link cable assembly, is also supplied with the system to interconnect the controller with the aircraft’s dc power
supply.
5-1. CONTROL PENDANT ASSEMBLY - REMOVAL
1. Disconnect the electrical power from the control pendant assembly.
2. Disconnect the electrical connector from the control pendant assembly.
3. Remove the control pendant assembly, with the control pendant cable, from the helicopter.
5-2. CONTROL PENDANT ASSEMBLY - INSTALLATION
1. Install the control pendant assembly on the support.
2. Connect the electrical connector to the control pendant assembly.
3. Let the control pendant cable in a stowed position in the cabin.

(BL20200-412) - CONTROL BOX
The control box is installed on the helicopter cabin roof inside of transmission firing.
6-1. CONTROL BOX - REMOVAL
1. Open the transmission fairing on the cabin roof.
2. Disconnect electrical connectors from central box.
3. Remove mounting hardware and remove the control box.
6-2. CONTROL BOX - INSTALLATION
1. Put the control box in position and secure it with mounting hardware.
2. Connect the electrical connectors.
3. Close transmission fairing.
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(BL20200-412) - RESCUE HOIST CABLE HANDLING
The following information is provided to facilitate maintenance personnel to observe good cable handling practices while
removing and installing the cable before and after maintenance on the cable.
— Rescue hoist cables are subjected to severe operating conditions. Properly applied operating technics and inspection
and maintenance procedures can extend cable life considerably and eliminate causes of fouling failures, resulting in a
greater degree of safety during hoisting operations.
— Rescue hoist cables are made of strands of stainless steel. Nineteen strands consisting of seven individual wires each
are used to achieve a flexible, spin-restraint cable.
— Cable strength is on the order of four times working load; therefore, cable breakage failures will not occur unless the
cable is damaged and proper maintenance guidelines are not followed.
— Proper hoist function depends on the wrap of the cable on the hoist drum and the cable load created by the tension
roller system. If the wrapped cable loses tension, fouling will occur.
7-1. RESCUE HOIST CABLE HANDING - CABLE INSPECTION AND MAINTENANCE
Refer to chapter 5 of AB-412-MPM and Hoist Manufacturer Manual.

(BL20200-412) - OPERATING OF LIMIT SWITCH SETTINGS
Refer to Hoist Manufacturer Manual.

(BL20200-412) - OPERATING OF LIMIT SWITCH SETTINGS
WARNING
WHEN NOT IN USE, THE HOOK MUST BE HOMED COMPLETELY IN THE

FULL IN POSITION TO AVOID FATIGUE OF THE CABLE NEAR THE BALL
END BECAUSE OF VIBRATION.
NOTE
In the operation of the hoist, the cable rate is automatically slowed to a safe speed
when the hoist is operated near the end of the cable travel (full in and full out) by
redundant, intermediate limit switches.
1. Redundant limit switches control full in, full out, and intermediate cable travel with the purposes that follow
(see figure 2):
a. The up intermediate switch (S1) slows down the rescue hoist speed when reeling in, and within a specified
distance from full in switch actuation.
b. The down intermediate switch (S1) slows down the rescue hoist speed when reeling out, and within a specified
distance from full out switch actuation.
c. The full out switch (S2) stops rescue hoist operation at a specified number of dead wraps on the cable drum.
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d. The full in switch (S3) stops rescue hoist operation when the bumper assembly makes contact with the cable
guide.
The limit switches are directly connected to the hoist drum to control full out and intermediate cable positions (hook
approach to helicopter and approach to full extension). The cable full in switch is built into the cable guide to ensure of
proper homing of the hook.

(BL20200-412) - CABLE CUTTER
WARNING
THE CARTRIDGE IS AN EXPLOSIVE DEVICE AND MUST BE SHIPPED,

KEPT AND HANDLED WITH REFERENCE TO ALL LOCAL STANDARDS
AND REGULATORY PRACTICES.
The hoist is equipped with a cable cutter that is located in the cable guide; it has an electrically fired pressure cartridge
(squib), a cable cutter, and an anvil to cut the cable in an emergency. At 28 Vdc, the minimum all-fire current of the cartridge
is 5.0 amp per bridge wire and the minimum no-fire current for the cartridge is 1,0 amp. The cartridge is contained in a
pressure cartridge kit, which is supplied with the system. The kit has one cartridge in a hermetically sealed container, three
shims, and one O-ring, all to be used for the installation of the cartridge.

(BL20200-412) - CABLE FOUL SENSOR
WARNING
OPERATION OF THE HOIST WITH A FOULED CABLE CAN CAUSE THE

CABLE TO BREAK AND CAUSE DANGEROUS INJURY OR DEATH. THE
CAUSE OF ANY CABLE FOUL FIRST MUST BE DETERMINED, AND THEN
THE PROBLEM CORRECTED, BEFORE THE HOIST IS PUT TO AN
OPERATIONAL CONDITION.
DO NOT TRY TO CLEAR A FOULED CABLE IN FLIGHT. A FOULED CABLE

MAY BREAK, AND THIS MAY CAUSE INJURY OR DEATH.
The hoist includes a cable foul sensor, which is a switch actuated safety device, and is mounted on the hoist’s flanges parallel
to the drum axis. This cable foul sensor is made to interrupt the power to the hoist motor if a cable foul develops on the hoist
drum, and to prevent possible cable breakage because of continued cable entanglement.

(BL20200-412) - VARIABLE SPEED CONTROLLER
The variable speed controller is a speed control which incorporates the latest pulse-width-modulated speed control
techniques.
Hoist speed control is done through a speed command applied to the controller from the variable speed operator’s pendant
control or from the constant speed priority override pilot’s control switch.
The greater the deflection of the thumb wheel on the hoist operator’s pendant control assembly, the greater average DC
voltage applied to the motor, hence, faster cable speeds.
25-91-00
Page 6 Rev. 3
E-AB412-PT6T-2
Full deflection of the thumb wheel on the pendant control assembly applies maximum voltage to the DC motor, hence,
maximum cable speed.
The signal that controls the direction of cable motion also is sent to the controller and processed by a circuit located in its
main board. The board includes a time delay that allows a minimum lapse of inactive time, which is recommended for proper
switching of hoist operation between cable up to cable down directions.
The variable speed controller, being highly efficient, dissipates minimal power. The heat sink on the side of the controller is
used to decrease heat from the controller and installation must be vertical with the heat sink that points up or horizontal for
heat dissipation.
12-1. VARIABLE SPEED CONTROLLER - REMOVAL
1. Disconnect the electrical power from the variable speed controller.
2. Disconnect the electrical connectors from the variable speed controller.
3. Remove the four screws from the variable speed controller.
4. Remove the variable speed controller from the helicopter.
12-2. VARIABLE SPEED CONTROLLER - INSTALLATION
1. Install the variable speed controller on the support.
2. Attach the variable speed controller to the support with the four screws.
3. Connect the electrical connectors to the variable speed controller.

(BL20200-412) - HOIST MAINTENANCE AND REFURBISHING
Refer to Hoist Manufacturer Manual.

(BL20200-412) - SLIDING PANEL INSTALLATION RH
14-1. SLIDING PANEL INSTALLATION RH - REMOVAL
1. Remove the cargo compartment sliding door.
2. Rotate sliding panel latch handle to open position.
3. Slide the panel aft out of tracks.
14-2. SLIDING PANEL INSTALLATION RH - INSTALLATION
1. Position the sliding panel on helicopter with forward edge in line with aft end of door tracks.
2. Start rollers and slider through cut-outs aft ends of tracks.
3. Push sliding panel forward.
25-91-00
Rev. 3 Page 7
E-AB412-PT6T-2
14-3. SLIDING PANEL INSTALLATION RH - INSPECTION
1. Visually inspect panel latch far binding, wear, damage and secure mounting.
2. Inspect structure, rollers and rollers support for damage, cracks, wear, deformation and damage.
3. Inspect panel window for damage.
4. Inspect panel seal for secure bonding and deterioration.

(BL20200-412) - CABLE PROTECTION
15-1. CABLE PROTECTION - REMOVAL
1. Remove screws and washers fixing the cable protection on skid assy.
2. Remove protection.
15-2. CABLE PROTECTION - INSTALLATION
1. Position the cable protection on skid assy and secure with screws and washers.
15-3. CABLE PROTECTION - INSPECTION
1. Inspect cable protection for wear and damage.
25-91-00
Page 8 Rev. 3
E-AB412-PT6T-2
A
8
5
B
9
10
A 3
11
1. Support assy 7. Control box assy (Controller)

2. Rescue hoist 8. Copilot hoist control panel
3. Cowlings 9. Cable
4. Hook assembly 10. Cable protection
5. Pendant control assy 11. Bumper assembly
6. Belt assy
G6AB1039A
Figure 1. External electrical rescue hoist installation
25-91-00
Rev. 3 Page 9
E-AB412-PT6T-2
FULL IN LIMIT SWITCH

ACTUATION
UP INTERMEDIATE LIMIT
SWITCH ACTUATION
4.5 TO 5.5 M
(14.8 TO 18 FEET)
USABLE
FULL SPEED CABLE LENGTH
CABLE TRAVEL 74,7 M (245 FEET)
DOWN INTERMEDIATE
LIMIT SWITCH ACTUATION
3 TO 5 M (9.8 TO 16.4 FEET)
FULL OUT LIMIT SWITCH ACTUATION

(3 ½ TO 4½ WRAPS ON DRUM)
G6AB1040B
Figure 2. Limit switch actuation
25-91-00
Page 10 Rev. 3
E-AB412-PT6T-2
25-91-01
25-91-01
EXTERNAL RESCUE HOIST - HOOK ASSEMBLY
1. HOOK ASSEMBLY - DISASSEMBLY
1. Pay out approximately 6 feet (1,8 meters) of wire rope cable to allow the hook assembly to rest on flat surface.
2. Remove power to hoist assembly.
3. Separate the bumper assembly from the hook assembly. Pull bumper assembly from top of sleeve (13, figure 1) then
slide it up wire rope cable toward the hoist assembly.
4. Remove and discard cotter pins (16). Remove locking screws (15) from hook assembly.
5. While holding the body (3), unthread nut (14) and remove bottom half of hook assembly.
CAUTION
PARTS LOCATED INSIDE OF HOOK ASSEMBLY WILL FALL FREE AFTER

DISENGAGEMENT OF NUT FROM HOUSING. PLACE THE HOOK
ASSEMBLY ON A FIRM SURFACE BEFORE REMOVING NUT.
6. Slide nut (14) and sleeve (13) up wire rope cable away from the ball end to expose terminal clamp (11).
NOTE
Terminal clamp (11) is two-piece matched set. Keep both halves together for future
use.
7. Remove retaining ring (18) from terminal clamp (11) to allow removal of terminal clamp, sleeve (13), nut (14) and
bumper assembly from wire rope cable.
8. Remove rubber bumper (10) with label (12) from bottom half of hook assembly.
9. Remove label (12) from rubber bumper (10), if required.
10. Align the holes in the body (3) to allow access to the spring pin (9) in the hook assembly. Gently tap out the spring pin
using a punch and a mallet. Discard spring pin.
11. Remove castellated nut (8) from hook assembly (1).
12. Remove body (3) from hook.
13. Remove bearing retainer (7) with preformed packing (6), needle thrust bearing races (4), needle thrust bearing (5), ball
bearing (2) from body (3).
14. Remove and discard preformed packing (6) from bearing retainer (7).
15. Remove spacer (17) from stem of hook.
25-91-01
Rev. 2 Page 1
E-AB412-PT6T-2
2. HOOK ASSEMBLY - ASSEMBLY
MATERIALS REQUIRED
NUMBER NOMENCLATURE
C-007 BEARING GREASE
1. Slide bumper assembly, nut (14, figure 1) then sleeve (13) up wire rope cable toward rescue hoist assembly. Install
terminal clamp (11) over ball end of cable and secure clamp with ring (18) over ball.
WARNING
ORIENTATION OF TERMINAL CLAMP DURING INSTALLATION IS

CRITICAL FOR PROPER LOAD CARRYING CAPABILITY OF THE HOOK.
THE RETAINING RING MUST BE ON THE END OF THE TERMINAL CLAMP
LOCATED CLOSEST TO THE HOOK WITH THE CHAMFERED, OR CONE
SHAPED, END OF THE TERMINAL CLAMP FACING TOWARD THE HOIST.
2. Slide sleeve (13) and nut (14) down cable until sleeve sits properly over terminal clamp (11).
3. Slide bumper assembly down to top surface of nut (14). Bumper must sit flush with top of nut.
4. Apply light coat of bearing grease (C-007), or equivalent, onto preformed packing (6) and install preformed packing
into groove of bearing retainer (7).
5. Completely coat needle thrust bearing (5) and both needle thrust bearing races (4) with bearing grease (C-007), or
equivalent, prior to installation.
6. Install ball bearing (2), needle thrust bearing race (4), needle thrust bearing (5), needle thrust bearing race (4) and
bearing retainer (7) with preformed packing (6) into body (3).
7. Install spacer (17) over stem of hook assembly (1). Install body (with components installed inside) onto stem of hook
assembly.
8. Install castellated nut (8) onto hook assembly and hand tighten until body is fully seated onto hook assembly.
9. Back castellated nut (8) off slightly to next nearest slot to allow pin hole in hook stem and slot in nut to be in line. Tap
in spring pin (9) using mallet and drift, through hole in body (3). Centralize pin with castellated nut.
CAUTION
ROTATE HOOK WHILE HOLDING HOUSING TO CHECK FOR BINDING OF

BEARINGS (2 AND 5). IF BINDING EXISTS, REMOVE SPRING PIN (9) AND
BACK OFF CASTELLATED NUT ONE ADDITIONAL GAP. INSTALL PIN
AND ROTATE HOOK WHILE HOLDING HOUSING TO CHECK FOR
BINDING OF BEARING AGAIN. REPEAT BINDING CHECK AND
REPOSITIONING OF NUT AS NECESSARY UNTIL BINDING IS
ELIMINATED. IF BINDING CONTINUES TO OCCUR, REPLACE BEARINGS
(2 AND 5).
10. If label is damaged or removed, peel off backing of new label (12), activate adhesive with alcohol and install new label
onto rubber bumper (10).
25-91-01
Page 2 Rev. 2
E-AB412-PT6T-2
11. Install rubber bumper (10) with label (12) onto body (3).
12. Install assembled hook parts onto nut (14) by threading body (3) and nut (14) together until bottomed.
13. Back off nut (14) to line up tapped holes with next nearest slots in body (3). Insert locking screws (15) and screw home
to bottom of slot in body. Ensure hook rotates freely.
14. Install cotter pins (16) in accordance with MS33540 through the slot in locking screw (15). If necessary back the screw
off ¼ turn prior to installing cotter pins. Ensure hook rotates freely.
15. Position the bumper assembly towards the hook assembly.
16. Power hoist to reel cable and hook assembly back to home position.
3. HOOK ASSEMBLY (P/N 412-8800-05-101) DISASSEMBLY/ASSEMBLY

(POST BT 412-103)
1. Disassembly the new hook assembly (figure 2) up to the bushing (2) by unscrewing the adapter (12), in order to allow
the hook assembly installation.
2. According to figure 2, connect the new hook assembly with the hoist cable as follows:
a. Install the new bumper assembly (1) and run it along the cable.
b. Insert the hoist cable end in the hole of the new adapter (12). Run it along the cable.
c. Using the applicable ring (11), connect both the parts of the new bushing (2) to the cable extremity.
d. Put the bushing (2) into the adapter (12).
e. Completely screw the new adapter (12) on the adapter (10) and rotate it back to find the correct alignment of the
holes.
f. Attach the adapter (12) to adapter (10) with the screw (9), the washers (3), the nut (4) and the cotter pin (5).
Check the correct alignment of the screw (8) connection holes.
g. Return the bumper assembly as shown in figure 2.
3. Apply the power supply to the hoist.
4. Using the control pendand, operate the hoist and roll up the cable.
5. Check the hoist for correct installation of the hook assembly:
a. Unroll the cable on the floor and attach a weight of 50 kg (110 lbs) to the hoist hook.
b. Slowly lift the load.
c. When the load is lifted, unroll the cable and put down the load again.
d. Unhook the load and roll up the cable.
25-91-01
Rev. 2 Page 3
E-AB412-PT6T-2
13 11
14
16
9
18
12
15
8 10
6 5
7 4
3
2
17
1. Hook 10. Rubber bumper

2. Bearing 11. Terminal clamp
3. Body 12. Label
4. Thrust washer 13. Sleeve
5. Thrust bearing 14. Nut
6. Preformed packing 15. Locking screw
7. Bearing retainer 16. Cotter pin
8. Plain nut 17. Spacer
9. Spring pin 18. Retaining ring
G6AB1041A
Figure 1. Hook assembly
25-91-01
Page 4 Rev. 2
E-AB412-PT6T-2
2
11 3
10
4
9
8 5
3
1. Bumper assembly
2. Bushing
3. Washer
4. Nut
5. Cotter pin
6. Hook
7. Pin
8. Screw
9. Adapter
10. Ring
11. Adapter
G6AB1042A
Figure 2. Hook assembly (P/N 412-8800-05-101)
25-91-01
Rev. 2 Page 5
E-AB412-PT6T-2
25-91-01
Page 6 Rev. 2
E-AB412-PT6T-2
25-91-02
INTERNAL RESCUE HOIST (P/N 214-706-003-103)
1. INTERNAL RESCUE HOIST (P/N 214-706-003-103) - DESCRIPTION
An electrical powered hoist is provided to enable pick-up or delivery of personnel or cargo in areas not suitable for helicopter
landing.
A receptacle is mounted centrally in the roof of the aft cabin to provide power to the hoist when the hoist is installed. The
hoist is a portable assembly. It consists of a winch with cable and hook, boom head, a control unit for the crewman operator
and accessories which include a safety vest, hoisting sling and straps for lifting a litter.
Two control locations for the operation of the hoist are provided: one for the pilot and one for the hoist operator. The pilot's
hoist control switch is located on the collective control stick; the hoist operator's controls are located on the hoist control
pendant.
The crew hoist operator's control has sufficient cord to permit full movement about the cabin. In operation, the boom
assembly electrically traverses outboard to position the boom head and cable beyond the skid landing gear. The boom
assembly will electrically traverse inboard when loaded to full capacity in order to assist in getting the load onboard.
An electrically initiated, ballistically actuated cable cutter (guillotine) is provided with two grounded electrical switches.
The pilot's cable cut switch (figure 1) is located on the center pedestal and the hoist operator's cable cut switch is mounted
on top of the hoist control box.
The hoist has a 90 m (260 ft) cable length (of which 76 m (250 ft) is usable) a 272 kg (600 lb) rate load and lift speed of 38
m (125 ft) per minute.
The system is powered by 28 V dc and is protected by three circuit breakers labeled HOIST CABLE CUT, HOIST PWR
and HOIST CONT.
The pilot has full override control over the crewman.
NOTE
Refer to Chapter 98 for Internal Rescue Hoist wiring diagram.
2. INTERNAL RESCUE HOIST (P/N 214-706-003-103) - REMOVAL
1. Disconnect battery and open left and right cargo doors.
2. Disconnect electrical cable from receptacle (4, figure 2), and from connector located near center of cabin roof.
3. Pull out quick release pin (12), disengage quick release fitting (1) from stud in floor of cabin and remove reaction
arm (10).
4. Pull and twist vertical adjustment detent (3).
5. Unlock and loosen vertical adjustment shaft (2) until quick release fitting (1) clears ceiling stud.
6. Remove hoist from helicopter.
25-91-02
Rev. 2 Page 1
E-AB412-PT6T-2
G6AB1008A
Figure 1. Internal hoist control panel
3. INTERNAL RESCUE HOIST (P/N 214-706-003-103) - INSTALLATION
MATERIALS REQUIRED
NUMBER NOMENCLATURE
1. Disconnect battery and make helicopter safe for ground maintenance.
2. Open left and right cargo doors.
3. Select position in cabin where hoist is to be used. (See figure 3).
NOTE
The hoist is shipped without lubricating oil. To fill unit to required level, it is
necessary to stand unit in a vertical position or install in aircraft to allow for more
convenient access to filler plugs.
4. Pull pin (12, figure 2) and remove reaction arm (10) from stowed position on hoist stanchion (8). Set arm side.
5. Rotate the base place pointer (13) on reactor base plate (15) to pre-selected cabin position shown on identification ring
(14) and aircraft position plate on cover (9). Install quick release positioning pin (11) thru (13) and (15).
25-91-02
Page 2 Rev. 2
E-AB412-PT6T-2
6. Lift the lock lever of switch (6) located on control box (7) and move to the preselected cabin position as shown on
decal (6), and position plate on cover (9).
7. Check quick release fittings as top and bottom of hoist for security, cleanliness and case of operation. Clean out any
debris from receptacles in floor and roof and aircraft.
CAUTION
REPLACE QUICK RELEASE FITTINGS IF THEY SHOW EVIDENCE OF

DAMAGE. HOIST IS TOO HEAVY. DO NOT ATTEMPT TO INSTALL WITH
INSUFFICIENT PERSONNEL.
8. Position bottom quick release fitting over stud in floor of cabin.
9. Pull and twist vertical adjustment detent (3). Align top locking stud in cabin roof.
CAUTION
IF HOIST IS TO BE USED IN AFT POSITION 2 OR 3 REMOVE AND STOW

THE CARGO DOOR UPPER LATCH PLASTIC GUARD.
NOTE
Store straps, vest and sling with aircraft loose equipment.
10. Tighten vertical adjustment screw (2) until quick release locking stud (1) bottoms on ceiling stud. Lock quick release
fitting and twist vertical adjustment detent (3). Back vertical adjustment shaft down until detent engages.
11. Position arm length and position quick release locking stud (1) over stud in floor of cabin.
12. Adjust arm length and position quick release locking stud (1) over stud in floor of cabin.
CAUTION
ENSURE THAT LOCKING COLLARS ON QUICK RELEASE LOCKING STUD

(3 PLACES) ARE LOCKED BY THEIR DETENTS LEVERS.
13. Plug connector of cable assembly into connector, located near center of cabin roof.
14. Plug connector of cable assembly into power cable receptacle (4) located on top of winch. Perforate insulated tubing
on cable assembly to provide drainage. Use 1/8 in (3.175 mm) in diameter hole at lowest point in tubing.
15. Remove filler plugs on both sides of boom head and winch and add required lubricant until oil level sight glass
indicates proper amount. There are three plugs to remove for filling. Lockwire must be removed and replaced during
this operation.
NOTE
Fill the fuelmark of glass with hydraulic fluid (C-107) for operation below -40°F
(-40°C). Drain and refill with hydraulic fluid (C-002).
25-91-02
Rev. 2 Page 3
E-AB412-PT6T-2
1. Locking stud 8. Stanchion 16. Plate

2. Screw adjustment 9. Cover 17. Attaching parts
3. Spring detent 10. Reaction arm 18. Cable cutter and lanyard
4. Power cable receptacle 11. Positioning pin and hole 19. Pouch
5. Lower stanchion support 12. Pin-traverse arm 20. Strap
6. Lock lever switch and 13. Pointer-base plate 21. Overtemperature light
instruction decal 14. Identification ring-position 22. 20 foot warning light
7. Control box 15. Base plate-reactor
G6AB1009B
Figure 2. Hoist installation
25-91-02
Page 4 Rev. 2
E-AB412-PT6T-2
CAUTION
IF HOIST IS TO BE USED IN AFT POSITION 2 OR 3, REMOVE AND STOW

THE CARGO DOOR UPPER LATCH PLASTIC GUARD.
NOTE:
Store straps, vest and sling with aircraft loose equipment.
G6AB1010B
Figure 3. Hoist locations
25-91-02
Rev. 2 Page 5
E-AB412-PT6T-2
4. INTERNAL RESCUE HOIST (P/N 214-706-003-103) - OPERATIONAL CHECK
1. Visually inspect the internal rescue hoist installation for defective components, wiring, and rigging. Check all moving
parts for freedom of movement. Check that cable is properly installed on hoist and that it is properly positioned in the
pulleys. Check that all hoist circuit breakers are open and all hoist switches are the OFF position.
2. Disconnect plug on cable cutter electrical cable assembly receptacle on control unit. Energize the 28 V dc buses. Close
CABLE CUT circuit breaker. Check for no voltage between pins A and B (ground) of cable cutter receptacle.
3. Close CABLE CUT switch on pedestal control panel. Check for approximately 28 V dc between pins A and B of cable
cutter receptacle.
4. Open CABLE CUT switch on pedestal control panel. Check for no voltage between pins A and B of cable cutter
receptacle.
5. Repeat steps 3. and 4. except use CABLE CUT switch on hoist control panel. Check for no voltage between pins A
and B of cable cutter receptacle on control unit regardless of position of CABLE CUT switch on hoist control panel.
6. Open CABLE CUT circuit breaker. Close HOIST POWER circuit breaker. Close CABLE CUT switch on hoist control
panel. Check for approximately 28 V dc between pins A and B of cable cutter receptacle on control unit.
7. Open CABLE CUT switch on hoist control panel. Check for no voltage between pins A and B of cable cutter receptacle
on control unit.
8. Repeat steps 6. and 7. except use CABLE CUT switch on pedestal control panel. Check for no voltage between pins
A and B of cable cutter receptacle regardless of position of the CABLE CUT switch on pedestal control panel.
9. Open HOIST POWER circuit breaker. Reconnect cable cutter plug. Check that conductor is properly mated, tight and
secure.
10. Close ICS circuit breakers and adjust each ICS station for normal interphone operation. Actuate ICS switch on the hoist
control pendant. Check for normal communication between hoist operator and each ICS station.
11. Place HOT MIC switch on the right hand crew ICS panel to ON. Check that hoist operator's microphone is
continuously energized allowing him to communicate with other ICS stations without operating ICS ”talk” switch on
the control pendant.
12. Return HOT MIC switch to OFF. Check for normal communication using the ICS ”talk” switch on the control pendant.
13. Close HOIST POWER and HOIST OVERLOAD circuit breakers and press pilots HOIST CONT switch.
14. Press pilots HOIST CONT switch to DN. Check that hoist hook is lowered at constant speed and stops when switch is
released.
15. Press pilots HOIST CONT switch to UP. Check that hoist hook is raised at constant speed and stops when switch is
released.
16. Press pilots HOIST CONT switch to UP and check that cable is stopped by the up-limit switch.
17. Press pilots HOIST CONT switch to IN. Check that hoist boom swings in and stops when hoist is in the stowed
position.
18. Press the boom actuator switch on the control pendant to the OUT position. Check that hoist boom swings out. Check
that the boom switch returns to center position.
25-91-02
Page 6 Rev. 2
E-AB412-PT6T-2
19. Slowly press the pendant DOWN-UP switch toward the DOWN-FAST position. Check that the cable is let out slowly
and increases in speed as the cable control is pressed nearer the extreme DOWN-FAST position. When the cable
control is pressed to the DOWN-FAST position, the cable should be unreeling at the maximum speed. Check that cable
remains taut while unreeling and that cable is stopped by the down limits switch when approximately three turns of
cable remain on the drum.
20. Slowly press the pendant DOWN-UP switch toward the UP-FAST position. Check that the cable is reeled in slowly
and increases in speed as the cable control is pressed nearer extreme UP-FAST (aft) position. When the cable control
is pressed to the extreme UP-FAST position, the cable should be reeling in at the maximum speed.
21. Continue to reel in the cable. Check that 20 FOOT WARNING light illuminates when approximately 8 m (26 ft) of
cable remains to be reeled in.
22. Release switch to stop cable travel a few inches before reaching the full up position. Beep the hoist switch to the UP
position until cable is stopped by the up-limit switch. Check that cable is stopped when hook reaches the full UP
position and before excessive strain or tension is placed on the cable.
23. Press hoist switch on pendant to DN position. After downward travel of cable begins, press pilots hoist switch to UP
to check pilots override capability. Cable should reverse direction and travel upward.
24. Press hoist switch on pendant to UP position. After upward travel of cable begins, press pilots HOIST CONT switch
to DN to check pilots override capability. Cable should reverse direction and travel downward.
25. Press hoist switch on pendant to UP and boom switch on pendant to IN. Check that cable reels in and stops, the boom
travels in and stops, and that hoist stops in the stowed position.
5. INTERNAL RESCUE HOIST (P/N 214-706-003-103) - TROUBLESHOOTING
Table 1. Internal rescue hoist troubleshooting
Rescue hoist inoperative. No power input. Check external power.
POWER-ON indicator does not glow. Defective input power cable. Disassemble control panel and
replace cable. (Refer to Manufacturer
Publication).
POWER-ON indicator does not glow. Defective POWER-ON indicator. Replace indicator lamp. (Refer to
paragraph "8. Internal rescue hoist (P/
N 214-706-003-103) - up-limit switch
adjustment").
Hoist boom inoperative when Boom In Control connector cable not Connect control connector cable of
Out switch is activated. connected. the control pendant assembly.
Defective control connector cable. Replace control connector.
Boom motor cable not connected. Connect boom motor cable.
25-91-02
Rev. 2 Page 7
E-AB412-PT6T-2
(Cont.d)
Boom motor cable defective. Replace.
Boom IN OUT switch defective. Replace control pendant assembly.
Defective electric motor. Remove, and disassemble boom

position actuator and support
assembly. Disassemble motor and
repair. (Refer to Manufacturer
Publication).
Boom position switch in wrong Place boom position switch in proper

setting. setting.
Boom position switch defective. Disassemble control panel and

replace switch. (Refer to
Manufacturer Publication).
Defective limit switch assembly. Remove switch from winch

assembly. Disassemble limit switch
assembly and replace defective
component. (Refer to Manufacturer
Publication).
Hoist boom does not swing full 90°. 90° cam not adjusted properly. Adjust 90 limit cam. (Refer to
Limit switch assembly not adjusted Adjust limit switch assembly. (Refer
properly. to Manufacturer Publication).
Defective limit switch assembly. Remove switch from winch

assembly. Disassemble limit switch
assembly and replace defective
component. (Refer to Manufacturer
Publication).
Hoist winch inoperative when hoist UP Control connector cable not Control control connector cable of the
DWN switch is activated. connected. control pendant assembly.
Defective control connector cable. Replace control connector.
Defective relays. Disassemble control panel assembly

and replace relay. (Refer to
25-91-02
Page 8 Rev. 2
E-AB412-PT6T-2
(Cont.d)
No positive action deceleration when Limit switch drive assembly drive Connect limit switch drive assembly
rescue hook is within 1 m (3 ft) of down cable not connected. cable.
limit stop during reelout or 0.30 m (1 ft)
from up stow position. Limit switch(s) in limit switch drive Adjust limit switch(s). (Refer to
assembly not adjusted properly. Manufacturer Publication).
Limit switch drive assembly or Remove limit switch assembly from

cable defective. winch assembly. Disassemble limit
switch assembly and replace
defective component. (Refer to
Defective deceleration control Disassemble control panel assembly

circuit component(s) in logic PC and replace defective component(s)
board. on logic PC board. (Refer to
20-FOOT CAUTION indicator does not Defective 20-FOOT CAUTION Replace indicator lamp. (Refer to
glow when cable hook is within 8 m (26 ft) indicator lamp. Manufacturer Publication).
from up stow position.
20-FOOT CAUTION limit switch Disassemble limit switch assembly
out of adjustment. and replace switch.
Defective limit switch drive Disassemble limit switch assembly

assembly cable. and replace cable.
Defective control circuits Disassemble control panel assembly

component(s) in logic PC board. and replace defective components on
logic PC board.
Cable speed when operated at maximum is Defective hoist UP FAST OFF Replace control pendant assembly.
less than 30 m/min (100 f/pm). FAST DWN switch.
Defective voltage regulator Disassemble control panel assembly

(LM109K) in PC power supply and replace voltage regulator.
board.
Defective electric winch motor. Disassemble motor and repair.
Defective component(s) in PC logic Disassemble control panel assembly

board. and replace defective component(s)
on PC logic board.
25-91-02
Rev. 2 Page 9
E-AB412-PT6T-2
(Cont.d)
Cable speed when operated at minimum is Defective hoist UP FAST OFF Replace control pendant assembly.
more than 5 m/mm (15 f/pm). FAST DWN switch.
Defective voltage regulator Disassemble control panel assembly

(LM109K) in PC power supply and replace voltage regulator. (Refer
board. to Manufacturer Publication).
Defective electric winch motor. Disassembly winch motor and repair.

(Refer to Manufacturer Publication).
Defective component(s) in PC logic Disassemble control panel assembly

board. and replace defective component(s)
on PC logic board. (Refer to
No positive brake action. Defective brake assembly. Disassemble winch assembly.

Disassemble brake assembly and
replace defective component. (Refer
to Manufacturer Publication).
Hoist cable does not maintain proper cable Defective level wind screw Disassemble winch assembly and
position on hoist drum. assembly. replace defective component. (Refer
Electric winch motor overheats. Defective winch motor. Disassembly winch assembly and
replace defective component. (Refer
Obvious overheating temperature warning Defective temperature warning Replace. (Refer to Manufacturer
indicator does not glow. indicator lamp. Publication).
Defective thermal switch. Replace. (Refer to Manufacturer

Publication).
Winch assembly overheats. Oil level low. Add oil.
Boom head assembly overheats. Oil level low. Add oil.
Pilot's override controls inoperative. Defective power input cable. Disassemble control panel and
replace cable. (Refer to Manufacturer
Publication).
Defective component(s) in PC logic Disassemble control panel and

board. replace defective components. (Refer
25-91-02
Page 10 Rev. 2
E-AB412-PT6T-2
(Cont.d)
Intercom inoperative. Defective intercom switch. Replace control pendant assembly.
6. INTERNAL RESCUE HOIST (P/N 214-706-003-103) - CABLE REPLACEMENT
1. Reel cable of the drum (see figure 4) until the cam switches shut the winch motor off.
NOTE
There should now be approximately 5 wraps of cable remaining on the drum.
2. View instruction plate (figure 4) and locate switch 1, Down All Stop. Loosen cam per instructions and rotate away
from switch.
3. Slowly reel cable down with pendant control unit one wrap remains.
4. Remove all covers shown, and insert holding screw. Remove cable retainer with required allen wrench. When cable
end is free, cable can be pulled free and guided out thru cartridge cutter and under rollers.
CAUTION
DO NOT MOVE CABLE DRUM BECAUSE TIMING WILL BE CHANGED.
5. Inspect cable cutter, blade, and squib as follows:
a. Disconnect electrical plug.
b. Remove and inspect squib.
c. Inspect that cutter edge is just below cable slot ensuring that cable will not rub on edge during operation. This
will also ensure shear screw inside of cutter is locked in place.
6. Insert new cable by raising rollers and guiding through cable cutter. Make one wrap around drum and trap ball in drum
pocket with retainer. Tighten down and check cable lay to insure that it falls in proper groove.
7. Slowly push hoist UP button on pendant and reel in cable until three wraps are visible and laying in drum groove
properly. Adjust cam switch 1, until switch adjust actuates and tighten. Check by reeling more cable onto drum and
then reeling off cable until switch 1 shuts hoist off. Three wraps should be visible. Repeat procedure until correct.
8. When previous step is completed repeat procedure for five wraps using a switch 2 cam. Insure that both switch 1 and
switch 2 are tightened down and cannot rotate on shaft after setting.
9. Replace covers and reel remaining cable onto drum checking for proper lay of each wrap.
10. Check ”20 foot-caution” cam setting 8 m (26 ft) of cable between cable hook and boom head reset cam 3 is required
to 8 ± 0.8 m (26 ± 2 ft).
a. Check UP DECEL switch 4 position by reeling cable up slowly until there is 0.6 to 0.3 m (2.0 to 1.0 ft) between
hook disc and up limit switch actuator assembly. Reset cam 4 if required.
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E-AB412-PT6T-2
7. INTERNAL RESCUE HOIST (P/N 214-706-003-103) - CABLE CUTTER

REFURBISHMENT
1. After each firing, or when squib has been determined to require replacement, refurbish as follows:
a. Disconnect electrical power, and remove connector from cable cutter.
b. Using instruction with refire kit, remove unserviceable parts.
c. Clean cutter with cleaning solvent. Interior bore of body may require light burnishing.
d. Install new parts in refire kit, using instructions furnished with kit.
CAUTION
ENSURE THAT HELICOPTER ELECTRICAL POWER IS DISCONNECTED.
e. Reinstall electrical connector on squib.
8. INTERNAL RESCUE HOIST (P/N 214-706-003-103) - UP-LIMIT SWITCH

ADJUSTMENT
1. Bend back torque of up-limit switch actuator (1, figure 5) to allow arm (2) to droop below boom head (3)
approximately 0.75 in (19.05 mm). Arm is shown in switch-just-actuated position with arm droop approximately 0.44
in (11.2 mm).
2. Loosen switch mounting screws (4) and adjust switches (5) to just open (click). Switches need not operate
simultaneously but should both actuate with droop between 0.5 and 0.3 in (12.7 and 7.6 mm).
9. INTERNAL RESCUE HOIST (P/N 214-706-003-103) - LIGHTS REPLACEMENT
1. Remove associate wiring to control panel indicators (on top of cover (7, figure 2)) and overtemperature light (21 and
22) shroud.
2. Unscrew indicator lights and lamp and remove indicators.
3. Remove logic side cover assy (7) by removing screws. Remove lights from shroud.
25-91-02
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E-AB412-PT6T-2
1. Hoist cable 11. Cable retainer

2. Actuator 12. Cable drum
3. Pressure roller 13. Cover, chain guard
4. Cover, pressure roller 14. Box, cam switch
5. Cap, cable cutter 15. Instruction plate
6. Anvil 16. Cable cutter
7. Cover, upper post 17. Sheave pulley
8. Screw 18. Screws
9. Washer 19. Washers
10. Extracting screw (10-32 unf) 20. Screws
G6AB1011B
Figure 4. Cable replacement and instruction plate
25-91-02
Rev. 2 Page 13
E-AB412-PT6T-2
1. Up-limit switch actuator

2. Arm
3. Boom head
4. Mounting screw
5. Switch
G6AB1012B
Figure 5. Up-limit switch adjustment
25-91-02
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E-AB412-PT6T-2
25-92-00
EXTERNAL RESCUE HOIST [B]
1. EXTERNAL RESCUE HOIST (P/N 212-8800-01-101) [B] - DESCRIPTION
The rescue hoist is secured to a support installed on the RH side of the helicopter roof.
Maximum loads are 600 lb (272 kg). The hydraulic motor drives the cable drum which can reel in or pay out 240 ft (73 m)
of 3/16 in (4,76 mm) diameter corrosion-resistant steel cable. The self-energizing type brake enables the operator to stop the
cable at any desired length and hold it in place, with or without a load.
The drum and brake housings are partially filled with oil for lubrication and cooling. The level wind mechanism serves to
distribute cable evenly on the reel and limit switches provide automatic stopping of the hoist at extreme upper and lower
cable positions. An intermediate limit switch actuates the flow control valve to limit the speed to 98 ft/min (30 m/min) when
about 7,0 ft (2,1 m) from full extend or retract. This to assure the reeling-in speed reduction when the hoist is still below
landing gear skid.
A ballistic-type guillotine cartridge permits shearing of the hoist cable in case of emergency. An oil filler hole and sight gage
on the hydraulic motor-end of the hoist housing are used for servicing the hoist.
2. EXTERNAL RESCUE HOIST (P/N 212-8800-01-101) [B] - REMOVAL
1. De-energize current and remove outer fairing (10, figure 1).
2. Disconnect lines from hoist and collect fluid in a suitable container.
3. Disconnect electrical connectors from hoist.
WARNING
OBSERVE ALL POSSIBLE PRECAUTIONS WHEN PERFORMING THIS

PROCEDURE AND ENSURE THAT ALL ELECTRICAL SOURCES ARE
S W I T C H E D O FF T O P R E V E N T A C C I D E N T A L D E T O N A T I O N O F
CABLE-CUTTING CARTRIDGE.
4. Rescue hoist:
a. Remove rescue hoist (1) by unscrew the two screws (5 and 6) with washer, nuts and cotter pins.
b. Remove the inner fairing (11) and plate (2) from support (3) by unscrew the two eyebolts (5 and 6) with washers
and nuts.
5. Support.
a. Remove the hoist support (3) by unscrew the four bolts (7) that fix support legs to the fittings located on
helicopter cabin roof.
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E-AB412-PT6T-2
3. EXTERNAL RESCUE HOIST (P/N 212-8800-01-101) [B] - INSTALLATION
1. Support:
a. Place the hoist support ends in the fittings located on helicopter cabin roof. Verify that all hoist support legs are
fitted so that the hoist can not jiggle. Install four bolts with washers, torque 100 to 140 in-lbf (115,2 to 161,3
kgf·cm).
2. Rescue hoist:
a. Place the inner fairing (11, figure 1) and plate (2) on support (3).
To perform this action two coupled eyebolt (4 and 5) shall be used:
Two eyebolts P/N 212-8800-10-1 with washer P/N NAS1149D0663K nuts P/N MS21043-6, torque to 70-90
in-lbf (80,6-103,7 kgf·cm).
Two eyebolts P/N 212-8800-09-1 with washer P/N NAS1149D0763K nuts P/N NAS1291-7, torque to 110-150
in-lbf (126,7-172,8 kgf·cm).
b. Insert the hoist fitting tangs on the eyebolts and install the hoist on the support. To carry out this operation two
coupled screws (6) shall be used:
Two screws P/N AB26-26, with two washers P/N NAS1149F0663P, nuts P/N AN320-6, cotter pins
P/N MS24665-300, torque to 95-110 in-lbf (109,4-126,7 kgf·cm).
Two screws P/N AN24-26 with two washers P/N NAS1149F0463P, nuts AN320-4, cotter pins
P/N MS24665-153, torque to 30-40 in-lbf (34,6-46,1 kgf·cm).
3. Connect electrical connectors to hoist.
WARNING
OBSERVE ALL POSSIBLE PRECAUTIONS WHEN PERFORMING THIS

PROCEDURE AND ENSURE THAT ALL ELECTRICAL SOURCES ARE
S W I T C H E D O FF T O P R E V E N T A C C I D E N T A L D E T O N A T I O N O F
CABLE-CUTTING CARTRIDGE.
4. Connect lines to hoist.
5. Replace cowling.
6. Replenish system and operate hoist to bleed system.
4. EXTERNAL RESCUE HOIST (P/N 212-8800-01-101) [B] - RESCUE HOIST TEST
1. Connect hoist hydraulic system to a suitable test bench: pressurize to 3000 psi (211 kgf/cm²).
2. Operate hoist via manual selector valve and payout cable to a length of 7,0 ft (2,1 m) then recover cable.
Check that raising and lowering speed can vary between 0 to 98 ft/min (0 to 30 m/min).
3. Fully recover cable via manual selector valve. Ensure that upper limit switch shuts off hoist motor. Check that in the
event of a possible fault, limit switch does not prevent hoist from being operated.
4. Operate hoist manually and payout cable to about 7,0 ft (2,1 m). Verify that lowering cable from 7,0 to 235,0 ft (2,1 to
71,6 m) can vary from 0 to 197 ft/min (0 to 60 m/min).
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E-AB412-PT6T-2
NOTE
Payed out cable should be placed in a suitable container.
If not available, wind cable on a cleaned surface.
5. Completely payout cable ensuring that lower limit switch operates correctly and that lowering speed during last 7,0 ft
(2,1 m) decreases to 98 ft/min (30 m/min). Fully recover cable and verify that reeling-in speed reduces when the hook
is theoretically still below landing gear skid.
6. Set switch on central pedestal to PILOT position and switch on pilot's collective lever to DOWN position. Ensure that
lower limit switch shuts off hoist when cable is completely payed out. Lowering speed should be constant and should
correspond to 98 ft/min (30 m/min).
7. Set switch on collective lever to UP position. Ensure that upper limit switch shuts off hoist when cable has been
completely recovered. Raising speed should be constant and should correspond to 98 ft/min (30 m/min).
8. Set switch on pedestal to CREW position.
9. Pay out cable by setting manual selector valve lever to DOWN position or by setting switch on crew pendant control
to DOWN position.
10. Attach a weight of 300 lb (136 kg) to hook.
11. Rewind cable setting lever to UP position or switch to DOWN.

Ensure that upper limit switch shuts off hoist when cable is completely recovered and that the weight does not unwind
cable.
12. Lower cable and remove weight.
13. Pay out 29,5 ft (9,0 m) of cable and mark off a length of 19,7 ft (6,0 m).
14. Operate hoist by actuating manual selector valve lever, recover and pay out the 19,7 ft (6,0 m) of marked off cable.
Time taken must be 5 to 6 seconds for the recovery of cable and 5 to 6 seconds for the pay out.
15. By means of switch on crew pendant control, operate hoist and repeat procedure described in above step. Time taken
for recovery and pay out of cable must be 10 to 15 seconds for each operation.
16. Set switch on central pedestal to PILOT position and by operating hoist via switch on pilot's collective lever repeat
procedure described in step n. above. Time taken for recovery and pay out of cable must be 10 to 15 seconds for each
operation.
17. Remove marks marking off the 19,7 ft (6,0 m) of cable.
18. Manual operate directional control valve. Operate hoist via manual selector valve lever and ensure that hoist operates
smoothly.
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E-AB412-PT6T-2
1. Rescue hoist
2. Plate
3. Support
4. Eyebolt (upper)
5. Eyebolt (lower)
6. Screw
7. Bolt
8. Hook assy
9. Hoist operator safety belt bracket
10. Outer fairing
11. Inner fairing
G6AB0813B
Figure 1. External rescue hoist (sheet 1 of 3)
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E-AB412-PT6T-2
G6AB0814A
25-92-00
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E-AB412-PT6T-2
G6AB0815A
25-92-00
Page 6 Rev. 1
E-AB412-PT6T-2
5. EXTERNAL RESCUE HOIST [B] - ADJUSTMENT OF THE LIMIT SWITCHES
MATERIALS REQUIRED
NUMBER NOMENCLATURE
C-556 SEALING COMPOUND
NOTE
Before you adjust the limit switches, install the hoist with its hook, handwheel and
cable on the helicopter.
1. Adjust the limit switch (11, figure 2) as follows:
a. Wind off 3,0 to 4,0 ft (0,9 to 1,2 m) of cable from the drum.
b. Remove the screws (15) that keep the switch cover (14) and gasket (13) in position. Remove the switch cover
(14) and the gasket (13).
c. Wind in the cable. To make sure that the switch (11) operates correctly, do the operations below:
d. Apply a force of 1 or more kilograms to the pin (12) through the compression of bumper (1, figure 3).
e. Switch (11, figure 2) must stop the drum rotation at the cable's end of travel.
f. If necessary, loosen the screws that hold the switch and adjust it. Continue to adjust the switch, until it operates
at the conditions of step 1.c. above. Tighten the screws, that attach the switch.
2. Adjust the limit switch (9) as follows:
a. Remove the screws (1) and washers to release the cover (2) and gasket (3).
b. Wind off the cable from the drum and let it into a container. Switch (9) must stop the drum rotation when there
are approximately 3 to ½ turns of cable remaining on the drum.
c. Loosen the adjustable screws (8) that attach full-out cam. Put the cam (7) in the correct position and tighten the
screws (8). Wind back the cable on the drum.
d. Apply a layer of sealing compound (C-556) to both sides of gasket (3). Install the gasket and cover (2) with the
screws (1) and the washers.
3. Adjust the switch (5) as follows:
a. Remove the screws (1) and washers to release the cover (2) and gasket (3).
b. Wind off 7,0 ft (2,1 m) of cable from the full-in position. Adjust the cam (6) until the switch operates as
necessary. After adjustment of the cam, wind off the cable and let it into a container. Switch (5) must operate 7,0
ft (2,1 m) before the full-out position.
c. Fully wind the cable back on the drum and verify reeling-in speed reduces when the book is theoretically still
below landing gear skid.
d. Apply a layer of sealing compound (C-556) to both sides of gasket (3). With the same compound, fill the hole
of the electric cable duct.
e. Install the gasket and the cover (2) with the screws (1) and washers.
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Rev. 1 Page 7
E-AB412-PT6T-2
1. Screw 16. Cable guide

2. Cover bushing
3. Gasket 17. Retaining ring
4. Winch assembly 18. Cable guide
5. Switch bracket
6. Cam 19. Screw
7. Cam 20. Guide bar
8. Screw 21. Anvil cap
9. Switch 22. Cable cutter
10. Chain 23. Packing
11. Switch 24. Screw
12. Pin 25. Setscrew
13. Gasket 26. Cable guide
14. Cover 27. Packing
15. Screw 28. Cartridge
G6AB0782B
Figure 2. Rescue hoist assembly
25-92-00
Page 8 Rev. 1
E-AB412-PT6T-2
1. Bumper assembly 9. Nut attachment

2. Split bushing 10. Ball bearing
3. Snap ring 11. Pin
4. Swaged ball 12. Clamp nut
5. Handwheel 13. Hook
6. Threaded adapter 14. Roll pin
7. Nut 15. Pin
8. Washer
G6AB0783B
Figure 3. Rescue hoist, handwheel and bumper
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E-AB412-PT6T-2
25-92-00
Page 10 Rev. 1
E-AB412-PT6T-2
25-92-01
EXTERNAL RESCUE CABLE CUTTING CARTRIDGE
1. EXTERNAL RESCUE CABLE-CUTTING CARTRIDGE - DESCRIPTION
The rescue hoist cable-cutting cartridge (28, figure 1) is installed in the cable guide of the winch assembly (4).
2. EXTERNAL RESCUE CABLE-CUTTING CARTRIDGE - REMOVAL
1. Remove the external cowling of the rescue hoist.
2. Disconnect the electrical connector form the cartridge (28).
3. Remove the cartridge (28) and the packing (27).
3. EXTERNAL RESCUE CABLE-CUTTING CARTRIDGE - INSTALLATION
1. Install the cartridge (28) with a new packing (27) on the cable guide (26) of the winch assembly (4).
2. Connect the electrical connector to the cartridge (28).
3. Install the external cowling of the rescue hoist.
25-92-01
Rev. 1 Page 1
E-AB412-PT6T-2

2. Cover bushing
5. Switch bracket
6. Cam 19. Screw
G6AB0782B
25-92-01
Page 2 Rev. 1
E-AB412-PT6T-2
25-92-02
EXTERNAL RESCUE HOIST CABLE
1. EXTERNAL RESCUE HOIST CABLE - DESCRIPTION
The hoist cable is made of a 3/16 in (4,76 mm) diameter, 19x7, corrosion resistant steel with spin resistant characteristics.
Length of cable is 250 ft (76 m), cable usable length is 240 ft (73 m), allowing 3 to 3 ½ turns of cable to remain on drum.
2. EXTERNAL RESCUE HOIST CABLE - REMOVAL
1. Remove external fairing of the rescue hoist.
WARNING
KEEP HANDS AND CLOTHING CLEAR OF THE DRUM MECHANISM TO

PREVENT INJURIES.
2. Operate the hoist and wind off the cable into a container, until the down limit switch (9, figure 1) stops the hoist.
3. Remove the cover (2) and gasket (3).
4. Manually jog the switch (9). Continue until you can see on the drum flange the screws that attach the cable to the drum.
5. Remove the anvil cap (21) and the cable cutter (22).
6. Remove the set screws (cable-drum) from the drum flange
7. Push the cable aft through the rollers to loosen I on the drum. Remove the formed end of cable from the slot in the
drum flange.
8. Pull the cable to put its formed end in position at the entrance to the cable guide bracket (18). Remove the screws (19)
and the guide bar (20) Remove the screws (24) to release the guide bracket (18) and let it go off in cable end.
9. Pull the cable through the rollers. Be careful not to cause any damage to the rubber roller covers.
10. Move the cable guide casting until you see the guide bushing (16) and retainer (17).
Remove the retainer and the bushing. Pull the cable through the cable guide casting until it is free.
11. Loosen the set screw (25). Remove the cable guide (26) and inspect it for wear. Replace it, if necessary.
12. If necessary, remove the hook, the handwheel and bumper from the cable.
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E-AB412-PT6T-2

2. Cover bushing
5. Switch bracket
6. Cam 19. Screw
G6AB0782B
25-92-02
Page 2 Rev. 1
E-AB412-PT6T-2
3. EXTERNAL RESCUE HOIST CABLE - INSTALLATION
1. Move the cable guide housing until you see the hole for guide bushing and retainer.
2. Let the formed end to cable through the cable guide housing. Put the guide bushing (16) and retainer (17) in position
over the formed end of cable. Install the guide bushing and retainer in housing.
3. Make a loop with formed end of cable and push the cable through the rollers. Be careful not to damage the rubber roller
covers.
4. Install cable guide bracket (18) with the screws (24). Install guide bar (20). Let the formed end of cable through the
cable guide bracket.
5. Pull as much cable as necessary through cable guide housing, rollers and bracket to permit 4 wraps around the drum.
6. Position the formed end of cable in the slot of the drum flange.
NOTE
Make sure that the cable is inserted fully into the drum flange and that the white
marking is barely visible prior to securing with the cable set screw (see figure 2)
7. Tighten the set screw by applying a torque of 4,0 to 5,0 lbf·in (4,6 to 5,8 kgf·cm).
8. Apply tension to the cable, outboard of the cable guide, to remove slacks in the cable.
9. Make sure that hoist cable is vertically tangent to hoist drum with no wraps left, and the set screws positioned at 10 o'
clock. Verify the proper anchoring of hoist cable by applying a static load of 30 to 35 lb (14 to 16 kg) to the hoist cable
for one minute, using cable grip P/N A6170-99047-101.
10. Carefully wind in the cable. As the cable winds in, make it clean with a clean cloth.
11. Make sure that the cable guide moves in the correct direction and leads the drum groove lightly. If necessary, remove
the chain (10) from the drive sprocket and move the sprocket manually to adjust the level wind. Do this operation until
the level wind is in the correct position.
Install the chain back in position.
12. Install the cable cutter (22), packing (23), and anvil cap (21).
13. If removed, install the hook, handwheel and bumper (refer to module 25-92-03 "EXTERNAL RESCUE HOIST,
HANDWHEEL AND BUMPER").
14. Do the operational check and adjust the limit switches as necessary.
4. EXTERNAL RESCUE HOIST CABLE - INSPECTION
1. Inspect the hoist cable (See figure 3) for broken strands, kinks, twists, corrosion, fraying and wear. If you find one of
these defects, replace the cable.
2. Carefully inspect the cable winding mechanism to prevent fretting wear.
3. During the hoist functional test and while you wind in the cable, inspect the cable as follows:
a. Hold tightly a heavy, clean and lintfree cloth in your hand palm.
b. Let the cable through the cloth.
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E-AB412-PT6T-2
CAUTION
CABLE INCLINATION DURING WINDING MUST NOT BE MORE THAN 10

DEGREES IN RELATION TO THE VERTICAL. IF THE MOVEMENT OF THE
CABLE THROUGH THE CLOTH IS DIFFICULT, STOP IMMEDIATELY THE
OPERATION. INSPECT THE DEFECTIVE CABLE AREA TO FIND THOSE
DAMAGES (SUCH AS BROKEN WIRES) WHICH CAUSE LINTS, DIRT OR
OTHER DEFECTS IN THE CLOTH.
4. Replace the cable if there is record of overloads, although the cable looks serviceable.
5. If there is record of operations in salt laden atmosphere, remove with water all salt residuals from the hoist/cable.
ACCEPTABLE INSTALLATION
UNACCEPTABLE INSTALLATION
G6AB1022A
Figure 2. Hoist cable installation
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E-AB412-PT6T-2
G6AB0784A
Figure 3. Hoist cable check
25-92-02
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E-AB412-PT6T-2
25-92-03
EXTERNAL RESCUE HOIST, HANDWHEEL AND BUMPER
1. EXTERNAL RESCUE HOIST, HANDWHEEL AND BUMPER - DESCRIPTION
The hook, handwheel and bumper assembly attached to the hoist cable serves as a hand grip during rescue operations and
as a positive engaging cargo hook.
2. EXTERNAL RESCUE HOIST, HANDWHEEL AND BUMPER - REMOVAL
1. Cut the lockwire and remove the pin (15, figure 1) and washers.
2. Remove the threaded adapter (6) from the bumper assembly (1). Remove the handwheel (5).
3. Move the bumper assembly (1) up along the cable. Remove the snap ring (3) and split bushing (2) from the swaged
ball (4). Remove the bumper assembly (1) from the cable.
4. Remove the roll pin (14) and the threaded adapter (6) from the clamp nut (12).
5. Move the clamp nut (12) and the ball bearing (10) down. Align the hole in the clamp nut (12) with the pin (11). Push
the pin (11) through the clamp nut (12) until it is clear of the nut (7) and nut attachment (9).
6. Remove the nut (7) and the washer (8). Lift the nut attachment (9) out of the stud of the hook (13). Remove the ball
bearing (10) and the clamp nut (12).
3. EXTERNAL RESCUE HOIST, HANDWHEEL AND BUMPER - INSTALLATION
1. Move the bumper assembly (1) up along cable with its threaded end that points down.
2. Put the split bushing (2) in position around the swaged ball. Attach the split bushing in place with the snap ring (3).
3. Move the bumper assembly down until it touches the cable end.
NOTE
If the hook is new, make sure its threaded stud is already drilled 90 degrees apart
from the original hole (which is shown in figure 1 detail A). The diameter of this
second hole must be 0,1065 in (2,705 mm). If you do not find the hole, drill the stud
by yourself with a No. 36 drill.
NOTE
If the clamp nut (12) is new, drill a 0,1875 in (4,762 mm) diameter hole through one
wall (Refer to detail B).
4. Put ball bearing (10) in position in the clamp nut (12). Put the nut attachment (9) into the bearing and clamp nut.
5. Make the stud of hook (13) go through the nut attachment (9). Install as many washers (8) as necessary to permit a
correct tightening of the nut (7).
Install the nut and turn in until it touches the washer.
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E-AB412-PT6T-2
6. Let the ball bearing (10) and clamp nut (12) touch the hook and its keeper. Lightly loosen the nut (7). Align the drilled
holes of the clamp nut (12) and hook (13), and the slot in the nut (7).
7. Push the pin (14) through the hole in the clamp nut (12), nut attachment (9), nut (7) and hook (13).
8. Put the nut attachment (9) into the bearing (10) and clamp nut (12).
9. Install the threaded adapter (6) into clamp nut (12).
NOTE
If the clamp nut (12) or threaded adapter (6) are new, drill them together with a 0,125
to 0,129 in (3,17 to 3,28 mm) hole (Refer to detail C, figure 1). The hole in the clamp
nut (12) must be 0,414 in (10,51 mm) deep and approximately 0,30 in (7,62 mm)
below its top surface edge. The horizontal location of the hole can be anywhere
along the clamp nut circumference.
10. Push the roll pin (14) through the hole in the clamp nut (12) and install it into the threaded adapter (16).
11. Put the handwheel (5) in position on the threaded adapter (6).
12. Install the threaded adapter on the bumper assembly (1).
13. Align the holes in the threaded adapter, handwheel and bumper assembly.
14. Install pin (15) and washers. Safety with lockwire the pin to the clamp nut (12).
4. EXTERNAL RESCUE HOIST, HANDWHEEL AND BUMPER - PERIODICAL

INSPECTION
Perform inspection of retention pin (15, figure 1) as follows:
1. Remove the lockwire and the retention pin (15). Retain two washers for reuse.
Inspect retention pin (15) P/N BL2395 for conditions, verify that incisions and/or deformations are not present.
If failure are found, the retention pin (15) must be replaced with a new retention pin.
2. Install retention pin (15) and make sure that two washers are correctly installed Lockwire retention pin to hook.
25-92-03
Page 2 Rev. 1
E-AB412-PT6T-2
G6AB0783B
Figure 1. Rescue hoist, handwheel and bumper
25-92-03
Rev. 1 Page 3
E-AB412-PT6T-2
25-92-03
Page 4 Rev. 1
E-AB412-PT6T-2
25-92-04 EXTERNAL RESCUE HOIST - TEST BOX OF THE HOIST SHEAR CIRCUIT
25-92-04
EXTERNAL RESCUE HOIST - TEST BOX OF THE HOIST SHEAR CIRCUIT
1. TEST BOX OF THE HOIST SHEAR CIRCUIT - DESCRIPTION
The hoist shear circuit test box is installed on the structure, between the two door on the RH side of the helicopter.
2. TEST BOX OF THE HOIST SHEAR CIRCUIT - REMOVAL
1. Disconnect the electrical connector from the test box of the cable shear circuit of the hoist.
2. Remove the two screws, nuts and washers which attach the test box to the support.
3. Remove the test box.
3. TEST BOX OF THE HOIST SHEAR CIRCUIT - INSTALLATION
1. Put the test box in position and attach it with its two screws, the nuts and the washers.
2. Connect the electrical connector to the test box of the cable shear circuit of the hoist.
4. TEST BOX OF THE HOIST SHEAR CIRCUIT - INSPECTION
Inspect the test box for the defects below:
1. Physical damage to the case of control panel.
2. Binding or loose or defective switch.
3. Damaged test light.
4. Damaged connector or corroded connector receptacle; bent or broken connector pins.
5. TEST BOX OF THE HOIST SHEAR CIRCUIT - REPAIR
Replace the test box on the cable shear circuit if you find one of the above defects.
25-92-04
Page 1
E-AB412-PT6T-2
25-92-04
Page 2
E-AB412-PT6T-2
25-92-05 EXTERNAL RESCUE HOIST - NO. 3 HYDRAULIC PUMP AND ROTOR BRAKE DRIVE QUILL P/N 212-3101-22-9
25-92-05
EXTERNAL RESCUE HOIST - NO. 3 HYDRAULIC PUMP AND ROTOR
BRAKE DRIVE QUILL P/N 212-3101-22-9
1. EXTERNAL RESCUE HOIST - NO.3 HYDRAULIC PUMP AND ROTOR BRAKE DRIVE
QUILL P/N 212-3101-22-9 - DESCRIPTION
The No.3 hydraulic pump and rotor brake disc drive quill (figure 1) are installed on the LH side of the transmission. The
drive quill shaft drives the rotor brake disc directly whilst the No. 3 hydraulic pump is driven by the shaft through a gear
train.
QUILL P/N 212-3101-22-9 - REMOVAL
1. Remove the LH air intake and transmission fairings to get access to the drive quill.
2. Remove the No.3 hydraulic pump (refer to MODULE 25-92-13 EXTERNAL RESCUE HOIST - PUMP).
3. Remove the rotor brake disc and the brake units (refer to MODULE 25-93-00 TRANSMISSION OIL SYSTEM
COMPONENTS - ROTOR BRAKE KIT).
4. Cut the sealant around the edge of the quill with a sharp plastic scraper.
5. Remove the bolts and nuts that attach the drive quill to the transmission.
6. Pull the quill out of the transmission and remove it form the helicopter.
NOTE
To make the removal of the drive quill easier, heat the transmission case with a heat
lamp.
Do not use heater units that operate through open flames and do not use tools.
7. Soak a cloth with MEK and use it to remove all remaining sealant from case.
8. Put a cover on the transmission case opening.
QUILL P/N 212-3101-22-9 - INSTALLATION
1. Remove the cover from the transmission case opening.
2. Make sure that mating surfaces of quill sleeve and case are clean.
3. Install a new packing (4, figure 1) in the quill groove (2).
4. Apply heat to the quill port in the transmission main case. Put the quill into the transmission.
25-92-05
Rev. 3 Page 1
E-AB412-PT6T-2
NOTE
Be careful not to cause damage to the gear teeth.
5. Safety the drive quill in the transmission with its bolts and nuts.
6. Turn lightly the drive quill gear clockwise then counterclockwise. The gear are correctly engaged if there is backlash
between the gear teeth.
7. Seal all openings around the quill edge with adhesive EA934B. Apply only a small bead in the area where the quill
touches the transmission case.
8. Install the No.3 hydraulic pump (refer to MODULE 25-92-13 EXTERNAL RESCUE HOIST - PUMP).
9. Install the rotor brake disc and the brake units (refer to MODULE 25-93-00 TRANSMISSION OIL SYSTEM
COMPONENTS - ROTOR BRAKE KIT).
10. Install the fairings of the transmission and the LH air intake.
11. Inspect the leaks when you do the transmission run-up.
QUILL P/N 212-3101-22-9 - INSPECTION
1. Inspect the drive quill for wear and corrosion.
2. Inspect the bearing for freedom of movement.
3. Inspect the gear teeth for burr, wear and abrasions.
25-92-05
Page 2 Rev. 3
E-AB412-PT6T-2
A
(ROTATED BY 90°)
6 T 2
4 3
5 T
A 1
600 TO 1000 IN-LBS

(67.8 TO 113.0 Nm)
160 TO 190 IN-LBS
(18.0 TO 21.5 Nm)
1. Attaching plate
2. Drive quill
3. Rotor brake disc
4. Packing, preformed
5. Nut
6. Bolt
G6AB0806C
Figure 1. No.3 hydraulic pump and rotor brake disc drive quill
25-92-05
Rev. 3 Page 3
E-AB412-PT6T-2
25-92-05
Page 4 Rev. 3
E-AB412-PT6T-2
25-92-06 EXTERNAL RESCUE HOIST - UTILITY HYDRAULIC SYSTEM (FOR EXTERNAL RESCUE HOIST) [B] [C]
25-92-06
EXTERNAL RESCUE HOIST - UTILITY HYDRAULIC SYSTEM (FOR
EXTERNAL RESCUE HOIST) [B] [C]
1. UTILITY HYDRAULIC SYSTEM (FOR EXTERNAL RESCUE HOIST) [B][C] -

DESCRIPTION
The utility hydraulic system (figure 1, figure 2) provides hydraulic power to operate the external rescue hoist. The system
consists of a pump (14, figure 1) which, after pressurizing the fluid in the reservoir (10), directs it to the rescue hoist motor.
Valves and governors convey fluid from the pump (14) to the directional control valve (21). The valve (21) controls the
raising or lowering of the rescue hoist and may be actuated by either the pilot or the operator using the HOIST (UP-DOWN)
switches located respectively on the pilot's collective lever and on the operator pendant control.
Control is assigned to the pilot or to the operator by means of the HOIST PWR (CREW-OFF-PILOT) switch located on the
central pedestal.
When pilot or operator actuates the hoist using either of these switches, the electro valve (27) become deenergized and
pressure line is activated, then, the solenoid controlling the flow valve (18) becomes energized, causing fluid to flow through
the governor (19) to the shut-off valve (20). When passing through the governor (19) which is se a t 7,38 lt/min (1,62 gall/
min), fluid pressure is reduced form 210 to 105 kg./cm² (from 3000 to 1500psi). Under these conditions, raising and lowering
speeds are about 30 m/min (98 feet).
The rescue hoist may also be controlled manually by the operator using a manual selector valve (22). In this case the shut-off
valve (20) remains closed and the flow valve (18) being de-energized, is able to direct fluid to the manual selector valve (22)
by causing it to pass through the governor (7). The governor, without altering the pressure, regulates the flow at 14,76 lt7min
(3,25 gall/min).
The manual selector valve (22) permits the operator to select a raising or lowering speed between 0 to 60 m/min. (0 and 197
feet per minute) by setting the selector valve lever to the position UP and DOWN. Two limit switches ensure that the raising
and lowering speed during the last 2 m (6 feet) of travel is reduced to 30m/min (98 feet per minute) even when the distributor
lever has been set to a higher speed.
The manual selector valve also permits the rescue hoist to be used in the event of electrical failure. In this case the directional
control valve must be pre-set by two buttons fitted on the valve.
System operating pressure is 3000 psi. If pressure falls below this value, the pressure switch (5) installed on the pump supply
line illuminated the warning lamp UTL HYDR PRESS, on the caution panel. A pressure relief valve installed in the supply
line discharges excessive pressure in the system into the return line.
2. UTILITY HYDRAULIC SYSTEM (FOR EXTERNAL RESCUE HOIST) [B][C] - HEAT

EXCHANGER
The system is provided with an heat exchanger located in the LH engine compartment near the cabin roof bulkhead and
consists of a radiator and a fan. The fan produces a flow of air which cools the fluid of the return circuit during hoist
operation or the fluid from the pump return port when the hoist is not operated. A thermal switch provides the start or stop
the fan when the fluid temperature rises to 68 °C or falls below 63 °C.
A thermostat valve incorporated in the exchanger opens and directs fluid directly to the reservoir, by-passing the cooler when
fluid temperature falls below 27 °C.
25-92-06
Page 1
E-AB412-PT6T-2
3. UTILITY HYDRAULIC SYSTEM (FOR EXTERNAL RESCUE HOIST) [B][C] -

INDICATION AND TEST
Temperature and hydraulic pressure indications are provided by a thermometer and pressure gauge installed n the pedestal.
The temperature indicator system is energized by 28 Vdc and protected by the No.1 HIDR TEMP circuit breaker, while the
pressure indicator system is energized by 26 Vac and protected by the 26 Vac 3 HYDR circuit breaker located on the
overhead console panel. The system is also fitted with receptacles for ground testing (15).
4. UTILITY HYDRAULIC SYSTEM (FOR EXTERNAL RESCUE HOIST) [B][C] - CABLE

SHEAR CARTRIDGE
Either the pilot or the operator may fire the cable shear cartridge, if required, by operating the HOIST CABLE CUT switch
located on the central pedestal, for the pilot, and on the cabin ceiling, for the operator; the operator’s switch is only
operational when the HOIST PWR PILOT/OFF/CREW selector switch is set to CREW.
Faulty wiring in the guillotine circuit can be detected by means of the hoist shear circuit test box located on the RH door
post. When the FIRE-TEST switch on the text box is set to TEST and the HOIST CABLE CUT switch is operated, the TEST
light, on the same box, illuminates; for normal operation the FIRE-TEST switch must be set to FIRE. The rescue hoist
system is energized by 28 V DC and protected by the HOIST CABLE CUT circuit breaker located on the overhead console
panel.
25-92-06
Page 2
E-AB412-PT6T-2
25-92-06
G6AD0204A
Figure 1. Utility hydraulic system (No. 3)
25-92-06
Page 3
E-AB412-PT6T-2
G6AD0205A
Figure 2. Utility hydraulic system (No. 3) schematic
25-92-06
Page 4
E-AB412-PT6T-2
25-92-07
EXTERNAL RESCUE HOIST - TROUBLESHOOTING
1. TROUBLESHOOTING - DESCRIPTION
See table 1 for a detailed description and relative corrective actions for troubleshooting.
Table 1. External rescue hoist - troubleshooting
"UTIL HYD PRESS" CAUTION LIGHT IS ILLUMINATED
No pressure supplied by pump Check pump Replace pump if defective
Insufficient oil level in reservoir Check oil level Replenish system
Lines defective Check lines for leaks Replace defective lines
Electro valve defective Check electro valve for leaks Replace electro valve
Pressure switch faulty Check pressure switch Replace pressure switch
Caution light circuit faulty Check circuit Repair or replace wiring
UTILITY HYDRAULIC PRESSURE INDICATOR FAILS TO RESPOND WHEN PRESSURE EXISTS
Inverter de-energized Check inverter Energized inverter
Open or defective 26 V AC 3HYDR Check circuit breaker Reset or replace circuit breaker
circuit breaker
Defective utility hydraulic pressure Check utility hydraulic pressure trans- Replace defective unit
transmitter and/or indicator mitter and/or indicator
Defective wiring Check wiring for continuity Repair or replace wiring
UTILIY HYDRAULIC PRESSURE INDICATOR DRIVES DOWN SCALE
Wire reversed at pins of transmitter Check wiring Repair wiring

plug
UTILITY HYDRAULIC PRESSURE INDICATOR DRIVES DOWN SCLALE
Wire reversed at pins of transmitter Check wiring Repair wiring

plug
25-92-07
Page 1
E-AB412-PT6T-2
(Cont.)
UTILITY HYDRAULIC PRESSURE INDICATION INCORRECT
Detective utility hydraulic pressure Check utility hydraulic pressure trans- Replace defective unit
transmitter and/or indicator mitter and/or indicator
Defective wiring Check wiring to continuity Repair or replace wiring
NO.1 HYDR TEMP CIRCUIT BREAKER WILL NOT RESET
Defective circuit breaker Check circuit breaker Replace circuit breaker
Internal short in utility hydraulic tem- Check utility hydraulic temperature Replace defective unit
perature transmitter indicator transmitter or indicator
UTILITY HYDRAULIC TEMPERATURE INDICATOR FAILS TO OPERATE
28 V DC bus-de-energized Check 28 V DC bus Energize 28 V DC bus
Open or defective No.1 HYDR TEMP Check circuit breaker Reset or replace circuit breaker
circuit breaker
Defective utility hydraulic tempera- Check utility hydraulic temperature Replace defective unit
ture transmitter and/or indicator transmitter and/or indicator
UTILITY HYDRAULIC TEMPERATURE INDICATION INCORRECT
Detective utility hydraulic temperature Check utility hydraulic temperature Replace defective unit
transmitter and/or indicator transmitter and/or indicator
UTILITY HYDRAULIC TEMPERATURE INDICATOR DRIVES DOWN SCALE
Wires reversed at pins of indicator Check wiring Repair wiring

connector
SYSTEM OVERHEATS
Pressure increase due to faulty pump Functionally check pump Replace pump
governor
RESCUE HOIST FAILS TO OPERATE WHEN MANUALLY OPERATED BY CREW (SWITCH ON CENTRAL
PEDESTAL SET TO CREAW POSITION
Defective wiring Check manual selector valve wiring Repair or replace wiring
Manual selector valve defective Functionally check manual selector Replace manual selector valve
valve
25-92-07
Page 2
E-AB412-PT6T-2
(Cont.)
Hydraulic motor defective Check motor Replace motor
Limit switches defective Functionally check switches Replace hoist
Directional control valve defective Check valve Replace valve
RESCUE HOIST, WHEN MANUALLY OPERATED BY CREW, FAILS TO REDUCE SPEED OF 30 m/min (98 ft./
min) DURING LAST 2 m (6 feet) OF TRAVEL
Intermediate switches defective Functionally check switches Replace hoist
Governor 0-7344 defective or nor cor- Check that governor flow rate is 7,38 Set governor to correct value or
rectly lt/min (1,62 gall/min) replace governor
RESCUE HOIST FAILS TO OPERATE WHEN OPERATED BY CREW 8SWITCH ON CENTRAL PEDESTAL SET
TO "CREW POSITION")
WHEN OPERATED BY EITHER PILOT OR CREW, RESCUE HOIST FAILS TO STOP WHEN CABLE HAS BEEN
COMPLETELY RETRIEVED
Upper limit switch defective Functionally check switch Replace hoist
WHEN OPERATED MANUALLY BY CREW, RESCUE HOIST FAILS TO REACH MAXIMUM SPEED OF 60 m/
min (197 ft./min)
Governor 0-7343 defective or incor- Check flow rate of governor 14,76 lt/ Replace governor or set to correct
rectly set min (3,24 gall/min) value
Manual selector valve defective Functionally check manual selector Replace manual selector valve defec-
valve tive
WHEN OPERATED BY EITHER PILOT OR CREW RESCUE HOIST FAILS TO STOP WHEN CABLE IS FULLY
UNWOUND
Lower limit switch defective Functionally check switch Replace hoist 60 m/min (197 fl/min)
WHEN ACTUATED BY THE PILOT, RESCUE HOIST FAILS TO OPERATE (SWITCH ON CENTRAL PEDESTAL
SET TO "PILOT" POSITION)
25-92-07
Page 3
E-AB412-PT6T-2
(Cont.)
Shut-off valve defective Functionally check valve Replace valve if defective
WHEN ACTUATING EITHER HOIST SWITCH, RESCUE HOIST RAISING OR LOWERING SPEED FAILS TO
REMAIN AT A CONSTANT 30m/min (98 lt/min)
Flow valve defective Functionally check valve Replace valve
Governor 0-7344 defective Check governor Replace governor and recheck
LOAD TENDS TO UNROLL CABLE WHEN SYSTEM DE-PRESSUREIZED
Hoist break defective Replace hoist
HEAT EXCHANGER BLOWER DOES NOT OPERATE
Defective circuit breaker Check circuit breaker for continuity, Replace defective circuit breaker
using multimeter
Blower control replay does not ener- Check relay for continuity, using mul- Replace defective relay
gize timeter
Defective blower motor Substitute blower known to be unser- Repair or replace defective blower
viceable motor
Electrical malfunction Check wiring for continuity using Repair or replace defective wiring
multimeter
25-92-07
Page 4
E-AB412-PT6T-2
25-92-08 EXTERNAL RESCUE HOIST - OPERATIONAL CHECK
25-92-08
EXTERNAL RESCUE HOIST - OPERATIONAL CHECK
1. OPERATIONAL CHECK - DESCRIPTION
CAUTION
BEFORE THE GROUND TEST OF THE RESCUE HOIST, DISCONNECT THE

RESERVOIR VENT TUBE (ON THE TOP OF THE RESERVOIR) FROM ITS
CONNECTION. THEN CONNECT IT TO THE TEST BENCH THROUGH A
FLEXIBLE HOSE. THIS PREVENT OVERFLOWING OF HYDRAULIC FLUID
FROM THE VENT.
1. Connect a 28 Vdc power sources (external) to the helicopter.
2. Connect a test beach to the system and pressurize to 3000 psi (210 kg/cm²).
3. Disconnect to HOIST CABLE CUT, 26 Vac 3 HYDR, N.1 HYDR TEMP, and MASTER CAUTION circuit breakers.
4. Keep the pressure for approximately 15 minutes then do a functional check of all system components. Inspect all lines
and components for leaks and correct operation.
5. Make sure that the fluid temperature indicator of the utility hydraulic system reads approximate ambient temperature.
6. Make sure that the fluid pressure indicator of the utility hydraulic system reads 3000 psi. If the system provides the
correct pressure of 3000 psi (210 kg/cm²) the UTIL HYDR PRESS caution light (in the caution panel) will go off.
7. Depressurize the system. Disconnect the test bench from the ground test receptacles and disconnect the flexible hose
from the reservoir vent. Connect the vent tube to the vent connection.
8. Fill the system with approved oil.
9. Start the engine and do again the functional check of the system.
10. Do again the procedures in steps 5 and 6.
11. Stop the engine and push the HOIST CABLE CUT, 26 V AC 3 HYDR, NO.1 HYDR TEMP, and MASTER CAUTION
circuit breakers.
12. Disconnect the external power source from the helicopter.
25-92-08
Page 1
E-AB412-PT6T-2
25-92-08
Page 2
E-AB412-PT6T-2
25-92-09
EXTERNAL RESCUE HOIST - FLUSHING
1. FLUSHING - DESCRIPTION
MATERIALS REQUIRED
NUMBER NOMENCLATURE
NOTE
Flush the system each time you notice contamination in the filter cartridge and when
you replace a system component.
Fully flush each component with hydraulic fluid (C-002) before installation.
1. Install all hydraulic components to the helicopter and make sure that their installation is correct. Before the flushing,
do the procedure below:
a. Disconnect from the rescue hoist motor (1, figure 1) the line of the present safety valve (4) and that of the
accumulator (2). Connect them together with a flexible hose.
b. Disconnect the lines below:
— line at the flow valve (18) inlet.
— Line at the governor outlet (19).
— T-fitting at the governor outlet (7).
c. Connect all three lines in step 1.b together with a 3 way connection and two flexible hoses.
d. Disconnect the T-fitting at the shut-off valve (20) inlet and the line at the shut-off outlet. Connect the T-fitting
and the line together with a flexible hose.
e. Disconnect the pump supply line and the return line from the reservoir (10) and connect them together.
f. Disconnect the T-fitting from the pump (14). Install a plug AN929-12 in the hole.
2. After these operations, connect the test bench to the ground test receptacle (15) (their location is on the helicopter RH
side, aft of cabin door) and flush the system.
3. Flush system with hydraulic fluid (C-002) at a pressure of 500 psi (35 kg/cm²) for a about 20 minutes.
4. During flushing operate the manual selector valve (22) and (at the same time) turn buttons (19) of the directional
control valve as follows:
5. Move the lever to the left and push the LH button.
6. Move the lever to the right and push the RH button.
7. When the flushing is completed, install all components and fill the system through the reservoir filler.
25-92-09
Page 1
E-AB412-PT6T-2
8. Do a functional check of the system.
25-92-09
Page 2
E-AB412-PT6T-2
25-92-09
G6AD0204A
25-92-09
Page 3
E-AB412-PT6T-2
25-92-09
Page 4
E-AB412-PT6T-2
25-92-10 EXTERNAL RESCUE HOIST - RESERVOIR
25-92-10
EXTERNAL RESCUE HOIST - RESERVOIR
1. RESERVOIR - DESCRIPTION
The utility hydraulic system reservoir in installed by means of bolts above the No.2 system reservoir, the cover of which
forms the base for the other.
The reservoir is made of light aluminium ally and has a capacity of 1,10 gallons (5 lt) or 0,96 gallons (4,4 lt) at minimum
level. It is provided with a filler cap and screen, a sight gauge, a vent line and filter.
A filter cartridge, installed in the lower section of the reservoir, filters any impurities in the fluid before they reach the pump.
2. RESERVOIR - REMOVAL
1. Remove the forward transmission fairing.
2. Disconnect the pump supply line and drain the reservoir. Collect the fluid in a container.
3. Disconnect the return line from the reservoir.
4. Remove the bolts and nuts that attach the No.3 reservoir to the No.2 reservoir.
3. RESERVOIR - INSPECTION
1. Inspect the reservoir for damage and corrosion.
2. Inspect the attachment flange for damage. Inspect the torque seal between the two reservoirs for general condition.
3. Inspect the vent filter for blockage.
4. Inspect the filter on supply line for metallic particles and clogging.
4. RESERVOIR - INSTALLATION
MATERIALS REQUIRED
NUMBER NOMENCLATURE
1. Put the reservoir in position above No.2 reservoir. Make sure that the filter cartridge and the seal are installed in their
housing. Align the holes and install the bolts and nuts that attach the two reservoirs together.
2. Connect the supply and return lines.
3. Fill the system with hydraulic fluid (C-002).
4. Install the fairing.
25-92-10
Page 1
E-AB412-PT6T-2
5. RESERVOIR - PRESSURE TEST
MATERIALS REQUIRED
NUMBER NOMENCLATURE
Pressure test of reservoir must be accomplished using hydraulic fluid (C-002) at a pressure of 7.96 psi (0.56 Kg/cm³). Check
for leaks.
25-92-10
Page 2
E-AB412-PT6T-2
25-92-1 EXTERNAL RESCUE HOIST - RESERVOIR FILTER
25-92-11
EXTERNAL RESCUE HOIST - RESERVOIR FILTER
1. RESERVOIR FILTER - DESCRIPTION
The reservoir filter is of the cartridge type and is installed in the lower section of the reservoir. It is held in place by a
diaphragm.
2. RESERVOIR FILTER - REMOVAL
1. Remove the reservoir.
2. Remove the filter.
3. RESERVOIR FILTER - INSTALLATION
1. Put the seal in position. Install the filter in the lower section of the reservoir.
2. Install the reservoir and fill the system.
4. RESERVOIR FILTER - INSPECTION
Inspect the filter for metallic particle, clogging and damage.
25-92-11
Page 1
E-AB412-PT6T-2
25-92-11
Page 2
E-AB412-PT6T-2
25-92-12 EXTERNAL RESCUE HOIST - RESERVOIR VENT FILTER
25-92-12
EXTERNAL RESCUE HOIST - RESERVOIR VENT FILTER
1. RESERVOIR VENT FILTER - DESCRIPTION
The reservoir vent filter is of the cartridge type and is installed in the upper section of the reservoir. Its function is to prevent
impurities from entering the reservoir.
2. RESERVOIR VENT FILTER - REMOVAL
1. Remove the forward transmission fairing.
2. Cut the lockwire and remove the plug and seal from the top of the reservoir.
3. Remove the filter from its hosing.
3. RESERVOIR VENT FILTER - INSTALLATION
1. Put the filter in position in the housing.
2. Install the seal and plug. Lock the plug to the vent tube with lockwire.
3. Install the fairing.
4. RESERVOIR VENT FILTER - INSPECTION
Inspect the cartridge for cleanliness and damage.
25-92-12
Page 1
E-AB412-PT6T-2
25-92-12
Page 2
E-AB412-PT6T-2
25-92-13 EXTERNAL RESCUE HOIST - PUMP
25-92-13
EXTERNAL RESCUE HOIST - PUMP
1. PUMP - DESCRIPTION
The utility hydraulic system is provided with a self-regulating, axial-piston type pump which is actuated by a fixed-cylinder
cam. The two main functions of the pump are:
To provide necessary flow or fluid under pressure to operate the rescue hoist:
To interrupt or re-establish automatically this flow according to the demands of the system.
The pump is actuated by a drivequill installed on the LH side of the transmission case, above the rotor brake disc, and is
self-regulating at pressure between 2500 and 3000 psi (175 to 210 kg/cm²).
The pump flow, which is constant and proportional to the pump rotation speed, is supplied by fluid in the reservoir for
transmission to the operating circuit.
When pressure increase, an internal self-regulating pressure device short-circuits the fluid absorbed by reducing the effective
pumping stroke of the pistons and by setting the final self-regulating position at the stabilized maximum pressure.
The power required to make the pump rotate is consequently very low.
When the pump operates under self-regulating conditions, fluid circulation is maintained by means of a forced pumping
action which, via the recovery intake, convey fluid back to the reservoir through the heat exchanger. The flow to the
pressurized circuit is then limited to making up the fluid losses within the circuit.
When pressure decreases, the self-regulating device establisher the full or partial pump flow to the operational circuit. Given
the minimum inertia of the parts forming the system, the pump immediately regulates the flow according to circuit demands.
2. PUMP - REMOVAL
Remove the pump of the utility hydraulic system as follows:
1. Remove the transmission fairings and the LH air intake.
2. Disconnect the pump supply line and drain the reservoir.
3. Disconnect the lines from the pump and collect the fluid in a container. Put a plug on al connections.
4. Loosen the bolts and nuts on the pump flange.
5. Remove the bolts and nuts and remove the pump from the drivequill. Pull the pump horizontally to prevent damages
to the shaft splines.
6. Put a plug or a cover on the drivequill to keep out dirt and other unwanted material.
25-92-13
Rev. 3 Page 1
E-AB412-PT6T-2
3. PUMP - INSTALLATION
MATERIALS REQUIRED
NUMBER NOMENCLATURE
C-555 RELEASE AGENT
Install pump as follows (Ref. S.B. 412-123):
NOTE
Install the insulating ring P/N 8072-14 between the pump and the transmission quill.
1. Lubricate the drivequill splines with lubricant Plastilube Moly No.3 or release agent (C-555).
2. Put the shaft into the drivequill splines. Then, align the flange holes and install the bolts and nuts.
3. Remove the plugs from the line connections and connect the lines to the pump.
4. Prime the pump as follows:
a. Check that the pump has been filled with hydraulic fluid.
NOTE
It is recommended to fill the pump before the installation, but this can also be done
with the pump installed slowly rotating main rotor and fill the hydraulic fluid
through the suction port. During this operation the fitting of supply line must be
removed to allow the escape of air.
b. Fill the reservoir with hydraulic fluid.
c. Remove the nut on the suction line of the pump adapter.
d. Bleed the hydraulic fluid until all the air was expelled from the line, then install the nut.
5. Fill the system with approved fluid.
6. Install fairing and air intake back in position.
4. PUMP - INSPECTION
Inspect the pump as follows:
1. Manually rotate the shaft to remove the fluid from the pump.
2. Inspect the shaft for binding. Rotate the shaft and make sure that is is not bound or jammed and that is rotates freely.
NOTE
The check for freedom of rotation of the pump is possible only in this way. Do not
rotate the pump in its circuit full of hydraulic fluid. The pumping effect of the
pistons cause the pump to be apparently stiff.
3. Look through the intake port and inspect the piston drive components. Make sure that there are no metal particles in
the pump.
25-92-13
Page 2 Rev. 3
E-AB412-PT6T-2
4. If inspection shows binding or metallic contamination, disassemble the filter on the aft LH area of the cabin ceiling.
Then, monitor the quantity of metal particles or other impurities in the cartridge. If the contamination is more than
normal, drain all hydraulic fluid and flush the system (obey the procedure you find in this section).
5. PUMP - LUBRICATION
Before the installation and each 50 hours, lubricate the pump as follows:
1. Remove the pump (obey the procedure in paragraph "2. Pump - removal").
2. Remove the splined drivequill shaft from the body of the pump with a tool. Use the forked end of the tool to remove
the snap ring that keep the shaft attached to the housing.
3. Lubricate the shaft housing with Plastilube Moby No.3
4. Install the splined shaft back in the housing. Lock the shaft in the housing with the snap ring (use the forked end of the
tool).
5. Remove all unwanted lubricant.
6. Install the pump (obey the instructions of the paragraph below).
25-92-13
Rev. 3 Page 3
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25-92-13
Page 4 Rev. 3
E-AB412-PT6T-2
25-92-14
EXTERNAL RESCUE HOIST - ELECTRO VALVE
1. ELECTRO VALVE - DESCRIPTION
The electro valve (27, figure 1) is installed on the cabin roof near the pump. If permits to eliminate the pressure on the
pressure lines of the roof area when the rescue hoist is not operative.
2. ELECTRO VALVE - REMOVAL
1. Remove the fairing of the LH air intake.
2. Disconnect the lines from the inlet and outlet connection. Collect the fluid in an applicable container.
3. Remove the bolts that keep the valve attached to the structure. Remove the valve.
3. ELECTRO VALVE - INSTALLATION
1. Put the valve in position and attach it to the structure.
2. Connect the lines and the electrical connectors.
3. Fill the utility hydraulic system with approved fluid. Connect the electrical system.
4. Operate the hoist and bleed system.
5. Install the fairing of the LH air intake.
4. ELECTRO VALVE - INSPECTION
1. Inspect the valve for damage, corrosion and leaks.
2. Do a check of the connectors and electrical fittings for damage and general condition.
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25-92-14
G6AD0204A
25-92-14
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25-92-15
EXTERNAL RESCUE HOIST - CHECK VALVES
1. CHECK VALVES - DESCRIPTION
Two check valves (13 and 16, figure 1) are installed on the pump pressure line connection and on the ground test pressure
line respectively. Two check valves (25 and 26) are also installed respectively on the return line and supply line connections.
2. CHECK VALVES - REMOVAL
1. Remove the fairing of the LH air intake and get access to the check valve(s).
2. Disconnect the supply line from the valve(s).
3. Remove the valve(s).
3. CHECK VALVES - INSTALLATION
1. Install the valve (13) on the supply line connection of the pump.
2. Connect the line to the valve (13).
3. Put valve (16) in position and connect the line to the valve.
4. Make sure the fluid level in the reservoir is correct. Connect the level, if necessary.
5. Install the fairing of the LH air intake back in position.
4. CHECK VALVES - INSPECTION
1. Inspect valve(s) for damage and leaks. Do a check for jamming or binding of the pistons.
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25-92-15
G6AD0204A
25-92-15
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25-92-16 EXTERNAL RESCUE HOIST - FILTER
25-92-16
EXTERNAL RESCUE HOIST - FILTER
1. FILTER - DESCRIPTION
The filter is of the cartridge type. It is installed in the supply line and is located aft on the LH area of the cabin ceiling.
2. FILTER - REMOVAL
1. Remove the sound proofing in the LH area of the cabin ceiling as necessary. Get access to the filter.
2. Disconnect the filter from the inlet and outlet connection. Collect fluid in an applicable container.
3. Remove the bolts and nuts that attach the filter to the structure. Remove the filter.
3. FILTER - REMOVAL OF THE CARTRIDGE
1. Cut the lockwire and remove the screws to release the reservoir.
2. Remove the reservoir and the cartridge.
4. FILTER - INSPECTION
1. Inspect the filter for damage or leaks.
2. Inspect the cartridge for metallic particles and clogging.
5. FILTER - INSTALLATION OF THE CARTRIDGE
1. Put the cartridge in position on the filter body. Install the reservoir with its screws then tighten and safety with lockwire.
6. FILTER - INSTALLATION OF FILTER
1. Put the filter in position and attach it to the structure with its bolts and nuts.
2. Connect the supply line of the hoist to the filter.
3. Make sure that the fluid level in the reservoir is correct. Fill to the correct level, if necessary.
4. Install the sound proofing you removed before.
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25-92-17 EXTERNAL RESCUE HOIST - PRESSURE SWITCH
25-92-17
EXTERNAL RESCUE HOIST - PRESSURE SWITCH
1. PRESSURE SWITCH - DESCRIPTION
The pressure switch signals any insufficient pressure existing in the utility hydraulic system. It is located aft on the RH area
of the cabin ceiling, near the pressure transmitter.
2. PRESSURE SWITCH - REMOVAL
1. Remove the sound proofing in the RH area of the cabin ceiling as necessary. Get access to the pressure switch.
2. Disconnect the electrical connector from the switch.
3. Remove the bolts and nuts that attach the pressure switch to the structure.
4. Disconnect the pressure switch from the tubing connection. Collect the fluid in an applicable and remove the switch.
3. PRESSURE SWITCH - INSTALLATION
1. Connect the pressure switch to the tubing connection. Attach it to the structure with the bolts and nuts available.
2. Connect the electrical connector to the switch.
3. Make sure that the fluid level in the reservoir is correct. Fill to the correct level, if necessary.
4. PRESSURE SWITCH - INSPECTION AND TEST
1. Inspect the electrical connector for damage.
2. Inspect the pressure switch for damage and leaks.
3. Connect a hydraulic test equipment to the switch.
4. Apply and slowly increase the pressure. Make sure that the UTIL HYDR PRESS caution light goes off at a pressure
of 1422,3 psi.
5. Decrease the pressure. Make sure that the UTIL HYDR PRESS caution light comes on at a pressure of 995,6 ± 71 psi.
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25-92-18 EXTERNAL RESCUE HOIST - PRESSURE TRANSMITTER
25-92-18
EXTERNAL RESCUE HOIST - PRESSURE TRANSMITTER
1. PRESSURE TRANSMITTER - DESCRIPTION
The pressure transmitter transmits the fluid pressure signal to the indicator on the instrument panel.
It is installed on a T-connector near the pressure switch, located aft on the RH area of the cabin ceiling.
The transmitter consists of a syncro similar to the indicator receiver syncro. The transmitter syncro movements are caused
by the movements of a membrane which senses the variation of the system pressure.
2. PRESSURE TRANSMITTER - REMOVAL
1. Remove the sound proofing in the RH area of the cabin ceiling as necessary. Get access to the pressure transmitter.
2. Disconnect the electrical connector from the transmitter.
3. Remove the clamp.
4. Disconnect the transmitter from the T-connector. Collect the fluid in an applicable container and remove transmitter.
3. PRESSURE TRANSMITTER - INSTALLATION
1. Put the transmitter in position and connect it to the T-connector.
2. Attach the transmitter to the structure with a clamp.
3. Connect the electrical connector to the transmitter.
4. Make sure that fluid level in the reservoir is correct. Fill to the correct level, if necessary.
5. Install the sound proofing you removed before temperature transmitter.
4. PRESSURE TRANSMITTER - INSPECTION
2. Inspect the transmitter for damage and leaks and correct operation.
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25-92-19 EXTERNAL RESCUE HOIST - TEMPERATURE TRANSMITTER
25-92-19
EXTERNAL RESCUE HOIST - TEMPERATURE TRANSMITTER
1. TEMPERATURE TRANSMITTER - DESCRIPTION
The temperature transmitter is installed on the reservoir return line connection. The temperature transmitter is a temperature
bulb consisting of a temperature sensitive variable resistor connect to the indicator bridge resistor.
2. TEMPERATURE TRANSMITTER - REMOVAL
1. Remove the transmission fairing.
2. Disconnect the connector from the transmitter.
3. Put an applicable container in position to collect the fluid that can fall off the transmitter.
4. Remove the transmitter from the T-fitting and put plugs on the openings.
3. TEMPERATURE TRANSMITTER - INSTALLATION
1. Remove the plugs and install the transmitter on the T-fitting.
3. Make sure that the fluid level is correct. Fill it as necessary.
4. Install the transmission fairing.
4. TEMPERATURE TRANSMITTER - INSPECTION
1. Inspect the transmitter for general condition.
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25-92-20 EXTERNAL RESCUE HOIST - FLOW VALVE
25-92-20
EXTERNAL RESCUE HOIST - FLOW VALVE
1. FLOW VALVE - DESCRIPTION
The flow valve is installed aft on LH area of the cabin ceiling. When the hoist is actuated by the pilot or operator by means
of the control switches, the valve directs fluid to the low flow-rate governor; when the hoist is manually actuated by the
operator, the valve sends fluid to the high flow-rate governor.
2. FLOW VALVE - REMOVAL
1. Remove the sound proofing in the LH area of the cabin ceiling as necessary. Get access to the flow valve.
2. Disconnect the electrical connector from the valve.
3. Disconnect the lines from the valve and collect the fluid in an applicable container.
4. Remove the attachment bolts and nuts.
5. Remove the valve.
3. FLOW VALVE - INSTALLATION
1. Put the valve in position and attach it to the structure with the bolts and nuts available.
2. Connect the lines and the electrical connector to the valve.
3. Fill the utility hydraulic system and connect the electrical system.
4. Operate the hoist to bleed the system.
4. FLOW VALVE - INSPECTION
2. Inspect connector and electrical fittings for damage, and general condition.
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25-92-21 EXTERNAL RESCUE HOIST - FLOW GOVERNOR (LOW SPEED)
25-92-21
EXTERNAL RESCUE HOIST - FLOW GOVERNOR (LOW SPEED)
1. FLOW GOVERNOR (LOW SPEED) - DESCRIPTION
This governor is installed aft on the LH area of the cabin ceiling at the outlet port of the flow valve. When fluid passes
through the governor, the hoist can operate at a maximum speed of 98 feet (30 m) per minute.
2. FLOW GOVERNOR (LOW SPEED) - REMOVAL
1. Remove the sound proofing in the LH area of the cabin ceiling as necessary. Get access to the flow governor.
2. Disconnect the supply line from the governor and collect the fluid an applicable container.
3. Disconnect the governor from the flow valve; remove the governor.
3. FLOW GOVERNOR (LOW SPEED) - INSTALLATION
1. Put the governor in position and attach it to the flow valve.
2. Connect the governor to the elbow.
3. Fill the hydraulic system.
4. FLOW GOVERNOR (LOW SPEED) - INSPECTION
1. Make sure that flow-rate is 1,61 gall/min (7,38 lt/min).
2. Inspect the governor for damage and corrosion.
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25-92-2 EXTERNAL RESCUE HOIST - FLOW GOVERNOR (HIGH SPEED)
25-92-22
EXTERNAL RESCUE HOIST - FLOW GOVERNOR (HIGH SPEED)
1. FLOW GOVERNOR (HIGH SPEED) - DESCRIPTION
Similar to the low speed flow governor (MODULE 25-92-21 "EXTERNAL RESCUE HOIST - FLOW GOVERNOR (LOW
SPEED)"), and located in the same position, it allows the hoist to operate at speeds up to 200 ft/min (61 m/min), depending
on the position of the manual selector valve lever.
2. FLOW GOVERNOR (HIGH SPEED) - REMOVAL
1. Remove the sound proofing in the LH area of the cabin ceiling as necessary. Get access to the flow governor.
2. Disconnect the supply line from the governor and collect the fluid in an applicable container.
3. Disconnect the governor from the flow valve; remove the governor.
3. FLOW GOVERNOR (HIGH SPEED) - INSTALLATION
1. Put the governor in position and attach it to the flow valve.
2. Connect the governor to the T-connector.
3. Fill the hydraulic system.
4. Operate the hoist to bleed system.
4. FLOW GOVERNOR (HIGH SPEED) - INSPECTION
1. Make sure that flow-rate is 3,22 gal/min (14,76 l/min).
2. Inspect the governor for damage and corrosion.
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E-AB412-PT6T-2
25-92-23 EXTERNAL RESCUE HOIST - SHUT-OFF VALVE
25-92-23
EXTERNAL RESCUE HOIST - SHUT-OFF VALVE
1. SHUT-OFF VALVE - DESCRIPTION
The shutoff valve is installed aft on the LH area of the cabin ceiling.
2. SHUT-OFF VALVE - REMOVAL
1. Remove the sound proofing in the LH area of the cabin ceiling as necessary. Get access to the shut-off valve.
4. Remove the attachment bolts and nuts.
3. SHUT-OFF VALVE - INSTALLATION
1. Put the valve in position and attach it to the support with the bolts and nuts available.
2. Connect the lines to the valve.
3. Fill the system and operate the hoist to bleed the system.
4. SHUT-OFF VALVE - INSPECTION
3. Make sure that mechanical controls operate correctly.
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25-92-24 EXTERNAL RESCUE HOIST - MANUAL SELECTOR VALVE
25-92-24
EXTERNAL RESCUE HOIST - MANUAL SELECTOR VALVE
1. MANUAL SELECTOR VALVE - DESCRIPTION
The manual control valve is installed on the structure between the two doors on the RH side of the helicopter. It is provided
with a control lever that allows the operator to select an operating speed ranging from 0 to 198 feet (0 to 60 m/min) per
minute.
2. MANUAL SELECTOR VALVE - REMOVAL
3. Remove the attachment bolts and nuts that attach the valve to the structure.
3. MANUAL SELECTOR VALVE - INSTALLATION
1. Put the valve in position and attach it to the structure with bolts.
2. Connect the lines to the valve with the correct packings.
3. Connect the electrical connector to the valve.
4. MANUAL SELECTOR VALVE - INSPECTION
1. Inspect the valve for damage, corrosion and freedom of movement.
2. Inspect the electrical connector and components for damage.
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25-92-25 EXTERNAL RESCUE HOIST - DIRECTIONAL CONTROL VALVE
25-92-25
EXTERNAL RESCUE HOIST - DIRECTIONAL CONTROL VALVE
1. DIRECTIONAL CONTROL VALVE - DESCRIPTION
The directional control valve is secured to a support on the structure between the two doors on the HR side of the helicopter.
This valve controls the direction of rotation of the rescue hoist hydraulic motor and is connected electrically to the manual
selector valve and to the hoist control switches. It is fitted with two push-button which present the direction of rotation of
the rotor if the electrical system should fail.
2. DIRECTIONAL CONTROL VALVE - REMOVAL
2. Disconnect the lines form the valve and collect the fluid in an applicable container.
3. Remove the attachment bolts and nuts that attach the valve to the support.
3. DIRECTIONAL CONTROL VALVE - INSTALLATION
1. Put the valve in position and attach it to the support with bolts.
2. Connect the lines to the valve.
3. Connect the electrical connector to the valve.
4. DIRECTIONAL CONTROL VALVE - INSPECTION
2. Inspect the electrical connector and components for damage.
3. Make sure that the mechanical parts of the valve operate correctly.
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25-92-26 EXTERNAL RESCUE HOIST - PRESET SAFETY VALVE
25-92-26
EXTERNAL RESCUE HOIST - PRESET SAFETY VALVE
1. PRESET SAFETY VALVE - DESCRIPTION
The safety valve creates a counter pressure in the oil return line during payout of cable thereby smoothing the hoist braking
action.
2. PRESET SAFETY VALVE - REMOVAL
3. PRESET SAFETY VALVE - INSTALLATION
1. Connect the valve to the lines.
2. Fill the utility hydraulic system.
4. PRESET SAFETY VALVE - INSPECTION
1. Inspect the valve for damage and corrosion.
2. Make sure that the fluid flows freely through the valve when the line operates as supply line. Make sure also, that the
valve makes a resistance of 227,5 psi (16 kg/cm²) when line operates as return line.
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25-92-27 EXTERNAL RESCUE HOIST - PRESSURE RELIEF VALVE
25-92-27
EXTERNAL RESCUE HOIST - PRESSURE RELIEF VALVE
1. PRESSURE RELIEF VALVE - DESCRIPTION
The pressure relief valve is installed in the supply line near the pressure switch on the RH aft cabin area. Its function is to
discharge excessive pressure in the system into the return line.
2. PRESSURE RELIEF VALVE - REMOVAL
1. Remove the sound proofing in the LH area of the cabin ceiling as necessary. Get access to the pressure relief valve.
2. Loosen the clamp that keeps the pressure relief valve attached to the helicopter structure.
3. Disconnect the pressure relief valve from the tubing connection. Collect the fluid in an applicable and remove the
valve.
3. PRESSURE RELIEF VALVE - INSTALLATION
1. Connect the pressure relief valve to rubbing connection. Install the valve on the helicopter structure with the clamp.
2. Make sure that the fluid level in the reservoir is correct. Fill to the correct level is necessary.
4. PRESSURE RELIEF VALVE - INSPECTION
1. Inspect the valve for damage, dents, corrosion and leaks.
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25-92-28 EXTERNAL RESCUE HOIST - HEAT EXCHANGER
25-92-28
EXTERNAL RESCUE HOIST - HEAT EXCHANGER
1. HEAT EXCHANGER - DESCRIPTION
The heat exchanger is installed on a support in the LH engine compartment near the cabin rear bulkhead, and consists of a
radiator and a fan.
2. HEAT EXCHANGER - REMOVAL
1. Remove (if connected) the electrical power from the exchanger fan.
2. Get access to the engine compartment. Disconnect the exchanger lines and drain the fluid into an applicable container.
3. Remove the bolts and nuts that keep the exchange attached to the support. Remove the exchanger.
3. HEAT EXCHANGER - INSTALLATION
1. Put the exchanger in position and install it on the support with its bolts and nuts.
2. Connect the hydraulic lines and the electrical source (if necessary) to the exchange fan.
3. Fill the system and connect the battery.
4. HEAT EXCHANGER - INSPECT AND TEST
1. Inspect the fan for freedom or rotation and cleanliness.
2. Inspect the fan blades for distortion and cracks.
3. Connect the exchanger to an applicable hydraulic circuit and set the pressure to 150 psi (105 kg/sq-cm). Inspect the
cooler for leaks.
25-92-28
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25-92-28
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25-92-29
EXTERNAL RESCUE HOIST - ACCUMULATOR
1. ACCUMULATOR - DESCRIPTION
The accumulator (figure 1) is installed on pressure line, near the rescue hoist whinch.
2. ACCUMULATOR - REMOVAL
1. Remove the rescue hoist cowling.
2. Remove clamp and loosen nut that connect accumulator to pressure line; remove accumulator.
3. Collect hydraulic filter in a suitable container.
4. Cap the open end of line.
3. ACCUMULATOR - INSTALLATION
1. Remove cap from accumulator attachment point on pressure line.
2. Connect accumulator to pressure line.
3. Install clamp.
4. Install rescue hoist cowling.
4. ACCUMULATOR - INSPECTION
1. Inspect the accumulator for dents, scratches and damage.
2. Check the accumulator for correct charge; if the accumulator is low charge for air leakage as described in accumulator
manufacturer publication.
3. Charge the accumulator at 300 psi air pressure.
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25-92-29
Page 2
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25-92-29
G6AD0205A
Figure 1. Utility hydraulic system (No. 3) schematic
25-92-29
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E-AB412-PT6T-2
25-92-29
Page 4
E-AB412-PT6T-2
25-92-30 EXTERNAL RESCUE HOIST - UTILITY HYDRAULIC SYSTEM
25-92-30
EXTERNAL RESCUE HOIST - UTILITY HYDRAULIC SYSTEM
1. UTILITY HYDRAULIC SYSTEM - SERVICING
MATERIALS REQUIRED
NUMBER NOMENCLATURE
Hydraulic fluid (C-002) is used to service the utility hydraulic system. For the capacity of the system refer to module
25-92-10 "EXTERNAL RESCUE HOIST - RESERVOIR". The reservoir of the utility hydraulic system is located above
the reservoir of the No. 2 hydraulic system and is accessible by removing the transmission forward fairing. The reservoir is
provided with a filler cap, vent tubes and a level sight gage which can be viewed through a window obtained in the LH side
of the transmission forward fairing.
To drain the hydraulic fluid from the system, connect two lines equipped with quick-disconnecting couplings to the fittings
for the ground tests and collect the fluid in a suitable receptacle.
CAUTION
DURING BENCH TESTS OF THE RESCUE HOIST IT IS NECESSARY TO

DISCONNECT THE VENT TUBE FROM THE FITTING ON TOP OF
RESERVOIR AND CONNECT A FLEXIBLE HOSE TO CONVERT
HYDRAULIC FLUID INTO THE TEST BENCH RESERVOIR. THIS IS TO
PREVENT FLUID SPILL-OUT FROM THE VENT TUBE AND CONSEQUENT
SOILING.
25-92-30
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25-92-31 EXTERNAL RESCUE HOIST - SUPPORTS
25-92-31
EXTERNAL RESCUE HOIST - SUPPORTS
1. SUPPORTS - DESCRIPTION
NOTE
For removal and installation refer to module 25-92-00 "EXTERNAL RESCUE
HOIST [B]".
2. SUPPORTS - INSPECTION (12 MONTHS)
MATERIALS REQUIRED
NUMBER NOMENCLATURE
C-201 ZINC CHROMATE PRIMER
C-202A EPOXY POLYAMIDE PRIMER
C-308 SEALANT
1. Classification of damage
a. Negligible damage.
Are considered as negligible smooth dents not over 1/20 of tube diameter in depth. They need not be repaired if
the dents are free from cracks, abrasion or sharp corners. Bowed tubes are considered as negligible damage if
the bow is not beyond 1/240 of the length of the tube. Smooth out nicks and scratches not over 0.25 mm (0.010
in). In depth in the aluminum alloy tubular supports. Smooth out nicks and scratches not over 0.13 mm (0.005
in). In depth in the fitting. Looseness of tubes due to elongation of rivet holes must be repaired, using oversize
rivets.
CAUTION
DO NOT ATTEMPT TO STRAIGHTEN TUBES BENT MORE THAN 1/240 OF

THE TUBES LENGTH AND DO NOT USE ANY WELDING PROCEDURES TO
REPAIR ANY DAMAGE TO THE ALUMINUM SUPPORTS.
b. Damage requiring replacement.

Damage that follows requires replacement of parts or the entire support:
(1) Damage greater than negligible to aluminum tubes requires replacement of tubes.
(2) Any damage greater than negligible to fittings requires replacement of involved fittings.
(3) Corroded steel bushings must be replaced after dye penetrant inspection of fitting in order to assure no
cracks exist in fitting.
25-92-31
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E-AB412-PT6T-2
c. Corrosion control
If on the external surface of support and in particular in the area of fittings you found some corrosions you may
suspect that also the inner surface is interested and you have to perform a detailed X-Ray inspection in
accordance with T.O.33B-1-1. In the other case you may assume that there are no corrosion on inner surface.
Tube found to be corroded shall be replaced. Tube found to be serviceable will be treated as follows:
(1) Clean interior of tubes with an approved corrosion cleaning compound.
(2) After a thorough water rinse and drying, coat the inside surface of each tube with corrosion preventive
compound (C-102).
(3) After tube have been treated, wet dip tube end fittings in epoxy polyamide primer, (C-202A) or zinc
chromate primer (C-201).
(4) Depending upon condition of fastener holes, install tubes and fittings using either original fasteners
(lockbolt; NAS529-6-12 pin; NAS 528-A6 collar), or next oversize hardware maintaining a tolerance fit
of 0.076 mm (0.003 in).
(5) Assembly fasteners using zinc chromate primer (C-201) to insulate dissimilar metals. After assembly, seal
fasteners and all tube joints with sealing compound, (C-308) or equivalent.
25-92-31
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25-93-00
TRANSMISSION SYSTEM COMPONENTS - ROTOR BRAKE KIT
1. ROTOR BRAKE KIT - DESCRIPTION
The rotor brake kit is composed of a master cylinder (1, figure 1), located on the cabin console to the left of the pilot, and a
brake assembly. The brake assembly consist of a disc (4) connected to a drive quill on the LH side of the transmission and
of a brake unit (5) which, when the master cylinder is actuated, rapidly stops the disc and consequently the rotor.
2. ROTOR BRAKE KIT - OPERATIONAL CHECK
1. Pull the actuator handle down and move it to the vertical position (stop at the center for the maximum braking effort).
Make sure the rotor brake light on the master caution panel comes on.
2. Move the handle back to OFF (horizontal position) to release the brake. Make sure the rotor brake light goes off
5
2
1
6
1. Master cylinder (pump)

2. Filler cap
3. Drive quill
4. Rotor brake disc
5. Brake units
6. Pressure switch
G6AB0774B
Figure 1. Rotor brake installation
25-93-00
Rev. 3 Page 1
E-AB412-PT6T-2
3. ROTOR BRAKE KIT - TROUBLESHOOTING
Refer to table 1 for troubleshooting.
Table 1. Rotor brake kit - troubleshooting
INDICATION OF TROUBLE PROBABLE CAUSE CORRECTIVE ATION
NO BRAKING ACTION WHEN ROTOR BRAKE IS APPLIED
Low quantity of fluid in the system Check fluid level Service the system
Fluid contaminated Drain the system and check fluid for Service the system
contamination
Master cylinder defective Check master cylinder for proper oper- Replace master cylinder
ation
Brake pucks excessively worn Check pucks for wear Replace puck and piston assemblies
ROTOR BRAKE CHATTERS WHEN APPLIED
Air in the rotor brake system Bleed and service rotor brake system
and piston assemblies
BREAKING ACTION DECREASES PROGRESSIVELY
Worn seals in master cylinder Check master cylinder for leakage Replace master cylinder
Worn seals in master cylinder Check master cylinder for leakage Replace master cylinder
Worn seals in brake units Check seals for condition Replace the brake unit with worn seals
Brake pucks excessively worn Check pucks for wear Replace puck and piston assemblies
seals
PUCKS RUB ON DISC WHEN BRAKE IS NOT APPLIED
Disc distorted for overheating Visually check the disc Replace the disc
Defective loosening of brake units With brake not applied check pucks Replace defective brake unit
position
Seals in brake units damage by use of Remove brake units drain and flush the
hydraulic fluid not approved system and install two new brake units.
Service with approved hydraulic fluid
Excessive torque of brake units bolts Check bolts for correct torque Torque bolts at correct value.
cause an excessive bending to the
brake casing
LEAKAGE OF HYDRAULIC FLUID
Leakage form line connections Check connection Tight hydraulic connections
25-93-00
Page 2 Rev. 3
E-AB412-PT6T-2
(Cont.d)
INDICATION OF TROUBLE PROBABLE CAUSE CORRECTIVE ATION
Leakage from master cylinder Check master cylinder Replace master cylinder
Brake units defective Replace defective brake unit
ROTOR BRAKE CAUTION LIGHT DOES NOT ILLUMINATE WHEN ROTOR BRAKE IS ACTUATED
Defective pressure switch Check pressure switch Replace pressure switch
Defective bulb Check bulb Replace bulb
Defective cable Check cable Repair or replace cable
4. ROTOR BRAKE KIT - MASTER CYLINDER (PUMP)
The Master Cylinder (4, figure 2), which is installed horizontally on the cabin roof structure, is a piston type.
Relief valves are purposely installed inside the master cylinder to control automatically the pressure exercised by the master
cylinder on the hydraulic fluid.
A reservoir, installed on the top of the master cylinder, acts as a spare supply for the system.
The master cylinder is controlled by a handle (6) which can be set in three different positions:
— Rotor brake free.
— Full braking (the handle remains in this position when it is held only).
— Parking.
4-1. MASTER CYLINDER (PUMP) - REMOVAL
1. Disconnect the electrical connector from the pressure switch (5, figure 2).
2. Remove the pressure switch to drain the hydraulic fluid.
3. If you must replace the master cylinder (4), do not discard the pressure switch and the elbow union. Keep these
components in store to use them, if necessary, on a new master cylinder. Install a cap in the open seat.
4. Disconnect the pressure lines of the fluid from the master cylinder.
5. Remove nut (9), washers (8) and bolts and remove the master cylinder (4) from the structure.
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E-AB412-PT6T-2
G0
8
9 A
7 1
13
4 20 21
18
6
16
T 1
30 TO 40 IN-LBS 14 17
(3.4 TO 4.5 Nm) 11
15
120 TO 160 IN-LBS
T 1
2 18
(13.5 TO 18 Nm) 17 10
19
16 T 2
3
1. Filler cap 8. Washer 15. Bolt

2. Brake unit 9. Nut 16. Bleeding
3. Rotor brake disc 10. Bolt 17. MODE STATUS label
4. Master cylinder (pump) 11. Washer 18. Washer
5. Pressure switch 12. Nut 19. Bolt
6. Handle of master cylinder 13. Shim 20. Nut
7. Bolt 14. Washer 21. Plate
G6AB0775B
Figure 2. Rotor brake system
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Page 4 Rev. 3
E-AB412-PT6T-2
4-2. MASTER CYLINDER (PUMP) - INSTALLATION
MATERIALS REQUIRED
NUMBER NOMENCLATURE
C-308 SEALANT
1. Install the master cylinder (4, figure 2) on the structure with its bolts (7), washers (8) and nuts (9).
2. Seal all openings you notice between the reservoir filler cap (1) and the cabin roof. Use sealant (C-308).
3. Connect the lines to the master cylinder (4).
4. Remove the cap from its seat. Install the pressure switch (5) and the elbow union in the master cylinder seat. Use a
new seal.
5. Connect the electrical connector of pressure switch.
6. Fill and bleed the system.
4-3. MASTER CYLINDER (PUMP) - TEST
1. Slowly move the handle (6, figure 2) to the full breaking position.
2. Make sure that the pressure in the system is 11,6 (plus or minus 0,35) Kg/cm² (160 to 170 psi). If the pressure is less
than the above value, replace the master cylinder (4) and send it for overhaul.
5. ROTOR BREAK KIT - BRAKE UNITS
The brake units are attached with bolts at the drive quill and are controlled by the hydraulic pressure generated by the
actuation of the master cylinder.
5-1. BRAKE UNITS - REMOVAL
1. Open the transmission cowling to get access to the brake units (2, figure 2).
2. Disconnect the hoses from the brake units.
3. Cut the lockwire and remove the bolts that attach the brake units to the transmission quill. Remove the brake units.
5-2. BRAKE UNITS - INSTALLATION
1. Attach the brake units (2, figure 2) to the support flange of the drive quill with their bolts and nuts.
NOTE
The washer NAS1195-516 must be adjacent to the brake units.
2. Make sure that the brake units (2) are correctly installed along the pucks axis. The disc (3) must be in the center
between the two pucks of each brake unit. If necessary adjust the shims that are installed behind the support flange.
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E-AB412-PT6T-2
CAUTION
STEP 3. THAT FOLLOW APPLIES ONLY WHEN NEW PUCKS PART OF KIT
5120-K2 OR 5120-K3 HAVE BEEN INSTALLED AND NO BRAKING
ACTIONS HAVE BEEN PERFORMED.
3. If pucks have been replaced using 5120-K2 or 5120-K3, measure and record for each puck the measure G0 adjusting pin
is protruding respect to brake unit body, refer to detail B of figure 2. Pucks must be fully retracted when measure is taken.
4. Connect the hoses to the brake units.
5. Fill and bleed the system.
6. Close the transmission cowlings.
5-3. BRAKE UNITS - PUCKS REPLACEMENT
MATERIALS REQUIRED
NUMBER NOMENCLATURE
C-317 ADHESIVE
WARNING
PUCKS 5120-K1 MANUFACTURED UNTIL 1992 WERE PRODUCED WITH

MATERIAL CONTAINING ASBESTOS. IN CASE OF ANY DOUBT ABOUT
MANUFACTURING DATE, PLEASE COMPLY WITH YOUR COUNTRY
REGULATION RELATED TO DANGEROUS MATERIAL HANDLING
DURING PUCKS MAINTENANCE.
CAUTION
PUCKS MUST BE REPLACED WHEN, WITH BRAKE RELEASED, THE SELF

ADJUSTING PIN WHICH IS CONNECTED TO THE PISTON AND PUCK
ASSEMBLY, IS RECEDING INTO THE BRAKE BODY MORE THAN 3.7 MM
RESPECT TO THE G0 QUOTE MEASURED AND RECORDED DURING THE
INSTALLATION PROCEDURE OF THE BRAKE UNIT (2) WHEN PUCKS
HAVE BEEN REPLACED.
1. If MODE STATUS label (17, figure 2) marked with letter A is available on the brake unit body use 5120-K3 kit for
pucks replacement.
2. If MODE STATUS label (17) is not available on the brake unit body use 5120-K2 kit for pucks replacement.
NOTE
The two pucks replacement kits differ only for the MODE STATUS label P/N
5120-2-24 that is included only in 5120-K2 kit.
3. Replace pucks in accordance with the manufacturer manual TM 95-017.
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Page 6 Rev. 3
E-AB412-PT6T-2
4. If it is necessary to apply or restore the MODE STATUS label (17), P/N 5120-2-24, proceed as follows:
NOTE
MODE STATUS label must be installed on the brake unit body surface opposite
bleeding valve.
a. Fill in the label (17) with letter A on MOD STATUS field and with the other information that can be derived
from the component data label.
b. Clean the surface of the brake unit (2) where the label (17) has to be bonded as well as the surface of the label
to be bonded.
c. Apply the adhesive (C-317) on the rear surface of the label (17) using a plastic spatula.
d. Apply the label (17) in position.
6. ROTOR BRAKE KIT - DISC
The disc (3, figure 2) of the brake units assembly is attached to a flange installed on the shaft of the drive quill located on
the LH side of the helicopter.
6-1. DISC - REMOVAL
1. Open the transmission cowling.
2. Remove the brake units (2, figure 2).
3. Remove the nuts (12), washers (11) and bolts (10) that attach the brake disc (3) to the drive quill flange of the
transmission. Remove the disc.
6-2. DISC - INSTALLATION
1. Put the brake disc (3, figure 2) in position on the transmission quill flange and safety with its bolts (10), washers (11)
and nuts (12).
2. Install the brake units (2).
3. Make sure that the brake units (2) are correctly installed along the pucks axis. The disc must be in the center between
the two pucks o each brake unit. If necessary, adjust the shims (13) that are installed behind the support flange.
4. Safety with lockwire the four disc bolts (10) (which attach the disc to the flange) to the central nut.
6-3. DISC - INSPECTION
1. Inspect the brake disc (3, figure 2) for damage, deformation and cracks.
CAUTION
THE MINIMUM PERMITTED THICKNESS OF THE DISC IS 11,5 MM.
2. Inspect the holes for the bolts that attach the disc. Make sure there are no ovalizations or cracks.
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E-AB412-PT6T-2
3. Inspect the flange and the quill shaft for damage and cracks.
7. ROTOR BRAKE KIT - PRESSURE SWITCH
The pressure switch (5, figure 2) operates at 10 psig in pressure increase, and 5 psig in pressure decrease. The pressure switch
in installed on the master cylinder (4). It causes the caution light ROTOR BRAKE to illuminate when the brake is being
operated whilst causing this caution light to go off when the master cylinder handle (6) is brought back to the horizontal
position.
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Page 8 Rev. 3
E-AB412-PT6T-2
25-94-00
EXTERNAL CARGO SUSPENSION HOOK (P/N 212-706-103-101)
1. EXTERNAL CARGO SUSPENSION HOOK (P/N 212-706-103-101) - DESCRIPTION
The cargo hook (figure 2), which permits the transport of suspended loads, is fitted to the helicopter lift beam at helicopter
approximate center of gravity via a link and a slip ring which permit the hook to swivel and to pivot. Cargo release is
electrically controlled by the cyclic stick CARGO RELEASE switch, when the overhead panel CARGO REL switch is set
to ARM. In the event of electrical failure, cargo release can be obtained by depressing the cargo release pedal located in front
of the pilot's seat. The cargo hook has a capacity of 2268 kg (5000 lb).
NOTE
Refer to Chapter 98 for External Cargo Suspension Hook wiring diagram.
2. EXTERNAL CARGO SUSPENSION HOOK (P/N 212-706-103-101) - OPERATIONAL

CHECK
1. Direct assistant to observe cargo hook and reset to closed position.
2. Close cargo hook release circuit breaker on overhead console and position battery switch ON. Switch NON ESS BUS
to MANUAL.
3. Check CARGO RELEASE ARMED light (7, figure 1). Press to turn ON. Release it to turn OFF. Rotate light clockwise
to dim and rotate counterclockwise to brighten.
4. Position CARGO RELEASE switch (2) to ARM. CARGO RELEASE ARMED light (7) should illuminate. Press
cargo release button (1) on bottom of pilots control stick and hold for two or three seconds. Cargo hook should release.
5. Leave battery switch ON. Position CARGO RELEASE switch (2) to OFF. CARGO RELEASE ARMED light (7)
should go out. Depress stick cargo release button (1) and hold for two or three seconds. Cargo hook should not release.
6. Turn battery switch OFF.
7. Depress foot operated mechanical release (6). Cargo hook should release.
3. EXTERNAL CARGO SUSPENSION HOOK (P/N 212-706-103-101) - EMERGENCY

RELEASE CONTROL CABLE ADJUSTMENT
Carry out tension adjustment of emergency release control cable as follows:
1. Release control cable (7, figure 2) by loosening clamp (8) adjusting screws.
2. With pedal (18) full aft, adjust cable tension to 9 to 11 kg (20 to 24 lb) by operating turnbuckle (3).
3. Lockwire turnbuckle.
4. Tighten clamp with cable shield protruding 10 to 11 mm (0.4 in) from clamp.
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E-AB412-PT6T-2
5. Check that cable ball terminal protrudes 2.5 mm (0.1 in) below lever (16). Adjust cable shield to obtain protrusion of
0.8 to 2.0 mm (0.031 to 0.078 in).
6. Check that with hook closed, ball terminal of lower cable extends 3 to 4.5 mm (0.12 to 0.18 in) beyond seat of latch
lever, to provide proper slack.
NOTE
If stop bolt (13) position is altered during the above cable adjustment procedure,
repeat procedure.
7. With pedal pressed full forward, check that spring in pulley bracket (4) is not bottomed out. Check cable tension per
step 2. if spring is bottomed out.
8. Check proper hook release operation with at least 20 to 30 kg (44 to 66 lbs) on cargo hook load beam.
4. EXTERNAL CARGO SUSPENSION HOOK (P/N 212-706-103-101) - CARGO RELEASE

ELECTRICAL SYSTEM
For maintenance and troubleshooting procedures refer to module 96-25-03 "CARGO HOOK CONTROL CIRCUIT".
25-94-00
Page 2
E-AB412-PT6T-2
G6AB1013A
Figure 1. Cargo suspension provisions
25-94-00
Page 3
E-AB412-PT6T-2
G6AB1014A
Figure 2. Cargo suspension assembly
25-94-00
Page 4
E-AB412-PT6T-2
25-94-01 EXTERNAL CARGO SUSPENSION HOOK - SUSPENSION UNIT AND EMERGENCY RELEASE MECHANISM
25-94-01
EXTERNAL CARGO SUSPENSION HOOK - SUSPENSION UNIT AND
EMERGENCY RELEASE MECHANISM
1. SUSPENSION UNIT AND EMERGENCY RELEASE MECHANISM - REMOVAL
Remove suspension unit and emergency release mechanism as follows:
1. Suspension unit.
a. Remove access panels from front of pylon island.
b. With electrical power off, disconnect electrical cable (1, figure 1) at connector located on right underside of
structural lift beam.
c. Loosen clamp (8) and disengage control cable (7).
d. Remove cotter pin and disconnect control cable from cable connector (6).
e. Remove bolt (10). Remove suspension unit from helicopter.
2. Pedal assembly and forward part of control cable.
a. Remove access panels from cabin floor and lower skin on right hand side of helicopter.
b. Disconnect cable from cable adjustment turnbuckle (3) located in suspension unit compartment.
c. Disconnect cable from pedal by removing attaching hardware, and remove cable.
d. Remove bolts attaching pedal assembly to structure.
e. Remove pedal assembly from helicopter.
3. Aft part of control cable.
a. Remove cotter pin and disconnect cable from cable connector (6).
b. Remove spacer (5), guide and spring.
c. Remove pin from pulley bracket and slide out cable.
2. SUSPENSION UNIT AND EMERGENCY RELEASE MECHANISM - INSTALLATION
Install suspension unit and emergency release mechanism as follows:
1. Aft part of control cable.
a. Slide cable over pulley and through pulley bracket and fit cotter pin.
b. Install spring, guide and spacer.
c. Connect cable to cable connector and fit cotter pin.
2. Pedal assembly and forward part of release cable.
25-94-01
Page 1
E-AB412-PT6T-2
a. Position pedal assembly and fit attaching hardware.
b. Connect cable to pedal assembly.
c. Connect forward and aft sections of cable at turnbuckle (3, figure 1).
d. Install access panels.
3. Suspension assembly.
a. Fit suspension unit to suspension bracket, aligning bolt holes and install attaching bolt, washer and nut. Torque
58 to 69 kgcm (50 to 60 in-lb) and fit cotter pin.
b. Connect cable to connector (6), fit cotter pin and tighten clamp (8).
c. Connect electrical wiring (1) to connector on structure.
d. Ensure that release control cable and electrical wiring have enough slack to allow pivoting of suspension unit.
3. SUSPENSION UNIT AND EMERGENCY RELEASE MECHANISM - INSPECTION
1. Inspect suspension bracket (bushing, bracket and bolt) for wear, damage and signs of shearing stress on bolts.
2. Inspect spring and spring bracket for wear, and signs of shearing stress.
3. Inspect control cable for wear, frayed strands and outer damage.
4. Inspect pulley for wear and freedom of rotation and pulley bracket for damage.
25-94-01
Page 2
E-AB412-PT6T-2
G6AB1014A
Figure 1. Cargo suspension provisions
25-94-01
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E-AB412-PT6T-2
25-94-01
Page 4
E-AB412-PT6T-2
25-94-02
EXTERNAL CARGO SUSPENSION HOOK - REAR VIEW MIRROR (P/N
204-070-526-7)
1. REAR VIEW MIRROR (P/N 204-070-526-7) - DESCRIPTION
The helicopter is equipped with an adjustable rear view mirror (figure 1) located outside the forward cabin below the pilot's
lower window. This mirror, when properly adjusted, enables the pilot to visually check the operation of the external cargo
suspension hook. When the helicopter is employed on missions which do not require use of the external cargo suspension,
the rear view mirror may be covered or removed and stowed.
2. REAR VIEW MIRROR (P/N 204-070-526-7) - REMOVAL
1. Remove bolts, washers, nuts and/or quick-release pins (3, figure 1), which attach braces (2 and 5) and supports (4) to
structure and remove mirror assembly from helicopter.
2. To remove mirror from brace assembly, remove mirror cover, spring pins from adjustment handles.
3. REAR VIEW MIRROR (P/N 204-070-526-7) - INSTALLATION
1. Install braces (2 and 5, figure 1) and supports (4) to structure, using previously removed bolts, washers, nut and/or
quick-release pins (3).
2. Position rear view mirror and align mounting holes.
3. Screw adjustment handles through mounting holes. Adjust mirror to desired angle, tighten adjustment handles, and
insert spring pins in threaded ends of handles.
4. Slide protective cover over mirror and fasten holding snap.
4. REAR VIEW MIRROR (P/N 204-070-526-7) - ADJUSTMENT
1. Remove spring pin and loosen adjustment handles.
2. Manually adjust mirror to desired angle.
3. Tighten adjustment handles and insert spring pins.
25-94-02
Page 1
E-AB412-PT6T-2
G6AB1015A
Figure 1. Cargo hook mirror installation
25-94-02
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E-AB412-PT6T-2
25-94-03 EXTERNAL CARGO SUSPENSION HOOK - CARGO RESTRAINT NET (CARGO HOOK) (P/N 204-0900-08-1)
25-94-03
EXTERNAL CARGO SUSPENSION HOOK - CARGO RESTRAINT NET
(CARGO HOOK) (P/N 204-0900-08-1)
1. CARGO RESTRAINT NET (CARGO HOOK) (P/N 204-0900-08-1) - DESCRIPTION
To carry unusual shaped or flexible loads on the cargo hook a cargo sling may be used. This equipment consists of a braided
nylon net of approximately 8 meters diameter with attaching rings, and stainless steel cables fitted with spring catches. If
required the net may be attached directly to the cargo hook without using the cables.
25-94-03
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E-AB412-PT6T-2
25-94-03
Page 2
E-AB412-PT6T-2
CHAPTER 26 - FIRE PROTECTION

Module Page
Number Title Number
26-00-00 FIRE PROTECTION
1. Fire protection - general .......................................................................................................................... 1
26-11-01 FIRE DETECTION - ENGINE FIRE DETECTION
1. Fire detection - engine fire detection ...................................................................................................... 1

2. Engine fire detection - engine upper fire detection sensing elements .................................................... 1
2-1. Engine upper fire detection sensing elements - removal ............................................................... 1
2-2. Engine upper fire detection sensing elements - installation ........................................................... 2
2-3. Engine upper fire detection sensing elements - inspection and repair ........................................... 2
3. Engine fire detention - engine firewall fire detection sensing elements ................................................. 2
3-1. Engine firewall fire detection sensing elements - general ............................................................. 2
3-2. Engine firewall fire detection sensing elements - removal ............................................................ 2
3-3. Engine firewall fire detection sensing elements - installation ....................................................... 2
3-4. Engine firewall fire detection sensing elements - inspection and repair ....................................... 3
3-5. Engine firewall fire detection sensing elements - operational check ............................................. 3
26-12-01 FIRE DETECTION - BAGGAGE COMPARTMENT SMOKE DETECTION SYSTEM
1. Baggage compartment smoke detection system - general ...................................................................... 1

2. Baggage compartment smoke detection system - baggage compartment smoke detector ..................... 1
2-1. Baggage compartment smoke detector - removal .......................................................................... 1
2-2. Baggage compartment smoke detector - installation ..................................................................... 1
2-3. Baggage compartment smoke detector - inspection ...................................................................... 1
2-4. Baggage compartment smoke detector - operational check .......................................................... 2
26-21-01 FIRE EXTINGUISHERS - ENGINE COMPARTMENT FIRE EXTINGUISHERS
1. Engine compartment fire extinguishers - general ................................................................................... 1

2. Engine compartment fire extinguishers - removal .................................................................................. 5
3. Engine compartment fire extinguishers - installation ............................................................................. 5
4. Engine compartment fire extinguishers - inspection .............................................................................. 6
5. Engine compartment fire extinguishers - repair/replacement ................................................................. 6
6. Fire extinguishers - discharge indicator disc ........................................................................................ 13
6-1. Discharge indicator disc - general ............................................................................................... 13
6-2. Discharge indicator disc - removal .............................................................................................. 13
6-3. Discharge indicator disc - installation ......................................................................................... 13
6-4. Discharge indicator disc - inspection ........................................................................................... 13
26-22-01 FIRE EXTINGUISHERS - PORTABLE FIRE EXTINGUISHERS AND BRACKETS
1. Portable fire extinguishers and brackets - general .................................................................................. 1

2. Portable fire extinguishers and brackets - removal ................................................................................. 1
3. Portable fire extinguishers and brackets - installation ............................................................................ 1
4. Portable fire extinguishers and brackets - inspection ............................................................................. 1
5. Portable fire extinguishers and brackets - repair ..................................................................................... 2
26-Index
Rev. 3 Page 1
E-AB412-PT6T-2
FIGURES
Figure Page
Number Title Number
26-11-01 FIRE DETECTION - ENGINE FIRE DETECTION
Figure 1. Engine compartment fire detection sensing element (sheet 1 of 2) ................................................................4
Figure 1. Baggage compartment smoke detector ...........................................................................................................3
Figure 1. Engine compartment fire extinguisher schematic ...........................................................................................2

Figure 2. Engine compartment fire extinguisher (sheet 1 of 2)......................................................................................3
Figure 3. Fire extinguisher cartridge wiring diagrams (sheet 1 of 2) ...........................................................................11
26-22-01 FIRE EXTINGUISHERS - PORTABLE FIRE EXTINGUISHERS AND BRACKETS
Figure 1. Portable fire extinguishers and brackets .........................................................................................................3
26-Index
Page 2 Rev. 3
E-AB412-PT6T-2
26-0 -0 FIRE PROTECTION
26-00-00
FIRE PROTECTION
1. FIRE PROTECTION - GENERAL
Fire protection items include engine fire detection elements and extinguishers, baggage compartment smoke detector, and
two cabin mounted, hand-held, portable fire extinguishers.
26-00-00
Page 1
E-AB412-PT6T-2
26-00-00
Page 2
E-AB412-PT6T-2
26-1 -01 FIRE DETECTION - ENGINE FIRE DETECTION
26-11-01
FIRE DETECTION - ENGINE FIRE DETECTION
1. FIRE DETECTION - ENGINE FIRE DETECTION
Engine compartment fire detection consists of two heat sensing elements and two flexible cable assemblies for each power
section of the engine. A press-to-test switch is provided to test the system.
If a fire or overheat condition occurs, the heat sensing elements in the affected power section closes a circuit which causes
the corresponding FIRE PULL handle (located on the instrument panel) to illuminate. Pulling the handle turns off the heater
by de-energizing both bleed air valves and causes the engine air management bypass door and the fuel shutoff valve to close
shutting off both air and fuel to the affected power section. Pulling FIRE 1 PULL or FIRE 2 PULL handle also arms the
main and reserve fire extinguisher circuits for the corresponding power section. Placing the FIRE EXT switch to MAIN
causes the main fire extinguisher bottle to discharge extinguishing agent (Halon and nitrogen) into the selected power section
compartment. Placing the FIRE EXT switch to RESERVE discharges the reserve fire extinguisher bottle into the same
compartment.
Pressing the FIRE EXT PRESS TO TEST switch places a low resistance across each of the fire sensing elements to simulate
a fire/overheat condition. If sensing elements are operating properly, both FIRE 1 PULL and FIRE 2 PULL handles will
illuminate.
2. ENGINE FIRE DETECTION - ENGINE UPPER FIRE DETECTION SENSING

ELEMENTS
The upper fire detection sensing elements are mounted on the underside of the upper engine cowling (figure 1).
NOTE
Maintenance procedures are the same for both left and right upper sensing elements.
2-1. ENGINE UPPER FIRE DETECTION SENSING ELEMENTS - REMOVAL
1. Verify all electrical power removed from helicopter.
2. Disconnect electrical connectors (10 and 11, figure 1).
3. Remove screw (9) from clamp (8). Remove screws from six remaining clamps in same manner.
4. Spreading clamps as little as possible, remove element (2).
26-11-01
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E-AB412-PT6T-2
2-2. ENGINE UPPER FIRE DETECTION SENSING ELEMENTS - INSTALLATION
MATERIALS REQUIRED
NUMBER NOMENCLATURE
C-405 LOCKWIRE
2. Position sensing element (2, figure 1) on upper cowl as shown in view A.
3. Spreading clamps (8) as little as possible, install sensing element (2) in clamps (12).
4. Install screws (9) in clamps (8).
5. Connect electrical connectors (10 and 11). Install lockwire (C-405).
6. Perform operational check (paragraph "3-5. Engine firewall fire detection sensing elements - operational check").
2-3. ENGINE UPPER FIRE DETECTION SENSING ELEMENTS - INSPECTION AND REPAIR
Refer to Chapter 96 for inspection of sensing elements. Replace elements and/or retaining hardware if unserviceable.
3. ENGINE FIRE DETENTION - ENGINE FIREWALL FIRE DETECTION SENSING

ELEMENTS
3-1. ENGINE FIREWALL FIRE DETECTION SENSING ELEMENTS - GENERAL
NOTE
Maintenance procedures are the same for both left and right sensing elements.
3-2. ENGINE FIREWALL FIRE DETECTION SENSING ELEMENTS - REMOVAL
3. Remove screws (13) from clamps (12).
4. Spread clamps (12) as little as possible and remove sensing element (2).
3-3. ENGINE FIREWALL FIRE DETECTION SENSING ELEMENTS - INSTALLATION
2. Position sensing element (2, figure 1) in clamps (12).
3. Install retaining screws (13) in clamps (12).
4. Connect electrical connectors (14 and 15).
26-11-01
Page 2
E-AB412-PT6T-2
5. Perform operational check (paragraph "3-5. Engine firewall fire detection sensing elements - operational check").
3-4. ENGINE FIREWALL FIRE DETECTION SENSING ELEMENTS - INSPECTION AND REPAIR
Refer to Chapter 96 for inspection of sensing elements. Replace elements and/or retaining hardware if unserviceable.
3-5. ENGINE FIREWALL FIRE DETECTION SENSING ELEMENTS - OPERATIONAL CHECK
1. Apply 28 Vdc to helicopter electrical system.
2. Close ENG 1 FIRE DET circuit breaker.
3. Press and hold FIRE EXT PRESS TO TEST switch.
4. Verify FIRE 1 PULL handle illuminates.
5. Release PRESS TO TEST switch.
6. Verify FIRE 1 PULL handle extinguishes.
7. Open ENG 1 FIRE DET circuit breaker.
9. Press and hold PRESS TO TEST switch.
10. Verify FIRE 2 PULL handle illuminates.
11. Release PRESS TO TEST switch.
12. Verify ENG 2 PULL handle extinguishes.
13. Remove electrical power from helicopter.
26-11-01
Page 3
E-AB412-PT6T-2
G6AB0315A
Figure 1. Engine compartment fire detection sensing element (sheet 1 of 2)
26-11-01
Page 4
E-AB412-PT6T-2
G6AB0316A
Figure 1. Engine compartment fire detection sensing element (sheet 2 of 2)
26-11-01
Page 5
E-AB412-PT6T-2
26-11-01
Page 6
E-AB412-PT6T-2
26-12-01
FIRE DETECTION - BAGGAGE COMPARTMENT SMOKE DETECTION
SYSTEM
1. BAGGAGE COMPARTMENT SMOKE DETECTION SYSTEM - GENERAL
The baggage compartment smoke detector is a closed assembly housing solid-state electronic components and a light
sensitive detector. The detector (4, figure 1) is located in the forward end of the baggage compartment roof. A protective
screen is installed over the detector to provide protection from items stowed in the compartment. The instant smoke reduces
light transmission in the baggage compartment 30 to 35% below that of clear air, the detector causes the BAGGAGE FIRE
warning light on the instrument panel to flash intermittently. For more detailed description and wiring diagrams, refer to
Chapters 96 and 98.
The BAGGAGE FIRE TEST switch provides a means to test the baggage smoke detection system.
2. BAGGAGE COMPARTMENT SMOKE DETECTION SYSTEM - BAGGAGE

COMPARTMENT SMOKE DETECTOR
2-1. BAGGAGE COMPARTMENT SMOKE DETECTOR - REMOVAL
1. Remove all electrical power from helicopter.
2. Open baggage compartment door (9, figure 1).
3. Remove screws (7) and screen (6).
5. Remove screws (3) and thin aluminum washers (2). Remove smoke detector (4).
2-2. BAGGAGE COMPARTMENT SMOKE DETECTOR - INSTALLATION
1. Align mounting holes in smoke detector (4, figure 1) with airframe mounting holes.
2. Install screws (3) and thin aluminum washers (2).
3. Connect electrical connector (5).
4. Install protective screen (6) with screws (7) and thin steel washers (8).
5. Close baggage compartment door (9).
6. Perform operational check (paragraph "2-4. Baggage compartment smoke detector - operational check").
2-3. BAGGAGE COMPARTMENT SMOKE DETECTOR - INSPECTION
1. Inspect smoke detector for physical damage.
26-12-01
Rev. 3 Page 1
E-AB412-PT6T-2
2. Inspect electrical connector for pin alignment and contact retention.
2-4. BAGGAGE COMPARTMENT SMOKE DETECTOR - OPERATIONAL CHECK
1. Apply 28 Vdc power to the helicopter.
2. Close BAG COMPT FIRE circuit breaker.
3. Press and hold BAGGAGE FIRE TEST switch.
4. Verify BAGGAGE FIRE warning light flashes.
5. Release BAGGAGE FIRE TEST switch.
6. Verify BAGGAGE FIRE warning light extinguished.
7. Introduce smoke into baggage compartment.
8. Verify BAGGAGE FIRE warning light illuminates.
9. Remove smoke from baggage compartment.
10. Verify warning light extinguishes.
26-12-01
Page 2 Rev. 3
E-AB412-PT6T-2
1. Decal
2. Thin aluminum washer
3. Screw
4. Smoke detector
5. Electrical connector
6. Protective screen
7. Screw
8. Thin steel washer
9. Baggage compartment door
G6AB0759B
Figure 1. Baggage compartment smoke detector
26-12-01
Rev. 3 Page 3
E-AB412-PT6T-2
26-12-01
Page 4 Rev. 3
E-AB412-PT6T-2
26-21-01
FIRE EXTINGUISHERS - ENGINE COMPARTMENT FIRE EXTINGUISHERS
1. ENGINE COMPARTMENT FIRE EXTINGUISHERS - GENERAL
The helicopter is equipped with two engine compartment fire extinguishers.
The two engine compartment fire extinguishing bottles are interconnected by tubing to allow either container to be
discharged into either power section compartment (figure 1). Therefore, in the event discharging the first (main) bottle fails
to extinguish a fire, the second (reserve) bottle may be discharged into the same compartment.
The containers (figure 2) are spherical steel assemblies charged with freon and nitrogen to approximately 600 psi. If the
container is discharged, no special cleaning is required because of the non-corrosive properties of the extinguishing agent.
Each container has two outlets each equipped with electrically actuated pyrotechnic cartridges, a guarded pressure gage, and
a fill and thermal relief fitting connected to a discharge indicator disc. A pressure/temperature correction decal is attached
to each cylinder to aid during inspection and servicing.
In the event a container is subjected to excessive heat, the fill and thermal relief fitting will open and allow the extinguishing
agent to escape. During this process, the discharge indicator disc will be blown out to provide a visual indication of the event.
For further information, refer to Chapters 96 and 98.
NOTE
Maintenance procedures for both fire extinguisher containers are the same.
WARNING
THE FIRE EXTINGUISHER CONTAINERS ARE PRESSURIZED AND

EQUIPPED WITH PYROTECHNIC CARTRIDGES. ANY TIME CONNECTING
WIRES ARE DISCONNECTED, JUMPER WIRES (SHORTING DEVICES) (49
AND 50, FIGURE 2) SHALL BE INSTALLED TO PREVENT INADVERTENT
DETONATION.
DO NOT USE A VOLTMETER, FLASHLIGHT BATTERY, CONTINUITY

LIGHT OR SIMILAR DEVICE TO TEST CARTRIDGES.
DO NOT LOOSEN FITTINGS AT DISCHARGE OUTLETS (6 OR 30),

PRESSURE INDICATOR GAGE (26), OR FILL AND THERMAL RELIEF
FITTING (15) WHEN CONTAINER IS PRESSURIZED.
ENSURE THAT NO POWER IS APPLIED TO HELICOPTER ELECTRICAL

SYSTEMS AND HELI COPTER IS PROPERLY GROUNDED WHILE
PERFORMING MAINTENANCE ON FIRE EXTINGUISHING SYSTEM.
26-21-01
Rev. 3 Page 1
E-AB412-PT6T-2
RESERVE MAIN
BLEED AIR BLEED AIR
G6AB0317A
Figure 1. Engine compartment fire extinguisher schematic
26-21-01
Page 2 Rev. 3
E-AB412-PT6T-2
SEE DETAILS
A AND B
STA
205.89 SEE
DETAIL D SEE
DETAIL C
STA
162.97 SEE
STA DETAIL E
180.79
38 56
56
DETAIL A DETAIL A
(WALTER KIDDE) (HTL INDUSTRIES)
G6AB0318B
Figure 2. Engine compartment fire extinguisher (sheet 1 of 2)
26-21-01
Rev. 3 Page 3
E-AB412-PT6T-2
Left discharge indicator disc (24) installation shown.

Right discharge indicator disc installation is similar.
4.0 REF 9.0 REF
0.38 IN
(9.7 mm)
1. Forward tube 21. Hose 40. Nut

2. Manifold 22. Name plate 41. Nut
3. Tube 23. Fire extinguisher container (left) 42. Electrical wire
4. Cartridge 24. Discharge indicator disc 43. Terminal (ground wire)
5. Housing assembly 25. Support 44. Ground washer
6. Discharge outlet 26. Pressure indicator gauge 45. Nut
7. Support 27. Temperature/pressure correction 46. Electrical terminal nipple
8. Thin aluminum washer table 47. Electrical wire
9. Bolt 28. Tube 48. Terminal (hot wire)
10. Fire extinguisher container (right) 29. Manifold 49. Jumper wire (shorting device)
11. Bolt 30. Discharge outlet 50. Jumper wire (shorting device)
12. Thin aluminum washer 31. Cartridge 51. Screw
13. Bolt 32. Housing assembly 52. Washer (AN960C6L)
14. Thin aluminum washer 33. Terminal (hot wire) 53. Nut
15. Fill and thermal relief fitting 34. Electrical wire 54. Nipple
16. Nut 35. Electrical terminal nipple 55. Fill and thermal relief fitting
17. Hose assembly 36. Nut 56. Screw
18. Support 37. Terminal (ground wire) 57. Washer
19. Tube 38. Ground washer 58. Green range mark (31-113-1D)
20. Tube 39. Electrical wire 59. Red range mark (31-113-6A)
G6AB0319B
Figure 2. Engine compartment fire extinguisher (sheet 2 of 2)
26-21-01
Page 4 Rev. 3
E-AB412-PT6T-2
2. ENGINE COMPARTMENT FIRE EXTINGUISHERS - REMOVAL
WARNING
REMOVE HELICOPTER WIRING CONNECTORS ONE AT A TIME AND

INSTALL JUMPER WIRE (SHORTING DEVICE) AT VACANT TERMINAL
PRIOR TO REMOVING FURTHER WIRING. TAG DISCONNECTED WIRES
FOR REINSTALLATION IN PROPER LOCATION.
1. Verify all electrical power is removed from helicopter and helicopter is properly grounded.
2. Open engine cowling to gain access to extinguisher bottles.
3. Remove nut (40, figure 2). Tag and remove wire (39).
4. Install jumper wire (shorting device) (49) on terminal (ground wire) (37) and install nut (40) (HTL Industries
container), or on ground washer (38), and install nut (40) (Walter Kidde container).
5. Remove nut (36) and electrical wire (34) with electrical terminal nipple (35). Tag electrical wire (34).
6. Install loose end of jumper wire (shorting device) (49) on terminal (hot wire) (33) with nut (36).
7. Remove nut (45) and electrical wire (47) with electrical terminal nipple (46). Tag electrical wire (34).
8. Install jumper wire (shorting device) (50) on terminal (hot wire) (48) and install nut (45).
9. Remove nut (41) and electrical wire (42). Tag electrical wire (42).
10. Install loose end of jumper wire (shorting device) (50) on terminal (ground wire) (43) with nut (41) (HTL Industries),
or, on ground washer (44), and install nut (41) (Walter Kidde).
11. Disconnect tube (3 or 20) from discharge outlet (6).
12. Disconnect tube (19 or 28) from discharge outlet (30).
13. Remove hose assembly (17 or 21) from fill and thermal relief fitting (15 or 55).
14. Remove bolts (9 and 11) and thin aluminium washers (8 and 12).
15. Remove bolt (13), thin aluminum washer (14), and nut (16). Remove container from supports (7 and 18).
3. ENGINE COMPARTMENT FIRE EXTINGUISHERS - INSTALLATION
1. If not previously accomplished, install green range marking (58) and red range marking (59) on face of pressure
indicator (26).
2. Position fire extinguisher container (10, figure 2) in supports (7 and 18).
3. Install bolts (9 and 11) with thin aluminum washers (8 and 12).
4. Install bolt (13), thin aluminium washer (14), and nut (16).
5. Install hose assembly (17 or 21) on fill and thermal relief fitting (15).
6. Install tube (3 or 20) on discharge outlet (6).
26-21-01
Rev. 3 Page 5
E-AB412-PT6T-2
7. Install tube (19 or 28) on discharge outlet (30).
NOTE
Refer to wiring diagrams (figure 3) prior to connecting wires to cartridges (4 and 31,
figure 2). Ensure that wires are installed on correct terminals.
Remove ends of jumper wires one at a time and install helicopter wiring to each
terminal as jumper wire is removed.
8. Remove one end of jumper wire (shorting device) (50, figure 2). Install correct helicopter wire using attaching nut.
Remove remaining end of jumper wire and install correct helicopter wire. Verify attaching hardware is secure.
9. Repeat step 8. for jumper wire (shorting device) (49).
4. ENGINE COMPARTMENT FIRE EXTINGUISHERS - INSPECTION
1. Inspect container for obvious damage. Superficial damage that does not affect container structural integrity is
acceptable without repair. If damage is such that loss of structural integrity is suspected, container shall be replaced.
2. Inspect temperature/pressure correction decal for security and legibility.
3. Inspect pressure indicator gage (26, figure 2) for acceptable range as shown on temperature/pressure correction table
decal.
4. Inspect decals located on both pressure indicator gauges (26) for condition and security (chapter 11).
5. Replace or recharge container, if empty.
6. Inspect manifolds (2 and 29) and forward tubes (1) for obstructions or restrictions in holes provided for discharge.
7. Visually inspect the cartridge (4 or 31) for distortion of threads, cracks (not permitted), security, mechanical damage,
dents or corrosion.
5. ENGINE COMPARTMENT FIRE EXTINGUISHERS - REPAIR/REPLACEMENT
MATERIALS REQUIRED
NUMBER NOMENCLATURE
C-405 LOCKWIRE
WARNING
THE FIRE EXTINGUISHER CONTAINERS ARE PRESSURIZED AND

EQUIPPED WITH PYROTECHNIC CARTRIDGES. ANY TIME CONNECTING
WIRES ARE DISCONNECTED, JUMPER WIRES (SHORTING DEVICES) (49
AND 50, FIGURE 2) SHALL BE INSTALLED TO PREVENT INADVERTENT
DETONATION.
DO NOT USE A VOLTMETER, FLASHLIGHT BATTERY, CONTINUITY

LIGHT OR SIMILAR DEVICE TO TEST CARTRIDGES.
26-21-01
Page 6 Rev. 3
E-AB412-PT6T-2
WARNING
DO NOT LOOSEN FITTINGS AT DISCHARGE OUTLETS (6 OR 30),

PRESSURE INDICATOR GAUGE (26), OR FILL AND THERMAL RELIEF
FITTING (15) WHEN CONTAINER IS PRESSURIZED.
WARNING

1. Repair of the fire extinguisher system components is limited to replacement of unserviceable parts. For recharging or
leak testing of fire extinguisher containers, refer to appropriate Vendors Manuals. Recharge fire extinguisher
containers as required at a facility equipped and authorized to service extinguisher containers.
NOTE
No repairs to cartridges are permitted.
2. Refer to E-AB412-PT6T-6 for cartridge retirement and replacement schedule. For cartridge testing, refer to appropriate
Vendors Manuals. Replace cartridges as required, see step 4., below.
3. Replace container temperature/pressure table decal if illegible or otherwise unserviceable.
4. Replacement of cartridges.
WARNING
REMOVE HELICOPTER WIRING CONNECTORS ONE AT A TIME AND

INSTALL JUMPER WIRE (SHORTING DEVICE) AT VACANT TERMINAL
PRIOR TO REMOVING FURTHER WIRING. TAG DISCONNECTED WIRES
FOR REINSTALLATION IN PROPER LOCATION.
T H E C A RTR I D G E I S A P Y R O T E C H N I C D E V I C E . I N A D V E RT E N T
DETONATION OF THE CARTRIDGE CAN CAUSE PERSONAL INJURY. FOR
SAFE HANDLING, THE ELECTRICAL CONNECTION PINS MUST BE
SHORTED TOGETHER. THE SHORTING DEVICE MUST BE REMOVED
B E F O R E T E S T I N G O R C O N N E C T I N G T H E C A RT R I D G E TO T H E
HELICOPTER WIRING.
NOTE
Replacement procedures for fire extinguisher cartridges are typical. The cartridges
can be removed or installed with the container pressurized.
NOTE
For HLT Industries cartridges replacement, refer to step a. For Walter Kidde
cartridges replacement, refer to step b.
HLT Industries and Walter Kidde recharge kit and cartridges are not interchangeable.
26-21-01
Rev. 3 Page 7
E-AB412-PT6T-2
a. Replace (HTL Industries) cartridges (4 and 31, figure 2) in fire extinguisher containers (10 and 23) as follows:
(1) Disconnect battery and verify all electrical power is removed from helicopter and that helicopter is
properly grounded.
(2) Open engine cowling to gain access to fire extinguisher containers.
(3) Remove nut (40). Tag and remove electrical wire (39) from terminal (ground wire) (37).
(4) Install jumper wire (shorting device) (49) on terminal (ground wire) (37) and install nut (40).
(5) Install loose end of jumper wire (shorting device) (49, detail B) on terminal (hot wire) (33) with nut (36).
The jumper wire (shorting device) (49) must remain connected at all times when the cartridge (31) is
disconnected from the helicopter wiring.
(6) Remove nut (45) and electrical wire (47) with electrical terminal nipple (46). Tag electrical wire (47).
(7) Install jumper wire (shorting device) (50) on terminal (hot wire) (48) and install nut (45).
(8) Remove nut (41) and electrical wire (39). Tag electrical wire (39).
(9) Install loose end of jumper wire (shorting device) (50) on terminal (43) with nut (41). The jumper wire
(shorting device) (50) must remain connected at all times when the cartridge (4) is disconnected from the
helicopter wiring.
CAUTION
TO PREVENT ACCIDENTAL DISCHARGE OF CONTAINER DURING

CARTRIDGES (4 AND 31) REPLACEMENT, THE LARGE (1-1/4 IN.) HEX
HOUSING ASSEMBLIES (5 AND 32) MUST BE HELD TO PREVENT
TURNING.
(10) Remove lock wire from housing assemblies (5 and 32) and cartridges (4 and 31).
WARNING
DO NOT LOOSEN THE HOUSING ASSEMBLIES (5 AND 32). THIS MAY

CAUSE THE EXTINGUISHER TO DISCHARGE AND CAUSE SERIOUS
INJURY.
(11) Remove cartridges (4 and 31) from housing assemblies (5 and 32) by unscrewing the cartridge while
holding the hexagonal head of the housing assemblies (5 and 32), to prevent accidental discharge. Discard
seal.
(12) Install new seal on cartridges (4 and 31). Install cartridges (4 and 31) in housing assemblies (5 and 32).
Hold hexagonal head of housing assemblies (5 and 32) with a wrench while tightening cartridges (4 and
31) to prevent excessive torque on housing assemblies (5 and 32). Torque cartridges (4 and 31) to 70 to 80
in-lbs (7,91 to 9,04 Nm).
(13) Install lockwire (C-405) on housing assemblies (5 and 32) and cartridges (4 and 31).
NOTE
Refer to wiring diagram (figure 3) prior to connecting wires to cartridges (4 and 31,
26-21-01
Page 8 Rev. 3
E-AB412-PT6T-2
(14) Remove one end of jumper wire (shorting device) (50). Install correct helicopter wire using attaching nut.
Remove remaining end of jumper wire and install correct helicopter wire. Verify attaching hardware is
installed and secure.
(15) Repeat sub subordinate step 14., above for jumper wire (shorting device) (49).
b. Replace (Walter Kidde Co. Inc) cartridges (4 and 31, figure 2) in fire extinguisher containers (10 and 23) as
follows:
(1) Disconnect battery and verify all electrical power is removed from helicopter and helicopter is properly
grounded.
(2) Open engine cowling to gain access to fire extinguisher containers.
(3) Remove nut (40). Tag and remove electrical wire (39) from ground washer (38).
(4) Install jumper wire (shorting device) (49, detail B) on ground washer (38) and install nut (40).
(5) Install loose end of jumper wire (shorting device) (49) on terminal (hot wire) (33) with nut (36). The
jumper wire (shorting device) (49) must remain connected at all times when the cartridge (31) is
disconnected from the helicopter wiring.
(6) Remove nut (45) and electrical wire (47) with electrical terminal nipple (46). Tag electrical wire.
(7) Install jumper wire (shorting device) (50) on terminal (hot wire) (48) and install nut (45).
(8) Remove nut (41) and electrical wire (42). Tag electrical wire.
(9) Install loose end of jumper wire (shorting device) (50) on ground wire (44) with nut (41). The jumper wire
(shorting device) (50) must remain connected at all times when the cartridge (4) is disconnected from the
helicopter wiring.
CAUTION
TO PREVENT ACCIDENTAL DISCHARGE OF CONTAINER DURING

CARTRIDGES (4 AND 31) REPLACEMENT, THE LARGE (1-1/4 IN.) HEX
HOUSING ASSEMBLIES (5 AND 32) MUST BE HELD TO PREVENT
TURNING.
(10) Remove lock wire from housing assemblies (5 and 32) and cartridges (4 and 31).
WARNING
DO NOT LOOSEN THE HOUSING ASSEMBLIES (5 AND 32). THIS MAY

CAUSE THE EXTINGUISHER TO DISCHARGE AND CAUSE SERIOUS
INJURY.
(11) Remove cartridges (4 and 31) from housing assemblies (5 and 32) by unscrewing the cartridge while holding
the hexagonal head of the housing assemblies (5 and 32), to prevent accidental discharge. Discard seal.
(12) Install new seal on cartridges (4 and 31). Install cartridges (4 and 31) in housing assemblies (5 and 32).
Hold hexagonal head of housing assemblies (5 and 32) with a wrench while tightening cartridges (4 and
31) to prevent excessive torque on housing assemblies (5 and 32). Torque cartridges (4 and 31) to 150 to
200 in-lbs (16,95 to 22,60 Nm).
(13) Install lockwire (C-405) on housing assemblies (5 and 32) and cartridges (4 and 31).
26-21-01
Rev. 3 Page 9
E-AB412-PT6T-2
NOTE
Refer to wiring diagrams (figure 3) prior to connecting wires to cartridges (4 and 31,
(14) Remove one end of jumper wire (shorting device) (50). Install correct helicopter wire using attaching nut.
Remove remaining end of jumper wire and install correct helicopter wire. Verify attaching hardware is
installed and secure.
(15) Repeat sub subordinate step 14., above for jumper wire (shorting device) (49).
26-21-01
Page 10 Rev. 3
E-AB412-PT6T-2
HELICOPTERS CODE A
G6AB0320A
Figure 3. Fire extinguisher cartridge wiring diagrams (sheet 1 of 2)
26-21-01
Rev. 3 Page 11
E-AB412-PT6T-2
HELICOPTERS CODE B C D
G6AB0321A
Figure 3. Fire extinguisher cartridge wiring diagrams (sheet 2 of 2)
26-21-01
Page 12 Rev. 3
E-AB412-PT6T-2
6. FIRE EXTINGUISHERS - DISCHARGE INDICATOR DISC
6-1. DISCHARGE INDICATOR DISC - GENERAL
Maintenance procedures for both discharge indicator discs are typical.
WARNING

6-2. DISCHARGE INDICATOR DISC - REMOVAL
1. Remove all electrical power from helicopter.
2. Disconnect hose (21, figure 2) from nipple (54).
3. Remove screws (51), washers (52), and nuts (53).
4. Remove discharge indicator disc (24).
6-3. DISCHARGE INDICATOR DISC - INSTALLATION
1. Position discharge indicator disc (24, figure 2) in support (25).
2. Install screws (51), washers (52), and nuts (53).
3. Install hose (21) on nipple (54).
4. Install hose (21) on fill and thermal relief fitting (55).
6-4. DISCHARGE INDICATOR DISC - INSPECTION
Inspect discharge indicator discs on both containers for missing red indicator, secure installation, and obvious damage. A
missing red disc indicates container may have discharged through fill and thermal relief fitting.
26-21-01
Rev. 3 Page 13
E-AB412-PT6T-2
26-21-01
Page 14 Rev. 3
E-AB412-PT6T-2
26-2 -01 FIRE EXTINGUISHERS - PORTABLE FIRE EXTINGUISHERS AND BRACKETS
26-22-01
FIRE EXTINGUISHERS - PORTABLE FIRE EXTINGUISHERS AND
BRACKETS
1. PORTABLE FIRE EXTINGUISHERS AND BRACKETS - GENERAL
The helicopter is equipped with two portable, cabin mounted fire extinguishers.
The two hand-held, portable fire extinguishers are installed in quick-release brackets at the locations illustrated in figure 1.
These extinguishers are filled with monobromotrifluoromethane extinguishing agent.
At the intervals of time specified in the table of the calendar replacements in Manual E-AB412-PT6T-6, weight the fire
extinguishers and make a comparison with the weight indicated on the dataplate to determine the charging condition. If the
weight is not within limits, replace the fire extinguisher.
NOTE
Maintenance procedures for both fire extinguishers and brackets are identical.
2. PORTABLE FIRE EXTINGUISHERS AND BRACKETS - REMOVAL
1. Release clamp (7, figure 1) and remove fire extinguisher (6).
2. Remove bolts (8) and thin aluminum washer (9). Remove bracket (11) and aluminum washers (10).
3. PORTABLE FIRE EXTINGUISHERS AND BRACKETS - INSTALLATION
1. Position bracket (11, figure 1) in position with aluminum washers (10) between bracket and mounting surface.
2. Install bolt (8) and thin aluminum washers (9). Tighten bolts.
3. Open retaining clamp (7) and position fire extinguisher (6) in bracket (11). Close retaining clamp.
4. Verify bracket (11) is securely installed in helicopter and fire extinguisher (6) is securely installed in retaining bracket.
4. PORTABLE FIRE EXTINGUISHERS AND BRACKETS - INSPECTION
1. Inspect fire extinguisher (6, figure 1) for state of charge by weight (or by visual indicator, if installed).
2. Record inspection on tag attached to extinguisher (6, detail A).
3. Inspect bracket (5) and attaching hardware for obvious damage and security of installation and serviceability.
26-22-01
Rev. 3 Page 1
E-AB412-PT6T-2
5. PORTABLE FIRE EXTINGUISHERS AND BRACKETS - REPAIR
1. Recharge fire extinguisher as required at a facility equipped and authorized to service monobromotrifluoromethane
type extinguishers.
2. Replace unserviceable bracket parts and retaining hardware.
26-22-01
Page 2 Rev. 3
E-AB412-PT6T-2
1. Fire extinguisher
2. Clamp
4. Screw
5. Bracket
6. Fire extinguisher
7. Clamp
8. Bolt
10. Aluminum washer
11. Bracket
12. Attachment wire
13. Inspection tag (front)
14. Inspection tag (back)
G6AB0044B
Figure 1. Portable fire extinguishers and brackets
26-22-01
Rev. 3 Page 3
E-AB412-PT6T-2
26-22-01
Page 4 Rev. 3
E-AB412-PT6T-2
CHAPTER 28 - FUEL SYSTEM

Module Page
Number Title Number
28-00-00 FUEL SYSTEM
1. Fuel system - general .............................................................................................................................. 1

2. Fuel system - safety precautions ............................................................................................................. 1
28-00-01 FUEL SYSTEM - FUEL STORAGE AND DISTRIBUTION SYSTEM (HELICOPTERS CODES
[A][B])
1. Fuel storage and distribution system (helicopters codes [A][B]) - description ...................................... 1
2. Fuel storage and distribution system (helicopters codes [A][B]) - troubleshooting ............................... 2
28-00-02 FUEL STORAGE AND DISTRIBUTION SYSTEM (HELICOPTERS CODES [C][D])
1. Fuel storage and distribution system (helicopters codes [C][D]) - description ...................................... 1
2. Fuel storage and distribution system (helicopters codes [C][D]) - troubleshooting................................ 8
28-10-01 FUEL STORAGE AND DISTRIBUTION SYSTEM (HELICOPTERS CODES [A][B]) - LOW
FUEL LEVEL WARNING SWITCHES
1. Low fuel level warning switches - description ....................................................................................... 1

2. Low fuel level warning switches - removal ............................................................................................ 1
3. Low fuel level warning switches - installation ....................................................................................... 1
28-10-02 FUEL STORAGE AND DISTRIBUTION (HELICOPTERS CODES [A][B]) - BOOST PUMPS
1. Boost pumps - description ...................................................................................................................... 1

2. Boost pumps - removal ........................................................................................................................... 1
3. Boost pumps - installation ...................................................................................................................... 5
28-10-03 FUEL STORAGE AND DISTRIBUTION SYSTEM (HELICOPTERS CODES [A][B]) -

CANISTER TYPE BOOST PUMPS
1. Canister type boost pumps - description ................................................................................................. 1

2. Canister type boost pumps - removal ..................................................................................................... 1
3. Canister type boost pumps - installation.................................................................................................. 3
28-10-04 FUEL STORAGE AND DISTRIBUTION (HELICOPTERS CODES [A][B]) - FORWARD CELL
INLET/OUTLET FITTINGS
1. Forward cell inlet/outlet fittings - description ........................................................................................ 1

2. Forward cell inlet/outlet fittings - removal ............................................................................................. 1
3. Forward cell inlet/outlet fittings - installation ......................................................................................... 5

FORWARD CELL CRASH RESISTANT VENT VALVES
1. Forward cell crash resistant vent valves - description ............................................................................ 1

2. Forward cell crash resistant vent valves - removal ................................................................................. 1
3. Forward cell crash resistant vent valves - installation ............................................................................ 1
28-Index
Rev. 3 Page 1
E-AB412-PT6T-2

Module Page
Number Title Number

FORWARD CELLS
1. Forward cells - description ......................................................................................................................1

2. Forward cells - removal ...........................................................................................................................1
3. Forward cells - installation ......................................................................................................................2
4. Forward cells - cleaning ..........................................................................................................................3
5. Forward cells - inspection .......................................................................................................................3
28-10-07 FUEL STORAGE AND DISTRIBUTION SYSTEM (HELICOPTERS CODES [A][B]) - CENTER
AFT CELL OUTLET FITTINGS
1. Center aft cell outlet fittings - description ...............................................................................................1

2. Center aft cell outlet fittings - removal ...................................................................................................1
3. Center aft cell outlet fittings - installation ...............................................................................................1
AFT CELL VENT COVER
1. Center aft cell vent cover - description ...................................................................................................1

2. Center aft cell vent cover - removal ........................................................................................................1
3. Center aft cell vent cover - installation ....................................................................................................2
28-10-09 FUEL STORAGE AND DISTRIBUTION SYSTEM (HELICOPTERS CODES [A][B]) - AFT
CELL VENT FITTINGS
1. Aft cell vent fittings - description ...........................................................................................................1

2. Aft cell vent fittings - removal ................................................................................................................1
3. Aft cell vent fittings - installation ...........................................................................................................1
AFT CELL REAR COVER
1. Center aft cell rear cover - removal .........................................................................................................1

2. Center aft cell rear cover - installation ....................................................................................................1
CELL OUTLET FITTINGS
1. Aft cell outlet fittings - description .........................................................................................................1

2. Aft cell outlet fittings - removal ..............................................................................................................1
3. Aft cell outlet fittings - installation ..........................................................................................................2
CELLS
1. Aft cells - description ..............................................................................................................................1

2. Aft cells - removal ...................................................................................................................................1
3. Aft cells - installation ...............................................................................................................................4
4. Aft cells - cleaning ..................................................................................................................................6
5. Aft cells - inspection ...............................................................................................................................6
28-Index
Page 2 Rev. 3
E-AB412-PT6T-2

Module Page
Number Title Number
AFT CELL
1. Center aft cell - description ..................................................................................................................... 1

2. Center aft cell - removal ......................................................................................................................... 1
3. Center aft cell - installation...................................................................................................................... 5
4. Center aft cell - cleaning .......................................................................................................................... 6
5. Center aft cell - inspection ...................................................................................................................... 6
28-10-14 FUEL STORAGE AND DISTRIBUTION SYSTEM (HELICOPTERS CODES [C][D]) - LOWER
FORWARD CELLS
1. Lower forward cells - description ........................................................................................................... 1

2. Lower forward cells - removal ................................................................................................................ 1
3. Lower forward cells - installation ........................................................................................................... 2
4. Lower forward cells - cleaning ................................................................................................................ 4
5. Lower forward cells - inspection ............................................................................................................ 4
FORWARD CELL VENT HOSES
1. Lower forward cell vent hoses - description ........................................................................................... 1

2. Lower forward cell vent hoses - removal ............................................................................................... 1
3. Lower forward cell vent hoses - installation............................................................................................ 2
FORWARD CELL INTERCONNECT HOSE AND FITTING
1. Lower forward cell interconnect hose and fitting - description .............................................................. 1

2. Lower forward cell interconnect hose and fitting - removal .................................................................. 1
3. Lower forward cell interconnect hose and fitting - installation .............................................................. 6
FORWARD CELL/LOWER MIDDLE CELL INTERCONNECT FITTING
1. Lower forward cell/lower middle cell interconnect fitting - description ................................................ 1

2. Lower forward cell/lower middle cell interconnect fitting - removal .................................................... 1
3. Lower forward cell/lower middle cell interconnect fitting - installation................................................. 3
MIDDLE CELLS AND LOWER MAIN CELLS
1. Lower middle cells and lower main cells - description .......................................................................... 1

2. Lower middle cells and lower main cells - removal ............................................................................... 1
3. Lower middle cells and lower main cells - installation .......................................................................... 5
4. Lower middle cells and lower main cells - cleaning .............................................................................. 9
5. Lower middle cells and lower main cells - inspection ............................................................................ 9
MIDDLE CELL VENT HOSES
1. Lower middle cell vent hoses - description ............................................................................................ 1
28-Index
Rev. 3 Page 3
E-AB412-PT6T-2

Module Page
Number Title Number
2. Lower middle cell vent hoses - removal .................................................................................................1

3. Lower middle cell vent hoses - installation..............................................................................................2
MIDDLE CELL INTERCONNECT HOSE AND FITTING
1. Lower middle cell interconnect hose and fitting - description ................................................................1

2. Lower middle cell interconnect hose and fitting - removal ....................................................................1
3. Lower middle cell interconnect hose and fitting - installation ................................................................2
MIDDLE CELL/LOWER MAIN CELL INTERCONNECT FITTINGS
1. Lower middle cell/lower main cell interconnect fittings - description ...................................................1

2. Lower middle cell/lower main cell interconnect fittings - removal ........................................................1
3. Lower middle cell/lower main cell interconnect fittings - installation ....................................................2
MAIN CELL INLET/OUTLET FITTINGS
1. Lower main cell inlet/outlet fittings - description ...................................................................................1

2. Lower main cell inlet/outlet fittings - removal ........................................................................................1
3. Lower main cell inlet/outlet fittings - installation ...................................................................................5
28-10-23 FUEL STORAGE AND DISTRIBUTION SYSTEM (HELICOPTERS CODES [C][D]) - UPPER
FORWARD CENTER CELL
1. Upper forward center cell - description ...................................................................................................1

2. Upper forward center cell - removal .......................................................................................................1
3. Upper forward center cell - installation ...................................................................................................3
4. Upper forward center cell - cleaning .......................................................................................................6
5. Upper forward center cell - inspection ....................................................................................................6
FORWARD CENTER CELL BOTTOM COVER (SHORT STANDPIPE) ASSEMBLY
1. Upper forward center cell bottom cover (short standpipe) assembly - description .................................1
2. Upper forward center cell bottom cover (short standpipe) assembly - removal .....................................1
3. Upper forward center cell bottom cover (short standpipe) assembly - installation..................................2
FORWARD CENTER CELL BOTTOM COVER (TALL STANDPIPE) ASSEMBLY
1. Upper forward center cell bottom cover (tall standpipe) assembly - description ...................................1
2. Upper forward center cell bottom cover (tall standpipe) assembly - removal ........................................1
3. Upper forward center cell bottom cover (tall standpipe) assembly - installation ....................................2
FORWARD CENTER CELL INTERCONNECT FITTINGS
1. Upper forward center cell interconnect fittings - description ..................................................................1

2. Upper forward center cell interconnect fittings - removal ......................................................................1
3. Upper forward center cell interconnect fittings - installation...................................................................2
28-Index
Page 4 Rev. 3
E-AB412-PT6T-2

Module Page
Number Title Number
FORWARD CENTER CELL TOP COVER ASSEMBLY
1. Upper forward center cell top cover assembly - description .................................................................. 1

2. Upper forward center cell top cover assembly - removal ....................................................................... 1
3. Upper forward center cell top cover assembly - installation ................................................................... 2
AFT CENTER CELL
1. Upper aft center cell - description ........................................................................................................... 1

2. Upper aft center cell - removal ............................................................................................................... 1
3. Upper aft center cell - installation ........................................................................................................... 2
4. Upper aft center cell - inspection ............................................................................................................ 3
5. Upper aft center cell - cleaning ............................................................................................................... 3
AFT CENTER CELL BOTTOM COVER ASSEMBLY AND FITTING
1. Upper aft center cell bottom cover assembly and fitting - description ................................................... 1
2. Upper aft center cell bottom cover assembly and fitting - removal ........................................................ 1
3. Upper aft center cell bottom cover assembly and fitting - installation .................................................... 2
AFT CENTER CELL BOTTOM FITTING
1. Upper aft center cell bottom fitting - description ................................................................................... 1

2. Upper aft center cell bottom fitting - removal ........................................................................................ 1
3. Upper aft center cell bottom fitting - installation ................................................................................... 1
AFT CENTER CELL TOP COVER ASSEMBLY
1. Upper aft center cell top cover assembly - description ........................................................................... 1

2. Upper aft center cell top cover assembly - removal ............................................................................... 1
3. Upper aft center cell top cover assembly - installation ........................................................................... 2
LEFT CELL AND UPPER RIGHT CELL
1. Upper left cell and upper right cell - description .................................................................................... 1

2. Upper left cell and upper right cell - removal ......................................................................................... 1
3. Upper left cell and upper right cell - installation ..................................................................................... 3
4. Upper left cell and upper right cell - cleaning ......................................................................................... 5
5. Upper left cell and upper right cell - inspection ..................................................................................... 5
LEFT CELL AND UPPER RIGHT CELL OUTLET FITTINGS
1. Upper left cell and upper right cell outlet fittings - description .............................................................. 1
2. Upper left cell and upper right cell outlet fittings - removal .................................................................. 1
3. Upper left cell and upper right cell outlet fittings - installation............................................................... 2
28-Index
Rev. 3 Page 5
E-AB412-PT6T-2

Module Page
Number Title Number
LEFT CELL AND UPPER RIGHT CELL TOP COVER ASSEMBLIES
1. Upper left cell and upper right cell top cover assemblies - description ..................................................1
2. Upper left cell and upper right cell top cover assemblies - removal .......................................................1
3. Upper left cell and upper right cell top cover assemblies - installation ...................................................2

FORWARD INTERCONNECT VALVE
1. Forward interconnect valve - description ................................................................................................1

2. Forward interconnect valve - removal ....................................................................................................1
3. Forward interconnect valve - installation ................................................................................................1
INTERCONNECT VALVE
1. Aft interconnect valve - description ........................................................................................................1

2. Aft interconnect valve - removal .............................................................................................................1
3. Aft interconnect valve - installation ........................................................................................................1
28-20-03 FUEL STORAGE AND DISTRIBUTION SYSTEM (HELICOPTERS CODES [A][B]) - SUMP
ASSEMBLIES
1. Sump assemblies - description ................................................................................................................1

2. Sump assemblies - removal .....................................................................................................................1
3. Sump assemblies - installation .................................................................................................................5
4. Sump assemblies - inspection .................................................................................................................5
28-20-04 FUEL STORAGE AND DISTRIBUTION (HELICOPTERS CODES [A][B]) - DEFUELING

VALVES
1. Defueling valves - description .................................................................................................................1

2. Defueling valves - removal .....................................................................................................................1
3. Defueling valves - installation .................................................................................................................1
INTERCONNECT VALVES
1. Sump interconnect valves - description ..................................................................................................1

2. Sump interconnect valves - removal .......................................................................................................1
3. Sump interconnect valves - installation ..................................................................................................1
DRAIN VALVES
1. Sump drain valves - description ..............................................................................................................1

2. Sump drain valves - removal ...................................................................................................................1
3. Sump drain valves - installation ..............................................................................................................1
28-Index
Page 6 Rev. 3
E-AB412-PT6T-2

Module Page
Number Title Number
28-20-07 FUEL STORAGE AND DISTRIBUTION SYSTEM (HELICOPTERS CODES [A][B]) - FLOW
SWITCHES
1. Flow switches - description .................................................................................................................... 1

2. Flow switches - removal ......................................................................................................................... 1
3. Flow switches - installation .................................................................................................................... 1

AUXILIARY FUEL CAPPED CONNECTOR
1. Auxiliary fuel capped connector - description ........................................................................................ 1

2. Auxiliary fuel capped connector - removal ............................................................................................ 1
3. Auxiliary fuel capped connector - installation ........................................................................................ 1
28-20-09 FUEL STORAGE AND DISTRIBUTION SYSTEM (HELICOPTERS CODES [A][B]) - FLAPPER
VALVES
1. Flapper valves - description .................................................................................................................... 1

2. Flapper valves - removal ......................................................................................................................... 1
3. Flapper valves - installation .................................................................................................................... 1
4. Flapper valves - inspection ..................................................................................................................... 4

EJECTOR PUMPS
1. Ejector pumps - description .................................................................................................................... 1

2. Ejector pumps - removal ......................................................................................................................... 1
3. Ejector pumps - installation ..................................................................................................................... 2
4. Ejector pumps - cleaning ........................................................................................................................ 2

EJECTOR PUMP SUPPORTS
1. Ejector pump supports - description ....................................................................................................... 1

2. Ejector pump supports - removal ............................................................................................................ 1
3. Ejector pump supports - installation ....................................................................................................... 1
28-20-12 FUEL STORAGE AND DISTRIBUTION SYSTEM (HELICOPTERS CODES [A][B]) - SIPHON
BREAKER VALVES
1. Siphon breaker valves - description ........................................................................................................ 1

2. Siphon breaker valves - removal ............................................................................................................ 1
3. Siphon breaker valves - installation ........................................................................................................ 1

SHUTOFF VALVES
1. Shutoff valves - description .................................................................................................................... 1

2. Shutoff valves - removal ......................................................................................................................... 1
3. Shutoff valves - installation ..................................................................................................................... 2
28-Index
Rev. 3 Page 7
E-AB412-PT6T-2

Module Page
Number Title Number

CROSSFEED VALVE
1. Crossfeed valve - description ..................................................................................................................1

2. Crossfeed valve - removal .......................................................................................................................1
3. Crossfeed valve - installation ..................................................................................................................1

GOVERNOR BLEED LINE CHECK VALVES
1. Governor bleed line check valves - description ......................................................................................1

2. Governor bleed line check valves - removal ...........................................................................................1
3. Governor bleed line check valves - installation ......................................................................................1
28-20-16 FUEL STORAGE AND DISTRIBUTION SYSTEM (HELICOPTERS CODES [A][B]) - FILLER
CAP AND ADAPTER ASSEMBLY (HELICOPTERS NOT EQUIPPED WITH PUMP
P/N 206-062-687-101)
1. Filler cap and adapter assembly (helicopters not equipped with pump P/N 206-062-687-101) -
description ...............................................................................................................................................1
removal ....................................................................................................................................................1
installation ...............................................................................................................................................1

IMPROVED FILLER CAP AND ADAPTER ASSEMBLY (EQUIPPED WITH PUMP
P/N 206-062-687-101)
1. Improved filler cap and adapter assembly (equipped with pump P/N 206-062-687-101) - description..1
2. Improved filler cap and adapter assembly (equipped with pump P/N 206-062-687-101) - removal ......1
3. Improved filler cap and adapter assembly (equipped with pump P/N 206-062-687-101) - installation..1
FORWARD CELL SUMP ASSEMBLIES
1. Lower forward cell sump assemblies - description .................................................................................1

2. Lower forward cell sump assemblies - removal ......................................................................................1
3. Lower forward cell sump assemblies - installation .................................................................................2
4. Lower forward cell sump assemblies - inspection ...................................................................................8
28-20-19 FUEL STORAGE AND DISTRIBUTION SYSTEM (HELICOPTER CODES [C][D]) -

TRANSFER PUMPS
1. Transfer pumps - description ...................................................................................................................1

2. Transfer pumps - removal .......................................................................................................................1
3. Transfer pumps - installation....................................................................................................................2
28-20-20 FUEL STORAGE AND DISTRIBUTION SYSTEM (HELICOPTERS CODES [C][D]) -

CANNISTER TYPE TRANSFER PUMPS
1. Cannister type transfer pumps - description ............................................................................................1
28-Index
Page 8 Rev. 3
E-AB412-PT6T-2

Module Page
Number Title Number
2. Cannister type transfer pumps - removal ................................................................................................ 1

3. Cannister type transfer pumps - installation ............................................................................................ 2
4. Cannister type transfer pumps - cartridge ............................................................................................... 2
28-20-21 FUEL STORAGE AND DISTRIBUTION SYSTEM (HELICOPTERS CODES [C][D]) - SUMP
DRAIN VALVES
1. Sump drain valves - description .............................................................................................................. 1

2. Sump drain valves - removal .................................................................................................................. 1
3. Sump drain valves - installation............................................................................................................... 2
FORWARD CELL CHECK VALVES
1. Lower forward cell check valves - description ....................................................................................... 1

2. Lower forward cell check valves - removal ............................................................................................ 1
3. Lower forward cell check valves - installation ........................................................................................ 2
MIDDLE CELL SUMP ASSEMBLIES
1. Lower middle cell sump assemblies - description .................................................................................. 1

2. Lower middle cell sump assemblies - removal ....................................................................................... 1
3. Lower middle cell sump assemblies - installation ................................................................................... 2
4. Lower middle cell sump assemblies - inspection and repair .................................................................. 2

EJECTOR PUMPS
1. Ejector pumps - description .................................................................................................................... 1

2. Ejector pumps - removal ......................................................................................................................... 1
3. Ejector pumps - installation ..................................................................................................................... 2
4. Ejector pumps - cleaning ........................................................................................................................ 2
5. Ejector pumpS - inspection ..................................................................................................................... 2
28-20-25 FUEL STORAGE AND DISTRIBUTION SYSTEM (HELICOPTER CODES [C][D]) - SUMP
DRAIN VALVES
1. Sump drain valves - description .............................................................................................................. 1

2. Sump drain valves - removal .................................................................................................................. 1
3. Sump drain valves - installation............................................................................................................... 2
MAIN CELL VENT VALVES AND HOSES
1. Lower main cell vent valves and hoses - description ............................................................................. 1

2. Lower main cell vent valves and hoses - removal .................................................................................. 1
3. Lower main cell vent valves and hoses - installation .............................................................................. 2
MAIN CELL INTERCONNECT HOSES
1. Lower main cell interconnect hoses - description .................................................................................. 1
28-Index
Rev. 3 Page 9
E-AB412-PT6T-2

Module Page
Number Title Number
2. Lower main cell interconnect hoses - removal ........................................................................................1

3. Lower main cell interconnect hoses - installation ....................................................................................2
MAIN CELL SUMP ASSEMBLIES
1. Lower main cell sump assemblies - description ......................................................................................1

2. Lower main cell sump assemblies - removal ..........................................................................................1
3. Lower main cell sump assemblies - installation ......................................................................................2
4. Lower main cell sump assemblies - inspection ........................................................................................3
28-20-29 FUEL STORAGE AND DISTRIBUTION SYSTEM (HELICOPTERS CODES [C][D]) - BOOST
PUMPS
1. Boost pumps - description .......................................................................................................................1

2. Boost pumps - removal ...........................................................................................................................1
3. Boost pumps - installation........................................................................................................................2

CANISTER TYPE BOOST PUMP
1. Canister type boost pump - description ...................................................................................................1

2. Canister type boost pump - removal .......................................................................................................1
3. Canister type boost pump - installation....................................................................................................2

CANISTER TYPE BOOST PUMP CARTRIDGE
1. Canister type boost pump cartridge - description.....................................................................................1

2. Canister type boost pump cartridge - removal .........................................................................................1
3. Canister type boost pump cartridge - installation.....................................................................................2
4. Canister type boost pump cartridge - cleaning.........................................................................................3
5. Cartridge pump cover packing - replacement ..........................................................................................3
28-20-32 FUEL STORAGE AND DISTRIBUTION SYSTEM (HELICOPTERS CODES [C][D]) - FLOW
SWITCH CHECK VALVES
1. Flow switch check valves - description ...................................................................................................1

2. Flow switch check valves - removal .......................................................................................................1
3. Flow switch check valves - installation....................................................................................................2
DRAIN VALVES
1. Sump drain valves - description ..............................................................................................................1

2. Sump drain valves - removal ...................................................................................................................1
3. Sump drain valves - installation ..............................................................................................................1
28-Index
Page 10 Rev. 3
E-AB412-PT6T-2

Module Page
Number Title Number

INTERCONNECT VALVE
1. Interconnect valve - description .............................................................................................................. 1

2. Interconnect valve - removal .................................................................................................................. 1
3. Interconnect valve - installation............................................................................................................... 2
28-20-35 FUEL STORAGE AND DISTRIBUTION SYSTEM (HELICOPTERS CODES [C][D]) - FILLER
CAP AND ADAPTER ASSEMBLY
1. Filler cap and adapter assembly - description ......................................................................................... 1

2. Filler cap and adapter assembly - removal ............................................................................................. 1
3. Filler cap and adapter assembly - installation ......................................................................................... 1

IMPROVED FILLER CAP AND ADAPTER ASSEMBLY
1. Improved filler cap and adapter assembly - description ......................................................................... 1

2. Improved filler cap and adapter assembly - removal .............................................................................. 1
3. Improved filler cap and adapter assembly - installation ......................................................................... 1
28-20-37 FUEL STORAGE AND DISTRIBUTION SYSTEM (HELICOPTERS CODES [C][D]) - ENGINE
FUEL FEED LINE PRESSURE SWITCHES
1. Engine fuel feed line pressure switches - description ............................................................................. 1

2. Engine fuel feed line pressure switches - removal ................................................................................. 1
3. Engine fuel feed line pressure switches - installation.............................................................................. 2
28-20-38 FUEL STORAGE AND DISTRIBUTION SYSTEM (HELICOPTERS CODES [C][D]) - FUEL
FEED LINE CHECK VALVES
1. Fuel feed line check valves - description ................................................................................................ 1

2. Fuel feed line check valves - removal .................................................................................................... 1
3. Fuel feed line check valves - installation................................................................................................. 2

SHUTOFF VALVES
1. Shutoff valves - description .................................................................................................................... 1

2. Shutoff valves - removal ......................................................................................................................... 1
3. Shutoff valves - installation ..................................................................................................................... 2

CROSSFEED VALVE
1. Crossfeed valve - description .................................................................................................................. 1

2. Crossfeed valve - removal ...................................................................................................................... 1
3. Crossfeed valve - installation................................................................................................................... 2
28-Index
Rev. 3 Page 11
E-AB412-PT6T-2

Module Page
Number Title Number
28-20-41 FUEL STORAGE AND DISTRIBUTION SYSTEM [C] [D] - FUEL PRESSURE
TRANSMITTERS
1. Fuel pressure transmitters - description ..................................................................................................1

2. Fuel pressure transmitters - removal .......................................................................................................1
3. Fuel pressure transmitters - installation ...................................................................................................2

PRESSURE TESTING
1. Pressure testing - description ...................................................................................................................1
28-40-02 FUEL STORAGE AND DISTRIBUTION SYSTEM (HELICOPTERS CODES [A][B]) - FUEL
PRESSURE TRANSMITTERS
1. Fuel pressure transmitters - description ..................................................................................................1

2. Fuel pressure transmitters - removal .......................................................................................................1
3. Fuel pressure transmitters - installation ..................................................................................................1
QUANTITY PROBES
1. Fuel quantity probes - description ...........................................................................................................1

FORWARD CELL FUEL QUANTITY PROBES
1. Forward cell fuel quantity probes - description ......................................................................................1

2. Forward cell fuel quantity probes - removal ...........................................................................................1
3. Forward cell fuel quantity probes - installation .......................................................................................3
AFT CELL FUEL QUANTITY PROBE
1. Center aft fuel quantity probe - description ............................................................................................1

2. Center aft fuel quantity probe - removal .................................................................................................1
3. Center aft fuel quantity probe - installation ............................................................................................1

PRESSURE TESTING
1. Pressure testing - description ...................................................................................................................1

FORWARD TO MIDDLE FUEL CELL LEAK CHECK
1. Forward to middle fuel cell leak - description ........................................................................................1
QUANTITY PROBES
1. Fuel quantity probes - description ...........................................................................................................1
28-Index
Page 12 Rev. 3
E-AB412-PT6T-2

Module Page
Number Title Number
2. Fuel quantity probes - lower forward cell fuel quantity probes .............................................................. 1
2-1. Lower forward cell fuel quantity probes - description .................................................................. 1
2-2. Lower forward cell fuel quantity probes - removal ....................................................................... 1
2-3. Lower forward cell fuel quantity probes - installation .................................................................. 2
3. Fuel quantity probes - lower middle cell fuel quantity probes ............................................................... 5
3-1. Lower middle cell fuel quantity probes - description .................................................................... 5
3-2. Lower middle cell fuel quantity probes - removal ......................................................................... 5
3-3. Lower middle cell fuel quantity probes - installation ..................................................................... 6
4. Fuel quantity probes - lower main cell fuel quantity probes ................................................................... 9
4-1. Lower main cell fuel quantity probes - description ....................................................................... 9
4-2. Lower main cell fuel quantity probes - removal ............................................................................ 9
4-3. Lower main cell fuel quantity probes - installation ....................................................................... 9
5. Fuel quantity probes - upper left and upper right cell fuel quantity probes........................................... 10
5-1. Upper left and upper right cell fuel quantity probes - description ............................................... 10
5-2. Upper left and upper right cell fuel quantity probes - removal ................................................... 10
5-3. Upper left and upper right cell fuel quantity probes - installation ............................................... 10
28-Index
Rev. 3 Page 13
E-AB412-PT6T-2
FIGURES
Figure Page
Number Title Number
[A][B])
Figure 1. Fuel storage and distribution system (helicopters codes [A][B]) (sheet 1 of 2) .............................................4
Figure 2. Fuel system schematic (helicopters codes [A][B]) .........................................................................................6
Figure 1. Fuel storage and distribution system (helicopters codes [C][D]) (sheet 1 of 2) .............................................3
Figure 2. Fuel system schematic (helicopters code [C]) (sheet 1 of 2) ..........................................................................5
Figure 3. Fuel burn sequence diagram (helicopters codes [C][D]) ................................................................................7
28-10-01 FUEL STORAGE AND DISTRIBUTION SYSTEM (HELICOPTERS CODES [A][B]) - LOW
FUEL LEVEL WARNING SWITCHES
Figure 1. Fuel storage distribution system (helicopters codes [A][B]) (sheet 1 of 2) ....................................................2
Figure 2. Low fuel level warning switch (helicopters codes [A][B]).............................................................................4
Figure 2. Boost pump (helicopters codes [A][B]) ..........................................................................................................4

CANISTER TYPE BOOST PUMPS
Figure 1. Canister type boost pump................................................................................................................................2
28-10-04 FUEL STORAGE AND DISTRIBUTION (HELICOPTERS CODES [A][B]) - FORWARD CELL
INLET/OUTLET FITTINGS
Figure 2. Forward cell inlet/outlet fitting (helicopters codes [A][B]) ............................................................................4

FORWARD CELL CRASH RESISTANT VENT VALVES
Figure 2. Forward cell crash resistant vent valve (helicopters codes [A][B]) ................................................................4

FORWARD CELLS
Figure 2. Forward fuel cell (helicopters codes [A][B]) ..................................................................................................6
Figure 3. Forward cell lacing (helicopters codes [A][B]) ..............................................................................................7
AFT CELL OUTLET FITTINGS
Figure 1. Center aft cell outlet fitting (helicopters codes [A][B]) ..................................................................................2
28-Index
Page 14 Rev. 3
E-AB412-PT6T-2
FIGURES (CONT.D)
Figure Page
Number Title Number
AFT CELL VENT COVER
Figure 1. Fuel storage and distribution system (helicopters codes [A][B]) (sheet 1 of 2)............................................. 3
Figure 2. Center aft vent cover (helicopters codes [A][B]) ........................................................................................... 5
CELL VENT FITTINGS
Figure 2. Left aft and right aft cell vent fitting (helicopters codes [A][B]) ................................................................... 4
AFT CELL REAR COVER
Figure 1. Center aft cell rear cover (helicopters codes [A][B]) ..................................................................................... 3
CELL OUTLET FITTINGS
Figure 2. Left aft and right aft cell outlet fitting (helicopters codes [A][B]) ................................................................. 5
CELLS
Figure 2. Left aft and right aft cell (helicopters codes [A][B])...................................................................................... 5
AFT CELL
Figure 2. Center aft cell (helicopters codes [A][B]) ...................................................................................................... 4
FORWARD CELLS
Figure 1. Lower forward cell (helicopters codes [C][D]) .............................................................................................. 3
FORWARD CELL VENT HOSES
Figure 1. Lower forward cell vent hose (helicopters codes [C][D]) .............................................................................. 3
FORWARD CELL INTERCONNECT HOSE AND FITTING
Figure 1. Lower forward cell interconnect hose and fitting (helicopters codes [C][D]) (sheet 1 of 3) ......................... 3
28-Index
Rev. 3 Page 15
E-AB412-PT6T-2
FIGURES (CONT.D)
Figure Page
Number Title Number
FORWARD CELL/LOWER MIDDLE CELL INTERCONNECT FITTING
Figure 1. Lower forward cell/lower middle cell interconnect fitting (helicopters codes [C][D]) ..................................4
Figure 2. Lower forward cell check valve (helicopters codes [C][D])...........................................................................5
MIDDLE CELLS AND LOWER MAIN CELLS
Figure 1. Lower middle cell/lower main cell (helicopters codes [C][D]) (sheet 1 of 2) ................................................3
Figure 2. Lower forward cell sump assembly (helicopters codes [C][D]) (sheet 1 of 2) ...............................................7
MIDDLE CELL VENT HOSES
Figure 1. Lower middle cell vent hose (helicopters codes [C][D]) ................................................................................3
MIDDLE CELL INTERCONNECT HOSE AND FITTING
Figure 1. Lower middle cell interconnect hose and fitting (helicopters codes [C][D])..................................................3
MIDDLE CELL/LOWER MAIN CELL INTERCONNECT FITTINGS
Figure 1. Lower middle cell/lower main cell interconnect fitting (helicopters codes [C][D]).......................................3
MAIN CELL INLET/OUTLET FITTINGS
Figure 1. Lower main cell inlet/outlet fitting (helicopters code [C]) (sheet 1 of 2) .......................................................3
FORWARD CENTER CELL
Figure 1. Upper forward center fuel cell (helicopters codes [C][D]) .............................................................................2
Figure 2. Upper forward center cell interconnect fittings (helicopters codes [C] [D]) ..................................................5
FORWARD CENTER CELL BOTTOM COVER (SHORT STANDPIPE) ASSEMBLY
Figure 1. Upper forward center cell bottom cover (short standpipe) assembly (helicopters codes [C][D]) ..................3
FORWARD CENTER CELL BOTTOM COVER (TALL STANDPIPE) ASSEMBLY
Figure 1. Upper forward center cell bottom cover (tall standpipe) assembly (helicopters codes [C][D]) .....................3
FORWARD CENTER CELL INTERCONNECT FITTINGS
Figure 1. Upper forward center cell interconnect fittings (helicopters codes [C] [D]) ..................................................3
28-Index
Page 16 Rev. 3
E-AB412-PT6T-2
FIGURES (CONT.D)
Figure Page
Number Title Number
FORWARD CENTER CELL TOP COVER ASSEMBLY
Figure 1. Upper forward center cell top cover assembly (helicopters codes [C][D]) .................................................... 3
AFT CENTER CELL
Figure 1. Upper aft center cell (helicopters codes [C][D]) ............................................................................................ 4
AFT CENTER CELL BOTTOM COVER ASSEMBLY AND FITTING
Figure 1. Upper aft center cell bottom cover and fitting (helicopters codes [C][D])..................................................... 3
AFT CENTER CELL BOTTOM FITTING
Figure 1. Upper aft center cell bottom fitting (helicopters codes [C][D]) ..................................................................... 2
AFT CENTER CELL TOP COVER ASSEMBLY
Figure 1. Upper aft center cell top cover assembly (helicopters codes [C][D]) ............................................................ 4
LEFT CELL AND UPPER RIGHT CELL
Figure 1. Upper left cell and upper right cell (helicopters codes [C][D])...................................................................... 2
Figure 2. Upper left cell and upper right cell outlet fittings (helicopters codes [C][D]) ............................................... 4
LEFT CELL AND UPPER RIGHT CELL OUTLET FITTINGS
Figure 1. Upper left cell and upper right cell outlet fittings (helicopters codes [C][D]) ............................................... 3
LEFT CELL AND UPPER RIGHT CELL TOP COVER ASSEMBLIES
Figure 1. Upper left cell and upper right cell top cover assembly (helicopters codes [C][D])...................................... 3

FORWARD INTERCONNECT VALVE
Figure 2. Forward interconnect valve (helicopters codes [A][B]) ................................................................................. 5
INTERCONNECT VALVE
Figure 2. Aft interconnect valve (helicopters codes [A][B]) ......................................................................................... 5
28-Index
Rev. 3 Page 17
E-AB412-PT6T-2
FIGURES (CONT.D)
Figure Page
Number Title Number
ASSEMBLIES
Figure 2. Sump assembly (helicopters codes [A][B]) ....................................................................................................4
28-20-04 FUEL STORAGE AND DISTRIBUTION (HELICOPTERS CODES [A][B]) - DEFUELING

VALVES
Figure 1. Defueling valve (helicopters codes [A][B])....................................................................................................2
INTERCONNECT VALVES
Figure 1. Sump interconnect valve (helicopters codes [A][B])......................................................................................2
DRAIN VALVES
Figure 1. Sump drain valve (helicopters codes [A][B]) .................................................................................................3
28-20-07 FUEL STORAGE AND DISTRIBUTION SYSTEM (HELICOPTERS CODES [A][B]) - FLOW
SWITCHES
Figure 2. Flow switch (helicopters codes [A][B])..........................................................................................................4

AUXILIARY FUEL CAPPED CONNECTOR
Figure 1. Auxiliary fuel capped connector (helicopters codes [A][B])..........................................................................2
28-20-09 FUEL STORAGE AND DISTRIBUTION SYSTEM (HELICOPTERS CODES [A][B]) - FLAPPER
VALVES
Figure 2. Flapper valve (helicopters codes [A][B])........................................................................................................4

EJECTOR PUMPS
Figure 2. Ejector pump (helicopters codes [A][B])........................................................................................................5

EJECTOR PUMP SUPPORTS
Figure 1. Ejector pump support (helicopters codes [A][B])...........................................................................................2
28-Index
Page 18 Rev. 3
E-AB412-PT6T-2
FIGURES (CONT.D)
Figure Page
Number Title Number
28-20-12 FUEL STORAGE AND DISTRIBUTION SYSTEM (HELICOPTERS CODES [A][B]) - SIPHON
BREAKER VALVES
Figure 2. Siphon breaker valve (helicopters codes [A][B]) ........................................................................................... 4

SHUTOFF VALVES
Figure 2. Shutoff valve (helicopters codes [A][B]) ....................................................................................................... 5

CROSSFEED VALVE
Figure 2. Crossfeed valve (helicopters codes [A][B]) ................................................................................................... 5

GOVERNOR BLEED LINE CHECK VALVES
Figure 1. Governor bleed line check valve (helicopters codes [A][B]) ......................................................................... 2
28-20-16 FUEL STORAGE AND DISTRIBUTION SYSTEM (HELICOPTERS CODES [A][B]) - FILLER
CAP AND ADAPTER ASSEMBLY (HELICOPTERS NOT EQUIPPED WITH PUMP
P/N 206-062-687-101)
Figure 2. Filler cap and adapter assembly (helicopters codes [A][B]) .......................................................................... 4

IMPROVED FILLER CAP AND ADAPTER ASSEMBLY (EQUIPPED WITH PUMP
P/N 206-062-687-101)
Figure 1. Improved filler cap and adapter assembly ...................................................................................................... 2
FORWARD CELL SUMP ASSEMBLIES
Figure 1. Fuel storage and distribution system (helicopters codes [C][D]) (sheet 1 of 2)............................................. 3
Figure 2. Lower forward cell sump assembly (helicopters codes [C][D]) (sheet 1 of 3) .............................................. 5
28-20-19 FUEL STORAGE AND DISTRIBUTION SYSTEM (HELICOPTER CODES [C][D]) -

TRANSFER PUMPS
Figure 1. Transfer pump (helicopters codes [C][D]) ..................................................................................................... 3

CANNISTER TYPE TRANSFER PUMPS
Figure 1. Cannister type transfer pump (helicopters codes [C][D]) .............................................................................. 3
28-Index
Rev. 3 Page 19
E-AB412-PT6T-2
FIGURES (CONT.D)
Figure Page
Number Title Number
DRAIN VALVES
Figure 1. Lower forward cell sump assembly (helicopters codes [C][D]) (sheet 1 of 2) ...............................................3
FORWARD CELL CHECK VALVES
Figure 1. Lower forward cell check valve (helicopters codes [C][D])...........................................................................3
MIDDLE CELL SUMP ASSEMBLIES
Figure 1. Lower middle cell sump assembly (helicopters codes [C][D]).......................................................................3

EJECTOR PUMPS
Figure 1. Ejector pump (helicopters codes [C][D])........................................................................................................3
28-20-25 FUEL STORAGE AND DISTRIBUTION SYSTEM (HELICOPTER CODES [C][D]) - SUMP
DRAIN VALVES
Figure 1. Lower middle cell sump assembly (helicopters codes [C][D]).......................................................................3
MAIN CELL VENT VALVES AND HOSES
Figure 1. Lower main cell vent valve and hose (helicopters codes [C][D])...................................................................3
MAIN CELL INTERCONNECT HOSES
Figure 1. Lower main cell interconnect hose (helicopters codes [C][D]) ......................................................................3
MAIN CELL SUMP ASSEMBLIES
Figure 1. Lower main cell sump assembly (helicopters codes [C][D]) (sheet 1 of 2)....................................................4
28-20-29 FUEL STORAGE AND DISTRIBUTION SYSTEM (HELICOPTERS CODES [C][D]) - BOOST
PUMPS
Figure 1. Boost pump (helicopters codes [C][D]) ..........................................................................................................3

CANISTER TYPE BOOST PUMP
Figure 1. Canister type boost pump (helicopters codes [C] [D])....................................................................................3
28-Index
Page 20 Rev. 3
E-AB412-PT6T-2
FIGURES (CONT.D)
Figure Page
Number Title Number

CANISTER TYPE BOOST PUMP CARTRIDGE
Figure 1. Boost pump cartridge (sheet 1 of 2) ............................................................................................................... 5
28-20-32 FUEL STORAGE AND DISTRIBUTION SYSTEM (HELICOPTERS CODES [C][D]) - FLOW
SWITCH CHECK VALVES
Figure 1. Flow switch check valve (helicopters codes [C][D]) ..................................................................................... 3
DRAIN VALVES
Figure 1. Lower main cell sump assembly (helicopters codes [C][D]) ......................................................................... 3

INTERCONNECT VALVE
Figure 1. Interconnect valve (helicopters codes [C] [D]) .............................................................................................. 3
28-20-35 FUEL STORAGE AND DISTRIBUTION SYSTEM (HELICOPTERS CODES [C][D]) - FILLER
CAP AND ADAPTER ASSEMBLY
Figure 1. Filler cap and adapter assembly...................................................................................................................... 2

IMPROVED FILLER CAP AND ADAPTER ASSEMBLY
Figure 1. Improved filler cap and adapter assembly ...................................................................................................... 2
28-20-37 FUEL STORAGE AND DISTRIBUTION SYSTEM (HELICOPTERS CODES [C][D]) - ENGINE
FUEL FEED LINE PRESSURE SWITCHES
Figure 1. Fuel feed line pressure switch (helicopters codes [C][D]) ............................................................................. 3
FEED LINE CHECK VALVES
Figure 1. Fuel feed line check valve (helicopters codes [C][D]) ................................................................................... 3

SHUTOFF VALVES
Figure 1. Shutoff valve (helicopters codes [C][D]) ....................................................................................................... 3

CROSSFEED VALVE
Figure 1. Crossfeed valve (helicopters codes [C][D]) ................................................................................................... 3
28-Index
Rev. 3 Page 21
E-AB412-PT6T-2
FIGURES (CONT.D)
Figure Page
Number Title Number
28-20-41 FUEL STORAGE AND DISTRIBUTION SYSTEM [C] [D] - FUEL PRESSURE
TRANSMITTERS
Figure 1. Left and right fuel pressure transmitter (helicopters codes [C] [D])...............................................................3
PRESSURE TRANSMITTERS
Figure 2. Fuel pressure transmitter (helicopters codes [A][B])......................................................................................5
QUANTITY PROBES
Figure 1. Fuel quantity probes (helicopters codes [A][B]).............................................................................................2

FORWARD CELL FUEL QUANTITY PROBES
Figure 1. Forward cell fuel quantity probe (helicopters codes [A][B])..........................................................................2
AFT CELL FUEL QUANTITY PROBE
Figure 1. Center cell fuel quantity probe (helicopters codes [A][B]).............................................................................2
QUANTITY PROBES
Figure 1. Fuel quantity probes (helicopters codes [C] [D])............................................................................................3

Figure 2. Lower forward cell fuel quantity probe (helicopters codes [C] [D]) ..............................................................4
Figure 3. Lower main cell fuel quantity probe (helicopters codes [C] [D]) ...................................................................7
Figure 4. Lower middle cell fuel quantity probe (helicopters codes [C] [D])................................................................8
Figure 5. Upper left and upper right cell fuel quantity probe (helicopters codes [C] [D])...........................................12
28-Index
Page 22 Rev. 3
E-AB412-PT6T-2
TABLES
Table Page
Number Title Number
[A][B])
Table 1. Fuel system troubleshooting (helicopters codes [A][B])................................................................................ 2
Table 1. Fuel system troubleshooting (helicopters codes [C][D])................................................................................ 8
28-Index
Rev. 3 Page 23
E-AB412-PT6T-2
28-Index
Page 24 Rev. 3
E-AB412-PT6T-2
28-0 -0 FUEL SYSTEM
28-00-00
FUEL SYSTEM
1. FUEL SYSTEM - GENERAL
For ease of use, this Chapter is divided into two parts. The first part provides complete maintenance instructions for
helicopters codes [A][B]. The second part provides the same depth of coverage for helicopters codes [C][D]. Before
proceeding with any maintenance on helicopter fuel system, carefully read the general safety precautions in the following
paragraph.
2. FUEL SYSTEM - SAFETY PRECAUTIONS
WARNING
ONLY APPROVED, EXPLOSION PROOF TYPE LIGHTS ARE TO BE USED

NEAR OPEN FUEL CELLS AND FUEL LINES.
CAUTION
HANDLE CELLS WITH EXTREME CARE DURING REMOVAL AND

INSTALLATION TO PREVENT DAMAGE TO CELLS. DO NOT ATTEMPT TO
REMOVE, FOLD, OR INSTALL A CELL WHEN CELL TEMPERATURE IS
BELOW 65F (18C).
CAUTION
ALL FUELING AND DEFUELING OPERATIONS SHALL BE CONDUCTED IN

AREAS WHERE FIRE HAZARDS ARE REDUCED TO A MINIMUM. FOR
COMPLETE DEFUELING/REFUELING PROCEDURES READ AND FOLLOW
INSTRUCTIONS CONTAINED IN CHAPTER 12 OF THIS MANUAL.
CAUTION
CAP OR PLUG ALL LINES, HOSES, AND PORTS AS COMPONENTS ARE

REMOVED.
28-00-00
Page 1
E-AB412-PT6T-2
28-00-00
Page 2
E-AB412-PT6T-2
28-0 -01 FUEL SYSTEM - FUEL STORAGE AND DISTRIBUTION SYSTEM (HELICOPTERS CODES [A][B])
28-00-01
FUEL SYSTEM - FUEL STORAGE AND DISTRIBUTION SYSTEM
(HELICOPTERS CODES [A][B])
1. FUEL STORAGE AND DISTRIBUTION SYSTEM (HELICOPTERS CODES [A][B]) -

DESCRIPTION
The following paragraphs provide a functional description of the components which store and deliver fuel to the engine
power sections for helicopters codes [A][B].
The fuel system (figure 1 and figure 2) is comprised of fuel storage cells, transfer system, venting system, dual engine feed
system, and electrical control and warning systems. The system is designed to provide fuel containment in the event of an
accident or incident during which fuel system rupture might occur. The cells are of a crash-resistant, laminated fabric and
rubber construction. The cells are suspended in the fuselage cavities by nylon cord laced between hangers attached to the
cells and fuselage structure.
The fuel system has a maximum capacity of 217 U.S. gallons (211 U.S. gallons usable). Fuel is contained in five
interconnected cells (1, 8, 13, 19, and 33, figure 1). The two forward cells (19 and 33), located under the cabin floor, are
supplied continuously by gravity feed from the three aft cells (1, 8, and 13). Under normal conditions, each forward cell
supplies fuel to the power section located on the same side of the helicopter. However, if boost pump (16 or 28) in either cell
ceases to function, crossfeed valve (4) opens automatically to permit flow from remaining pump to be directed to both power
sections.
Forward cells (19 and 33) are divided into forward and aft compartments by baffles (17 and 34). The aft compartments
contain sump assemblies (16 and 28) equipped with electrically operated boost pumps, crashworthy defueling valves, flow
switches connected to the FUEL BOOST caution panel segments, sump drain valves, sump interconnect valves, and low
fuel level warning switches connected to the FUEL LOW caution panel segments. The forward cells are connected by
forward and aft interconnect lines which are normally closed by electrically controlled interconnect valves (24 and 31).
These valves may be opened by the pilot to permit flow between cells. Fuel quantity probes (tank units) (25, 26, 29, and 35)
are installed in each compartment. Flapper valves (18 and 30) in baffles (17 and 34) between compartments allow front to
back flow. Ejector pumps (20 and 32) mounted on cell front walls continuously send fuel back over baffles (17 and 34) to
aft compartments to ensure maximum usability of fuel at all helicopter attitudes.
The three aft cells (1, 8, and 13) are aligned laterally across the fuselage. The right aft cell (1) supplies the right forward cell
(33), and the left aft cell (8) supplies the left forward cell (19). Interconnect fittings (11 and 22) connect the center aft cell
(13) to right and left aft cells (1 and 8) to maintain the same fuel level in all three aft cells. The helicopter is fueled through
a filler cap and adapter assembly (2) is installed on the right aft cell (1) for system servicing. A fuel quantity probe (23) is
installed in center cell (13). Capped connections for use with auxiliary fuel tanks are provided on system vent lines and on
fittings located aft of each forward cell (19 and 33).
The center aft cell (13) is vented through a line attached to vent cover (5). Right and left aft cells (1 and 8) are vented through
fittings (7 and 41) attached to ports in top of cells. Crashworthy vent valves (27 and 36) are used to vent forward cells (19
and 33).
A cover (9) on rear of center aft cell (13) provides main point of access to cell interior. Vent cover (5) may also be removed
for access when necessary. The rear cover contains two governor bleed line check valves (10) that enable excess fuel from
each engine fuel control to return to center aft cell (13).
Fuel is drained from center aft cell (13) through outlet fittings (12 and 38) mounted on underside of cell. Similarly, fuel is
drained from right and left aft cells (1 and 8) through outlet fittings (14 and 39) attached to underside of cells. Fuel enters
and leaves forward cells (19 and 33) through inlet/outlet fittings (15 and 37) installed in rear walls of aft compartment of
cells.
28-00-01
Page 1
E-AB412-PT6T-2
Two siphon breaker valves (21) are installed in vent lines near left shutoff valve (40) to prevent fuel loss due to siphoning
through vent tubes.
Engine fuel feed line pressure (boost pump pressure) is sensed by fuel pressure transmitters (3 and 6), and corresponding
electrical signals are transmitted to pressure (FUEL PRESS) indicators located in instrument panel.
Refer to Chapter 52 for locations of doors, panels, cowlings, and covers to be removed for access to fuel system components.
Refer to Chapters 95, 96, and 98 for maintenance and testing of associated electrical systems.
2. FUEL STORAGE AND DISTRIBUTION SYSTEM (HELICOPTERS CODES [A][B]) -

TROUBLESHOOTING
Refer to table 1 for fuel system troubleshooting.
Table 1. Fuel system troubleshooting (helicopters codes [A][B])
FUEL FILTER caution panel segment Filter element clogged. Remove and inspect filter element.
illuminated. Clean or replace filter element. (Refer
to engine maintenance manual.)
FUEL BOOST caution panel segment Obstructed pump line through flow Replace flow switch (module
illuminated. switch and ejector pump. 28-20-07 "FUEL STORAGE AND
DISTRIBUTION SYSTEM (HELI-
COPTERS CODES [A][B]) - FLOW
SWITCHES"), ejector pump (module
28-20-10 "FUEL STORAGE AND
COPTERS CODES [A][B]) - EJEC-
TOR PUMPS"), or obstructed hoses.
No electrical power to boost pump. Repair wiring or replace faulty units in

circuit.
Defective boost pump. Replace boost pump (module

DISTRIBUTION (HELICOPTERS
CODES [A][B]) - BOOST PUMPS").
Shutoff valve inoperative. Shutoff valve faulty or lacking electri- Repair circuit.
cal power.
Replace shutoff valve (module

COPTERS CODES [A][B]) - SHUT-
OFF VALVES").
28-00-01
Page 2
E-AB412-PT6T-2
(Cont.)
Interconnect valve (forward, aft, or Interconnect valve faulty or lacking Repair circuit.
crossfeed) inoperative. electrical power.
Replace interconnect valve (module

COPTERS CODES [A][B]) - FOR-
WARD INTERCONNECT VALVE",
module 28-20-02 "FUEL STORAGE
AND DISTRIBUTION SYSTEM
(HELICOPTERS CODES [A][B]) -
AFT INTERCONNECT VALVE", and
module 28-20-05 "FUEL STORAGE
AND DISTRIBUTION SYSTEM
(HELICOPTERS CODES [A][B]) -
SUMP INTERCONNECT VALVES").
FUEL LOW caution panel segment Defective float switch or wiring. Replace float switch. Repair wiring.
illuminated when fuel is not low or
fails to illuminate when fuel is low.
28-00-01
Page 3
E-AB412-PT6T-2
G6AB0322A
Figure 1. Fuel storage and distribution system (helicopters codes [A][B]) (sheet 1 of 2)
28-00-01
Page 4
E-AB412-PT6T-2
G6AB0323A
28-00-01
Page 5
E-AB412-PT6T-2
G6AB0324A
Figure 2. Fuel system schematic (helicopters codes [A][B])
28-00-01
Page 6
E-AB412-PT6T-2
28-0 -02 FUEL STORAGE AND DISTRIBUTION SYSTEM (HELICOPTERS CODES [C][D])
28-00-02
FUEL STORAGE AND DISTRIBUTION SYSTEM (HELICOPTERS CODES
[C][D])
1. FUEL STORAGE AND DISTRIBUTION SYSTEM (HELICOPTERS CODES [C][D]) -

DESCRIPTION
The following paragraphs provide a functional description for the fuel system components for helicopters codes [C][D]
which store and deliver fuel to the engine power sections.
The fuel system (figure 1 and figure 2) is comprised of fuel storage cells, transfer system, venting system, dual engine feed
system, and electrical control and warning systems. The system is designed to provide fuel containment in the event of an
accident or incident where fuel system rupture might occur. The cells are of a lightweight, crash-resistant, laminated fabric
and rubber construction. The cells are suspended in the fuselage cavities by nylon cord laced between hangers attached to
the cells and the fuselage structure.
The ten interconnected cells (1, 5, 8, 9, 13, 16, 22, 26, 28, and 34, figure 1) have a total capacity of approximately 337,5 U.S.
gallons (approximately 330,5 U.S. gallons usable). A quantity of fuel, 131 U.S. gallons (65,5 U.S. gallons per side), is
reserved by use of internal barriers and an interconnect valve to provide an isolated fuel supply for each engine.
There are six cells below the cabin floor and four cells located below engine compartments aft of cabin and pylon. The
helicopter is fueled through a filler cap and adapter assembly (2) in upper right cell (1). Fuel gravity feeds from upper cells
into lower cells through interconnecting lines. Transfer pumps (located on left and right forward sump assemblies) are used
to transfer fuel from lower forward cells (16 and 22) and lower middle cells (13 and 26) aft to lower main cells (9 and 28)
and from there through feed lines to the two engine fuel inlets.
The lower forward cell sump areas (18 and 21) contain fuel sump assemblies equipped with transfer pumps and drain valves.
The lower middle cell sump areas (12 and 25) contain sump assemblies equipped with drain valves. Ejector pumps (15 and
27) are installed near the lower middle cell sump assemblies. The lower main cell sump areas (10 and 29) contain sump
assemblies equipped with defueling valves, drain valves, flow switch check valves, and boost pumps.
Sump drain valves in the lower main cells (9 and 28) have solenoids and may be opened by either electrical or manual
actuation. Sump drain valves in other lower cells are manually operated, push-to-drain types. All six valves are
spring-loaded, poppet type valves. Defueling valves located in the lower main cell sump assemblies require removal of a
plug and insertion of a standard fitting to open the spring-loaded poppet.
A collective vent line on top of upper aft center cell connects the four upper cell vent spaces with two vertical lines (one
behind upper right cell (1) and one behind upper aft cell (5) which vent overboard beneath the fuselage. Each lower main
cell vents through a line connecting into the upper forward center cell. A forward vent line on each side of the fuselage
connects with the respective lower forward and lower middle cells. These lines rise through the doorposts to a waterline
above the upper cells and then double back downward to vent overboard beneath the fuselage.
To enable fuel transfer, an interconnect system joins lower cells together and also joins lower cells with upper
cells. Fuel drainage from upper cells to lower cells is controlled by standpipes that sequence depletion flow
among cells to maintain desired center-of-gravity during in-flight consumption. Isolation barriers in the upper
center cells and a normally closed interconnect valve in the interconnect line between lower main cells provide for isolation
of individual power section fuel supplies.
28-00-02
Page 1
E-AB412-PT6T-2
Flow of fuel from the lower forward cell transfer pumps provides motive force for lower middle cell ejector pumps to pump
fuel from lower middle cells into lower main cells. For helicopters S/N 25801 and subsequent fuel is pumped into aft center
cell. Fuel level sensors, (thermistors) located in the base of lower forward cell fuel quantity probes (tank units), cause
transfer pumps to shut off automatically when lower forward cells become empty. If a flow switch check valve senses fuel
flow has stopped and fuel is still present in forward midtanks, the corresponding caution panel segment (NO 1 FUEL
TRANS or NO 2 FUEL TRANS) is illuminated. However, if the interruption in flow is due to a cell (lower forward or lower
middle) becoming empty, a thermistor in fuel quantity probe in the empty cell provides a ground to the appropriate signal
conditioner to cancel segment illumination.
All fuel passes through lower main cells, from which the power sections are supplied. Check valves (17 and 23) in lower
forward cells, flow switch check valves in lower main cells (9 and 28), and power section fuel feed line check valves prevent
backflow of fuel during periods of shutdown or crossfeed operation. The power section fuel feed line check valves (33) and
electrically operated shutoff valves (36) also provide thermal pressure relief during system shutdown. Shutoff valves isolate
fuel from engine compartment during shutdown or in event of engine fire. Fuel pressure transmitters (3 and 6) sense fuel
feed line pressure and transmit corresponding electrical signals to engine 1 and engine 2 fuel pressure (FUEL PRESS)
indicators.
A crossfeed line and normally closed crossfeed valve (4) provide optional interconnection between left and right engine fuel
feed lines. This crossfeed valve opens automatically in event failure of a boost pump is sensed by fuel pressure switch (32)
in either feed line.
The capacitance type fuel quantity indicating system uses quantity probes, signal conditioners, and a dual pointer indicator
with digital fuel totalizer. There are quantity probes in the upper left and upper right cells, and each lower cell. Fuel level
signals from quantity probes are summed in signal conditioners and transmitted to the indicator. A switch near the indicator
enables checking lower forward and lower middle cell fuel quantities separately to ensure proper balance is maintained
during any shutdown period with partially empty tanks.
Boost pumps and transfer pumps are individually controlled by two-position BOOST PUMP switches located on engine and
fuel control panel. On the same panel are four switches for valve control: ENGINE 1 FUEL and ENGINE 2 FUEL switches
to control shutoff valves (36), FUEL XFEED switch to control crossfeed valve (4), and FUEL INTCON switch to control
interconnect valve (31). All are two-position switches except FUEL INTCON switch, which is a three-position switch. The
normal position of crossfeed valve and interconnect valve is closed; the interconnect valve also has an open position. The
FUEL INTCON and FUEL XFEED switches have an override (OVRD CLOSE) position to enable valves (4 and 36) to be
closed, if necessary, after being opened automatically.
Caution light segments in the caution panel annunciate conditions which may exist within the following functional areas in
the fuel system: Fuel transfer (NO. 1 FUEL TRANS and NO. 2 FUEL TRANS), engine feed line fuel pressure (FUEL
BOOST), fuel level (FUEL LOW), fuel filter (NO. 1 FUEL FILTER and NO. 2 FUEL FILTER), firewall shutoff (fuel)
valves (NO 1. FUEL VALVE and NO. 2 FUEL VALVE), crossfeed valve (FUEL XFEED), and interconnect valve (FUEL
INTCON).
Fuel burn sequence (figure 3) is established by system design to maintain center-of-gravity within an acceptable
range. The first burn uses fuel from all upper cells above tall standpipe in upper forward center cell. The second burn
empties fuel from lower middle cells. The third burn uses fuel from all upper cells above short standpipe in upper
forward center cell. The fourth burn empties fuel from lower forward cells. The fifth burn drops fuel level to the barriers in
upper center cells that isolate engine fuel supplies, and depletes remainder of fuel in upper cells. The sixth burn uses fuel
remaining in lower main cells.
A fuel level sensor (thermistor) in each lower forward cell quantity probe signals fuel depletion at the end of the fourth burn,
thereby causing automatic transfer pump shutdown and cancellation of the respective FUEL TRANS caution light signal. A
fuel level sensor (thermistor) in each upper outboard (left and right) cell fuel quantity probe signals depletion of fuel at end
of fifth burn, causing the FUEL LOW caution light to illuminate.
Refer to Chapter 96 for maintenance instructions for electrically operated components of the system and Chapter 98 for
applicable wiring diagrams.
28-00-02
Page 2
E-AB412-PT6T-2
G6AB0359A
Figure 1. Fuel storage and distribution system (helicopters codes [C][D]) (sheet 1 of 2)
28-00-02
Page 3
E-AB412-PT6T-2
G6AB0360A
28-00-02
Page 4
E-AB412-PT6T-2
G6AB0361A
Figure 2. Fuel system schematic (helicopters code [C]) (sheet 1 of 2)
28-00-02
Page 5
E-AB412-PT6T-2
G6AB0362A
Figure 2. Fuel system schematic (helicopters code [C]) (sheet 2 of 2)
28-00-02
Page 6
E-AB412-PT6T-2
G6AB0363A
Figure 3. Fuel burn sequence diagram (helicopters codes [C][D])
28-00-02
Page 7
E-AB412-PT6T-2
2. FUEL STORAGE AND DISTRIBUTION SYSTEM (HELICOPTERS CODES [C][D]) -

TROUBLESHOOTING
Refer to table 1 for fuel system troubleshooting.
Table 1. Fuel system troubleshooting (helicopters codes [C][D])
FUEL FILTER caution segment illu- Filter element clogged. Remove and inspect filter element.
minated. Clean or replace filter element (refer to
Engine Manual).
FUEL BOOST caution segment illu- Defective pressure switch in pump Replace pressure switch, or obstructed
minated. outlet line or obstructed line. hoses.
No electrical power to pump. Repair wiring or replace faulty units in

circuit.
Defective pump. Replace pump.
Shutoff valve inoperative. Valve faulty or lacking electrical Repair circuit.

power.
Replace valve.
Interconnect valve inoperative. Valve faulty or lacking electrical Repair circuit.

power.
Replace valve.
Cross feed valve inoperative. Valve faulty or lacking electrical Repair circuit.
power.
Replace valve.
FUEL TRANS caution segment illu- Defective pump. Replace pump.

minated.
No electrical power to pump. Repair circuit.
Defective thermistor or forward or Replace forward or mid fuel quantity

mid tank quantity probe. probe.
Fuel in mid tank when fwd tank Replace check valve in aft fuel tank.
empty due to leaking check valve
between aft and mid tank.
Defective fuel quantity signal condi- Replace signal conditioner.

tioner.
28-00-02
Page 8
E-AB412-PT6T-2
(Cont.)
FUEL LOW caution segment illumi- Defective thermistor on upper quan- Replace probe.
nated when fuel is not low or fails to tity probe.
illuminate when fuel is low.
Defective signal conditioner. Replace signal conditioner.
Faulty wiring. Repair wiring.
28-00-02
Page 9
E-AB412-PT6T-2
28-00-02
Page 10
E-AB412-PT6T-2
28-10-01 FUEL STORAGE AND DISTRIBUTION SYSTEM (HELICOPTERS CODES [A][B]) - LOW FUEL LEVEL WARNING SWITCHES
28-10-01
[A][B]) - LOW FUEL LEVEL WARNING SWITCHES
1. LOW FUEL LEVEL WARNING SWITCHES - DESCRIPTION
Float actuated low fuel level warning switches are connected to a FUEL LOW caution panel segment. The switches are
installed on a support on each sump assembly (16 and 28, figure 1).
NOTE
The maintenance procedures for left and right low fuel level warning switches are
the same.
2. LOW FUEL LEVEL WARNING SWITCHES - REMOVAL
1. Remove sump assembly (module 28-20-03 paragraph "2. Sump assemblies - removal").
2. Disconnect electrical leads (4, figure 2) from terminal block (8).
3. Hold support (3) and unscrew low fuel level warning switch (1).
4. Remove low fuel level warning switch (1) and attached electrical leads (4) from support (3). Remove and discard
packing (2).
5. Remove nut (7). Lift support (3) from sump assembly (5).
6. Remove and discard packing (9).
3. LOW FUEL LEVEL WARNING SWITCHES - INSTALLATION
MATERIALS REQUIRED
NUMBER NOMENCLATURE
C-405 LOCKWIRE
1. Place packing (2, figure 2) on low fuel level warning switch (1).
2. Insert electrical leads (4) through support (3). Install and tighten low fuel level warning switch (1).
3. Place packing (9) on support (3).
4. Position support (3) on sump assembly (5).
5. Install washer (6) and nut (7). Torque nut (7) 15 to 25 in.lbs. (1,70 to 2,83 Nm) and secure with lockwire (C-405).
6. Connect electrical leads (4) to terminal block (8).
7. Install sump assembly (5) (module 28-20-03 paragraph "3. Sump assemblies - installation").
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G6AB0322A
Figure 1. Fuel storage distribution system (helicopters codes [A][B]) (sheet 1 of 2)
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G6AB0323A
Figure 1. Fuel storage distribution system (helicopters codes [A][B]) (sheet 2 of 2)
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G6AB0327A
Figure 2. Low fuel level warning switch (helicopters codes [A][B])
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28-10-02
FUEL STORAGE AND DISTRIBUTION (HELICOPTERS CODES [A][B]) -
BOOST PUMPS
1. BOOST PUMPS - DESCRIPTION
The boost pumps (installed on sump assemblies) (16 and 28, figure 1) are electrically operated by 28 Vdc circuits controlled
by separate switches. Each boost pump is installed with a drain valve, a seal drain adapter, and a fuel outlet fitting.
NOTE
Maintenance procedures for left and right boost pumps are the same.
2. BOOST PUMPS - REMOVAL
1. Disconnect electrical power.
2. Defuel system (Chapter 12).
3. Drain trapped fuel through drain valve (14, figure 2).
4. Disconnect electrical leads (16) from terminal block (18).
5. Remove bolt (7), washer (6), packings (8 and 10), and plug (9). Discard packings.
6. Remove bolts (5) and grounding jumper wire (3).
7. Remove boost pump (17) and gasket (2) from sump assembly (19). Discard gasket.
8. Loosen nut (12) and remove seal drain adapter (13) with packing (11). Discard packing.
9. Remove pump drain valve (14) and packing (15). Discard packing.
10. Cover opening in cell.
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G6AB0322A
28-10-02
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G6AB0323A
28-10-02
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G6AB0329A
Figure 2. Boost pump (helicopters codes [A][B])
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3. BOOST PUMPS - INSTALLATION
MATERIALS REQUIRED
NUMBER NOMENCLATURE
C-024 ASSEMBLY FLUID
C-405 LOCKWIRE
1. Coat new packing (15, figure 2) with assembly fluid (C-024) and install on drain valve (14). Install drain valve (14) in
boost pump (17).
2. Apply assembly fluid (C-024) to packing (11). Install seal drain adapter (13) and nut (12) with packing (11).
3. Apply assembly fluid (C-024) to packings (8 and 10). Install washers (6) on bolt (7). Install packings (8 and 10) on
plug (9) and then install plug (9) on bolt (7).
4. Install new gasket (2) on boost pump (17).
5. Remove protective cover from cell opening.
6. Position boost pump (17) on sump assembly (19). Align pump (17) with fuel outlet fitting (1). Install bolt (7) and
lockwire (C-405).
NOTE
Install grounding jumper wire (3) on nearest bolt (5).
7. Install bolts (5).
8. Perform system pressure test (module 28-40-01 "FUEL STORAGE AND DISTRIBUTION SYSTEM
(HELICOPTERS CODES [A][B]) - PRESSURE TESTING").
9. Service fuel system (Chapter 12).
10. Perform operational check on boost pump (Chapter 96).
11. Check area for leaks.
12. Install sump access door.
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28-10-02
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28-10-03 FUEL STORAGE AND DISTRIBUTION SYSTEM (HELICOPTERS CODES [A][B]) - CANISTER TYPE BOOST PUMPS
28-10-03
[A][B]) - CANISTER TYPE BOOST PUMPS
1. CANISTER TYPE BOOST PUMPS - DESCRIPTION
The canister type boost pumps are electrically operated by 28 Vdc circuits controlled by separate switches. Each boost pump
incorporates an integral valve and filter assembly.
NOTE
Maintenance procedures for left and right canister type boost pumps are the same.
2. CANISTER TYPE BOOST PUMPS - REMOVAL
3. Drain trapped fuel through valve (13, figure 1).
5. Remove bolt (10), washer (9), packings (6 and 8), and plug (7). Discard packings.
6. Remove bolts (5) and ground wire (3).
7. Remove boost pump (16) and gasket (2) from sump assembly (18). Discard gasket.
8. Remove pump drain valve (13) and packing (14). Discard packing.
9. Cover opening in cell.
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G6AB0330A
Figure 1. Canister type boost pump
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3. CANISTER TYPE BOOST PUMPS - INSTALLATION
MATERIALS REQUIRED
NUMBER NOMENCLATURE
C-405 LOCKWIRE
1. Lubricate new packing (14, figure 1) with assembly fluid (C-024) and install on pump drain valve (13). Install drain
valve (13) in base of pump at cartridge drain port.
2. Lubricate packing (12) with assembly fluid (C-024) and install on plug (11). Install plug (11) in base of pump at seal
drain port.
3. Coat gasket (2) with assembly fluid (C-024). Install gasket (2) on pump (16).
4. Lubricate packings (6 and 8) with assembly fluid (C-024) and install on plug (7).
5. Install washer (9) on bolt (10). Insert bolt (10) through plug (7) and into discharge port of pump.
6. Position boost pump (16) on sump assembly (18). Align boost pump (16) with fuel outlet fitting (1). Tighten bolt (10)
and ensure fitting seats in discharge port.
7. Install ground wire (3) on nearest bolt (5).
8. Install bolts (5) and washers (4).
9. Secure drain valve (13), plug (11), and bolt (10) with lockwire (C-405).
12. Perform operational check on boost pump (Chapter 96).
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28-10-04 FUEL STORAGE AND DISTRIBUTION (HELICOPTERS CODES [A][B]) - FORWARD CELL INLET/OUTLET FITTINGS
28-10-04
FORWARD CELL INLET/OUTLET FITTINGS
1. FORWARD CELL INLET/OUTLET FITTINGS - DESCRIPTION
An inlet/outlet fitting (15 and 37, figure 1) is installed on the rear of each forward cell. The fitting provides an attachment
point for hoses from aft cells and for a supply hose from boost pump to shutoff valve. A check valve installed on forward
side of each fitting is connected to a hose from the boost pump.
2. FORWARD CELL INLET/OUTLET FITTINGS - REMOVAL
3. Remove access door located on bottom skin aft of sump access door.
NOTE
Refer to steps 4.a. through 4.e. for removal of right forward cell inlet/outlet fitting
and steps 5.a. through 5.e. for removal of left forward cell inlet/outlet fitting.
4. Remove inlet/outlet fitting from right forward cell:
a. Disconnect hoses (11, 14, and 17, figure 2, detail A).
b. Remove bolts (8), washers (7), and retainers (6).
c. Separate inlet/outlet fitting (5) from cell and disconnect hose (1). Remove and discard packing (4).
d. Remove check valve (2). Remove and discard packing (3).
e. Remove unions (10, 13, and 16) with packings (9, 12, and 15). Discard packings.
5. Remove inlet/outlet fitting from left forward cell:
a. Disconnect hoses (23 and 24, figure 2, detail B).
c. Separate inlet/outlet fitting (30) from cell and disconnect hose (18). Remove and discard packing (31).
d. Remove check valve (19) and packing (20). Discard packing.
e. Remove unions (22 and 25) with packings (21 and 26). Discard packings.
6. Cap or plug open lines and install protective cover over cell opening.
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G6AB0322A
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G6AB0323A
28-10-04
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G6AB0334A
Figure 2. Forward cell inlet/outlet fitting (helicopters codes [A][B])
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3. FORWARD CELL INLET/OUTLET FITTINGS - INSTALLATION
MATERIALS REQUIRED
NUMBER NOMENCLATURE
NOTE
Refer to steps 1.a. through 1.h. for installation of right forward cell inlet/outlet fitting
and steps 2.a. through 2.i. for installation of left forward cell inlet/outlet fitting.
1. Remove protective caps and covers. Install inlet/outlet fitting on right forward cell as follows:
a. A p p l y a s s e m b l y f l u i d ( C - 0 2 4 ) t o p a c k i n g s ( 9 , 1 2 , a n d 1 5 , figure 2, d e t ai l A) . I ns t a l l unions
(10, 13 and 16) with packings (9, 12 and 15).
b. Apply assembly fluid (C-024) to packing (3). Install check valve (2) and packing (3).
c. Place packing (4) in groove of cell. Packing (4) may be retained in place with a ss e m b l y f l u i d ( C - 0 2 4 ) .
d. Hold inlet/outlet fitting (5) near cell port and connect hose (1).
NOTE
The six bolts (8) used in top six holes of inlet/outlet fitting (5) with retainers (6) are
longer than two bolts (8) used in bottom holes without retainers.
e. Position inlet/outlet fitting (5) over cell port.
f. Install longer bolts (8) with washers (7) and retainers (6) at the upper six holes in inlet/outlet fitting (5).
g. Install two shorter bolts (8) with washers (7) at two lower holes in fitting (5). Torque bolts 50 to 100 in.lbs. (5,65
to 11,30 Nm).
h. Connect hoses (11, 14 and 17).
2. Install inlet/outlet fitting on left forward cell.
a. Apply a s s e m b l y f l u i d ( C - 0 2 4 ) to packing (20, figure 2, detail B).
b. Install check valve (19) and packing (20).
c. Install unions (22 and 25) with packings (21 and 26).
d. Coat packing (31) with as se m b l y f l u i d ( C- 0 2 4) and place packing (3) in groove of cell.
e. Hold inlet/outlet fitting (30) near cell port and connect hose (18).
NOTE
Six bolts (27) used in top six holes of inlet/outlet fitting (30) with retainers (29) are
longer than two bolts (27) used in bottom holes without retainers.
f. Position inlet/outlet fitting (30) over cell port.
g. Install longer bolts (27) with washers (28) and retainers (29) in upper six holes in inlet/outlet fitting (30).
h. Install shorter two bolts (27) with washers (28) in two lower holes in inlet/outlet fitting (30). Torque bolts 50 to
100 in.lbs. (5,65 to 11,30 Nm).
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i. Connect hoses (23 and 24).
3. Perform fuel system pressure test (module 28-40-01 "FUEL STORAGE AND DISTRIBUTION SYSTEM
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28-10-05 FUEL STORAGE AND DISTRIBUTION SYSTEM (HELICOPTERS CODES [A][B]) - FORWARD CELL CRASH RESISTANT VENT VALVES
28-10-05
[A][B]) - FORWARD CELL CRASH RESISTANT VENT VALVES
1. FORWARD CELL CRASH RESISTANT VENT VALVES - DESCRIPTION
A crash resistant vent valve (27 and 36, figure 1) is installed on inboard side of each forward cell. These valves connect the
forward cells into fuel vent system. In event of an impact severe enough to break cell loose from mounting points, the valve
section will separate. The valve portion remaining attached to cell seals automatically and prevents fuel spillage.
NOTE
Maintenance procedures for left and right ejector pumps are the same.
2. FORWARD CELL CRASH RESISTANT VENT VALVES - REMOVAL
3. Remove cabin floor panel above fuel cells.
4. Disconnect hose (7, figure 2).
5. Remove nut (6) and washer (5).
6. Remove bolts (4), washers (3), valve (2), and packing (1). Discard packing.
7. Install protective cover over cell opening.
3. FORWARD CELL CRASH RESISTANT VENT VALVES - INSTALLATION
1. Remove protective cover
2. Position packing (1, figure 2) and vent valve (2) on cell (8).
3. Install bolts (4) and washers (3). Torque bolts (4) 50 to 100 in.lbs. (5,65 to 11,30 Nm).
4. Install washer (5) and nut (6).
5. Connect hose (7) to valve (2).
6. Install cabin floor panel.
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G6AB0322A
28-10-05
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G6AB0323A
28-10-05
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G6AB0339A
Figure 2. Forward cell crash resistant vent valve (helicopters codes [A][B])
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28-10-06 FUEL STORAGE AND DISTRIBUTION SYSTEM (HELICOPTERS CODES [A][B]) - FORWARD CELLS
28-10-06
[A][B]) - FORWARD CELLS
1. FORWARD CELLS - DESCRIPTION
Two cells (19 and 33, figure 1) are located under cabin floor outboard of B.L. 14 main longitudinal beams, between F.S.102
and 155. Each cell has a vent port on the upper inboard side, interconnection ports on forward and aft ends, and a large
opening for sump assembly on lower side. A baffle divides each cell into forward and aft compartments and has a directional
flow flapper valve. The sump opening provides access to the aft compartment. A covered round opening on the upper surface
can be used as access to forward compartment. Cells are suspended in fuselage cavities by nylon cord laced between hangers
on cells and on structure. Each cell has threaded inserts on inboard wall for attachment of two fuel quantity probes.
NOTE
Maintenance procedures for left and right forward cells are the same.
2. FORWARD CELLS - REMOVAL
CAUTION
DO NOT HANDLE FUEL CELL WHEN CELL TEMPERATURE IS BELOW

65F (18C).
3. Remove cabin floor panels and access panels from fuselage underside for access to forward cell and connections.
5. Remove inlet/outlet fitting (9, figure 2) (module 28-10-04 paragraph "2. Forward cell inlet/outlet fittings - removal"),
except hose inside cell may remain connected and be removed with fitting.
6. Remove screws (1), cover (2), and packing (3). Discard packing.
7. Remove aft and forward fuel quantity probes (8 and 14) (module 28-40-05 paragraph "2. Center aft fuel quantity probe
- removal" and module 28-40-04 paragraph "2. Forward cell fuel quantity probes - removal").
8. Remove flapper valve (11) (module 28-10-06 paragraph "2. Flapper valves - removal").
9. Remove bolt (19) and washer (18).
10. Remove ejector pump (12) (module 28-20-10 paragraph "2. Ejector pumps - removal"), except hoses can remain
connected and be removed with ejector pump.
11. Remove ejector pump support (13) (module 28-20-11 paragraph "2. Ejector pump supports - removal").
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12. Remove forward interconnect hose (20).
13. Remove bolts (6 and 16) with washers (7 and 15).
14. Remove vent valve (4) (module 28-10-05 paragraph "2. Forward cell crash resistant vent valves - removal").
15. Remove nylon cord from hangers around top of cell and cavity.
16. Lift cell from cavity.
17. Install protective caps or plugs in open fuel lines and over cell openings.
3. FORWARD CELLS - INSTALLATION
MATERIALS REQUIRED
NUMBER NOMENCLATURE
C-408 TALCUM POWDER
C-480 NYLON CORD
CAUTION
DO NOT HANDLE FUEL CELL WHEN TEMPERATURE OF CELL IS BELOW

65F (18C
1. Inspect cell cavity for clean, smooth condition of surfaces.
2. Apply talcum powder (C-408) to cavity surfaces.
3. Remove protective caps, plugs and covers. Place cell in cavity and align ports with fuselage openings.
4. Install vent valve (4, figure 2) (module 28-10-06 paragraph "3. Forward cell crash resistant vent valves - installation").
5. Install bolt (6) with washer (7) and bolt (16) with washer (15). Torque bolts (6 and 16) 30 to 40 in.lbs. (3,39 to 4,52 Nm).
6. Install ejector pump support (13) (module 28-10-06 paragraph "3. Ejector pump supports - installation", steps 1. through
4.).
7. Install ejector pump (12) (module 28-20-10 paragraph "3. Ejector pumps - installation", steps 1. through 4.).
8. Install aft and forward quantity probes (8 and 14) (module 28-40-05 paragraph "3. Center aft fuel quantity probe -
installation" and module 28-40-04 paragraph "3. Forward cell fuel quantity probes - installation", steps 1.a. through
1.f. and all of step 2.).
9. Install bolt (19) with washer (18) to secure clamp (5) on hose (17) to cell wall. Torque bolt (19) 30 to 40 in.lbs. (3,39
to 4,52 Nm).
10. Install flapper valve (11) (module 28-20-09 paragraph "3. Flapper valves - installation", steps 1. through 6.).
11. Lace and tie a single length of nylon cord (C-480) between hangers around top of cell and cavity (figure 3).
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12. Install inlet/outlet fitting (9) (module 28-10-04 paragraph "3. Forward cell inlet/outlet fittings - installation", step 1. or
step 2., as applicable).
14. Install packing (3), cover (2), and screws (1).
15. Install cabin floor panels and doors on underside of fuselage.
18. Perform fuel system operational check (Chapter 96).
4. FORWARD CELLS - CLEANING
MATERIALS REQUIRED
NUMBER NOMENCLATURE
C-339 ETHYL ALCOHOL
CAUTION
WHEN USING HOT WATER TO CLEAN FUEL CELL, WATER

TEMPERATURE SHALL BE LIMITED TO 160F (71C). DO NOT USE SOAPS
OR STRONG DETERGENTS WHEN CLEANING FUEL CELL. CERTAIN
DETERGENTS ARE HARMFUL TO FUEL CELL. SOAPS CAN REACT WITH
FUEL TO FORM A COMPOUND WHICH TENDS TO PLUG FUEL FILTERS.
DO NOT USE MEK OR SIMILAR SOLVENTS FOR CLEANING FUEL CELLS.
1. Remove all fungus growth from cell by hand or with soft scrub brush using warm or hot water.
2. If fungus is observed in cell cavity, wipe cell cavity with clean cloths moistened with ethyl alcohol (C-339).
3. Inspect other cells for presence of fungus growth. Remove and clean if required.
5. FORWARD CELLS - INSPECTION
1. Inspect cell for cracks, scuffing, and general condition.
2. Inspect threaded inserts for serviceability. Inserts with thread damage which can be detected visually shall be replaced.
3. Inspect hoses for damage and deterioration. Hoses exhibiting damage or deterioration which can be detected visually
shall be replaced.
4. Inspect removed components for damage.
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G6AB0322A
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G6AB0323A
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G6AB0340A
Figure 2. Forward fuel cell (helicopters codes [A][B])
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G6AB0341A
Figure 3. Forward cell lacing (helicopters codes [A][B])
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28-10-07 FUEL STORAGE AND DISTRIBUTION SYSTEM (HELICOPTERS CODES [A][B]) - CENTER AFT CELL OUTLET FITTINGS
28-10-07
[A][B]) - CENTER AFT CELL OUTLET FITTINGS
1. CENTER AFT CELL OUTLET FITTINGS - DESCRIPTION

Two outlet fittings (figure 1) are installed on bottom of center aft cell. The fittings provide attachment points for hoses which
transfer fuel to forward cells.
NOTE
Maintenance procedures for left and right center aft cell outlet fittings are the same.
2. CENTER AFT CELL OUTLET FITTINGS - REMOVAL

3. Remove access door on underside of fuselage below outlet fitting (2, figure 1).
4. Disconnect hose (5).
5. Remove bolts (4), outlet fitting (2), and packing (1). Discard packing.
6. Cap or plug open lines and cover cell opening.
3. CENTER AFT CELL OUTLET FITTINGS - INSTALLATION

MATERIALS REQUIRED
NUMBER NOMENCLATURE
C-024 Assembly fluid
1. Apply assembly fluid (C-024) to packing (1, figure 1).
2. Remove protective caps, plugs and cover.
3. Position packing (1) and outlet fitting (2) over cell port. Install bolts (4) with washers (3). Torque bolts 50 to 100 in.lbs.
(5,65 to 11,30 Nm).
4. Connect hose (5).
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G6AB0346A
Figure 1. Center aft cell outlet fitting (helicopters codes [A][B])
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28-10-08 FUEL STORAGE AND DISTRIBUTION SYSTEM (HELICOPTERS CODES [A][B]) - CENTER AFT CELL VENT COVER
28-10-08
[A][B]) - CENTER AFT CELL VENT COVER
1. CENTER AFT CELL VENT COVER - DESCRIPTION
A vent cover located on top of center aft cell (5, figure 1) provides attachment points for four hoses in fuel vent system.
2. CENTER AFT CELL VENT COVER - REMOVAL
3. Remove large round access door from underside of fuselage aft of center aft fuel cell.
4. Remove center aft fuel cell rear cover (module 28-10-10 paragraph "1. Center aft cell rear cover - removal").
5. Disconnect hoses (1, 4, 13, and 17, figure 2).
6. Remove bolts (11) and washers (10).
8. Remove support (7), vent cover (15), and gasket (19).

Discard gasket.
9. Remove elbow (2) by removing nut (27), washer (28), packing (29), and nut (3). Discard packing.
13. Cover openings with caps or plugs and covers.
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3. CENTER AFT CELL VENT COVER - INSTALLATION
1. Remove protective caps, plugs, and covers.
2. Assemble elbow (2, figure 2) top vent cover (15) with nut (3), packing (29), washer (28), and nut (27).
3. Assemble elbow (5) to vent cover (15) with nut (6), packing (32), washer (31), and nut (30).
6. Position gasket (19), vent cover (15), and support (7) on fuel cell (20). Install bolts (8) with washers (9). Torque bolts
(8) 50 to 100 in.lbs. (5,65 to 11,30 Nm).
7. Install bolts (11) with washers (10).
8. Connect hoses (1, 4, 13, and 17).
9. Install center aft fuel cell rear cover (module 28-10-10 paragraph "2. Center aft cell rear cover - installation").
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G6AB0322A
28-10-08
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G6AB0323A
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G6AB0347A
Figure 2. Center aft vent cover (helicopters codes [A][B])
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28-10-09 FUEL STORAGE AND DISTRIBUTION SYSTEM (HELICOPTERS CODES [A][B]) - AFT CELL VENT FITTINGS
28-10-09
[A][B]) - AFT CELL VENT FITTINGS
1. AFT CELL VENT FITTINGS - DESCRIPTION
NOTE
Maintenance procedures for left aft and right aft cell vent fittings (7 and 41, figure 1)
are the same.
2. AFT CELL VENT FITTINGS - REMOVAL
3. Remove deck panel above cell.
6. Remove bolts (2) and washers (3). Remove bracket (4), plate (7), elbow (8), and packing (9). Discard packing.
7. Install protective cap or plug in vent line and cover cell opening.
3. AFT CELL VENT FITTINGS - INSTALLATION
1. Remove protective cap and cover.
2. Place packing (9, figure 2) in groove around cell port.
3. Assemble elbow (8), plate (7), and bracket (4).
4. Position assembled parts on top of cell. Install bolts (2) with washers (3). Torque bolts 50 to 100 in.lbs. (5,65 to 11,30 Nm).
6. Connect hose (1) to elbow (8).
10. Install sump access door and deck panel above cell.
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G6AB0322A
28-10-09
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G6AB0323A
28-10-09
Page 3
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G6AB0348A
Figure 2. Left aft and right aft cell vent fitting (helicopters codes [A][B])
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28-10-10 FUEL STORAGE AND DISTRIBUTION SYSTEM (HELICOPTERS CODES [A][B]) - CENTER AFT CELL REAR COVER
28-10-10
[A][B]) - CENTER AFT CELL REAR COVER
1. CENTER AFT CELL REAR COVER - REMOVAL
3. Remove large round access door from bottom of fuselage aft of center aft cell.
4. Remove governor bleed lines (tubes) (1, figure 1).
5. Disconnect electrical wiring from electrical connectors (2).
6. Remove bolts (2) and washers (3). Remove bracket (4), plate (7), elbow (8), and packing (9). Discard packing.
7. Remove screws (6) and washers (7) and remove fuel cell access panel (8).
8. Remove remaining bolts (3) and washers (4). Separate cover (9) from cell.
9. Reach through cell rear port and disconnect fuel quantity probe wires from electrical connectors (2) on inside of cover
(9).
10. Remove cover (9) and packing (10). Discard packing.
11. Cap governor bleed tube fittings on underside of engine deck. Cap removed tubing and install protective cover over
cell opening.
2. CENTER AFT CELL REAR COVER - INSTALLATION
MATERIALS REQUIRED
NUMBER NOMENCLATURE
2. Coat packing (10, figure 1) with assembly fluid (C-024) and place packing in groove around cell rear port opening.
3. Hold cover (9) close to cell rear port. Connect wires from fuel quantity probe to electrical connectors (2) on inside of
cover (9).
4. Position cover (9) over cell rear port and install only those bolts (3) and washers (4) not used with retainers (5). (Refer
to detail B for locations of hardware to be omitted at this time.).
5. Position fuel cell access panel (8) on bulkhead and install screws (6) and washers (7).
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E-AB412-PT6T-2
6. Position cover (9) against fuel cell access panel (8) and install retainers (5) with remaining bolts (3) and washers (4).
Torque all bolts (3) 50 to 100 in.lbs. (5,65 to 11,30 Nm).
7. Connect fuel quantity probe wires to electrical connectors (2).
8. Remove protective caps and plugs. Connect governor bleed tubes (1) between check valves (11) and fittings on
underside of engine deck.
10. Perform operational check of fuel quantity indicating system before servicing system. Refer to (Chapter 96) for
procedure.
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E-AB412-PT6T-2
G6AB0349A
Figure 1. Center aft cell rear cover (helicopters codes [A][B])
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28-10-10
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28-10-1 FUEL STORAGE AND DISTRIBUTION SYSTEM (HELICOPTERS CODES [A][B]) - AFT CELL OUTLET FITTINGS
28-10-11
[A][B]) - AFT CELL OUTLET FITTINGS
1. AFT CELL OUTLET FITTINGS - DESCRIPTION
An outlet fitting (14 and 39, figure 1) is installed on bottom of each outboard (left and right) aft cell. The fittings provide
hose attachment points for transfer of fuel from aft cells to forward cells.
2. AFT CELL OUTLET FITTINGS - REMOVAL
3. Remove lower access door.
4. Remove outlet fitting (4, figure 2) from right aft cell as follows:
a. Remove bolts (13), washers (12), hose (14), and packing (11). Discard packing.
b. Remove bolts (15), washers (16), hose (17), and packing (18). Discard packing.
c. Remove bolts (10), washers (9), fitting (4), and packing (3). Discard packing.
d. Remove plug (1) and packing (2). Discard packing.
e. Remove bolts (8), washer (7), cover (6), and packing (5). Discard packing.
5. Remove outlet fitting (23) from left aft cell as follows:
a. Remove bolts (31), washers (30), hose (32), and packing (33). Discard packing.
b. Disconnect hose (19).
c. Remove bolts (35), washers (34), hose (36), and packing (37). Discard packing.
d. Remove bolts (29), washers (28), fitting (23), and packing (22). Discard packing.
e. Remove union (20), and packing (21). Discard packing.
f. Remove bolts (27), washers (26), cover (25), and packing (24). Discard packing.
6. Cover cell opening and cap or plug open lines.
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3. AFT CELL OUTLET FITTINGS - INSTALLATION
MATERIALS REQUIRED
NUMBER NOMENCLATURE
1. Install outlet fitting (4, figure 2) on right aft cell as follows:
a. Remove cover and protective caps.
b. Coat packing (5) with assembly fluid (C-024). Install cover (6), packing (5), bolts (8), and washers (7).
c. Apply assembly fluid (C-024) to packing (2).
d. Install plug (1) and packing (2).
e. Coat packing (3) with assembly fluid (C-024). Position packing (3) and outlet fitting (4) on bottom of fuel cell.
Install bolts (10) and washers (9). Torque bolts (10) 50 to 100 in.lbs. (5,65 to 11,30 Nm).
f. Coat packing (18) with assembly fluid (C-024). Install packing (11) and hose (14) with bolts (13) and washers
(12).
g. Coat packing (11) with assembly fluid (C-024). Install packing (11) and hose (14) with bolts (13) and washers
(12).
2. Install outlet fitting (23) on left aft cell as follows:
a. Remove cover and protective caps.
b. Apply assembly fluid (C-024) to packing (21).
c. Install union (20) with packing (21).
d. Coat packing (24) with assembly fluid (C-024).
e. Install cover (25), packing (24), bolts (27) and washers (26).
f. Coat packing (22) with assembly fluid (C-024).
g. Position packing (22) and fitting (23) on bottom of fuel cell. Install bolts (29) and washers (28). Torque bolts
(29) 50 to 100 in.lbs. (5,65 to 11,30 Nm).
h. Coat packing (37) with assembly fluid (C-024).
i. Install packing (37) and hose (36) with bolts (35) and washers (34).
j. Connect hose (19).
k. Coat packing (33) with assembly fluid (C-024).
l. Install packing (33) and hose (32) with bolts (31) and washers (30).
3. Pressure test fuel system (module 28-40-01 module FUEL STORAGE AND DISTRIBUTION SYSTEM
(HELICOPTERS CODES [A][B]) - PRESSURE TESTING).
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G6AB0322A
28-10-11
Page 3
E-AB412-PT6T-2
G6AB0323A
28-10-11
Page 4
E-AB412-PT6T-2
G6AB0351A
Figure 2. Left aft and right aft cell outlet fitting (helicopters codes [A][B])
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28-10-12 FUEL STORAGE AND DISTRIBUTION SYSTEM (HELICOPTERS CODES [A][B]) - AFT CELLS
28-10-12
[A][B]) - AFT CELLS
1. AFT CELLS - DESCRIPTION
The left aft and right aft cells (1 and 8, figure 1) are outboard of main structural beams between F.S. 166 and 178. The cells
have interconnection ports on bottom and lower inboard sides and a vent port on top. The right aft cell has a port for filler
cap and adapter assembly.
NOTE
Maintenance procedures for left aft and right aft cells are the same.
2. AFT CELLS - REMOVAL
CAUTION
DO NOT HANDLE FUEL CELL WHEN AMBIENT TEMPERATURE IS

BELOW 65°F (18°C).
3. Remove deck panel above cell.
4. Remove vent fitting (2 or 4, figure 2) (module 28-10-09 paragraph "2. Aft cell vent fittings - removal").
5. Remove center aft cell rear cover (3) (module 28-10-10 paragraph "1. Center aft cell rear cover - removal").
6. Working through center aft cell rear access port, remove bolts (8) and washers (7). If removing right aft cell, fuel
quantity probe (9) is secured by these same bolts.
7. Remove inlet/outlet fitting (5 or 10) (module 28-10-04 paragraph "2. Forward cell inlet/outlet fittings - removal").
8. If removing right aft cell, remove filler cap and adapter assembly (1) (module 28-20-16 paragraph "2. Filler cap and
adapter assembly (helicopters not equipped with pump P/N 206-062-687-101) - removal" or module 28-20-17
paragraph "2. Aft cells - removal").
9. Lift cell from cavity.
10. Cover cell openings and cap or plug open lines.
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G6AB0322A
28-10-12
Page 2
E-AB412-PT6T-2
G6AB0323A
28-10-12
Page 3
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3. AFT CELLS - INSTALLATION
MATERIALS REQUIRED
NUMBER NOMENCLATURE
C-408 TALCUM POWDER
CAUTION

BELOW 65°F (18°C).
1. Inspect cell cavity for foreign objects and rough interior surfaces. Remove foreign objects and/or repair rough surfaces
prior to installing cell.
2. Apply talcum powder (C-408) to interior surfaces of cavity.
3. Coat packings (6, figure 2) with assembly fluid (C-024) and place packings in grooves of left aft or right aft and center
aft cell.
4. Remove protective covers, caps, and plugs.
5. Insert cell into cavity. Using care to avoid damage to cell, align cell ports with fuselage openings.
6. If installing right aft cell, install filler cap and adapter assembly (1, figure 2) (module 28-20-16 paragraph "3. Filler
cap and adapter assembly (helicopters not equipped with pump P/N 206-062-687-101) - installation").
7. Install inlet/outlet fitting (5 or 10) (module 28-10-07 paragraph "3. Center aft cell outlet fittings - installation").
8. Working through access port at rear of center aft cell, ensure packings (6) are in place in grooves of center aft and left
aft or right aft cell. If installing right aft cell, place fuel quantity probe (9) in position.
9. Install bolts (8) with washers (7). Torque bolts (8) 50 to 100 in.lbs. (5,65 to 11,30 Nm)
10. Install center aft cell rear cover (3) (module 28-10-10 paragraph "2. Center aft cell rear cover - installation", steps 1.
through 7. only).
11. Install vent fitting (2 or 4) (module 28-10-09 paragraph "3. Aft cell vent fittings - installation", steps 1. through 6.
only).
12. Perform operational check of fuel quantity indicating system before servicing system (Chapter 96).
15. Install deck panel and access doors.
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E-AB412-PT6T-2
G6AB0354A
Figure 2. Left aft and right aft cell (helicopters codes [A][B])
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4. AFT CELLS - CLEANING
MATERIALS REQUIRED
NUMBER NOMENCLATURE
C-339 ETHYL ALCOHOL
CAUTION

TEMPERATURE SHALL NOT EXCEED 160°F (71°C). DO NOT USE SOAPS
STRONG DETERGENTS ARE HARMFUL TO FUEL CELL. SOAPS CAN
REACT WITH FUEL TO FORM A COMPOUND WHICH CAN PLUG FUEL
FILTERS. DO NOT USE MEK OR SIMILAR SOLVENTS FOR CLEANING
FUEL CELLS.
1. Remove all fungus growth from cell by hand or with a soft scrub brush using warm water.
2. If fungus is observed in cell cavity, wipe cell cavity with clean cloth moistened with ethyl alcohol (C-339).
5. AFT CELLS - INSPECTION
CAUTION

BELOW 65°F (18°C).
1. Inspect cell for cracks and scuffing.
2. Inspect threaded insert for damage.
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28-10-13 FUEL STORAGE AND DISTRIBUTION SYSTEM (HELICOPTERS CODES [A][B]) - CENTER AFT CELL
28-10-13
[A][B]) - CENTER AFT CELL
1. CENTER AFT CELL - DESCRIPTION
The center aft cell (13, figure 1) is located between main structure beams at B.L. 14 and between bulkheads at F.S. 155 and
178.
The cell has interconnection ports on the bottom and both sides. A vent fitting port is located on top, and a port for a large
access cover is on the aft side.
NOTE
Maintenance procedures for left aft and right aft cells are the same.
2. CENTER AFT CELL - REMOVAL
CAUTION

BELOW 65°F (18°C).
1. Remove rear cover (2, figure 2) (module 28-10-10 module Center aft cell rear cover - removal).
2. Remove fuel quantity probe (8).
3. Working through access at rear of cell, remove bolts (6) and washers (5) from both sides of cell.
4. Remove outlet fittings (3 and 7) (module 28-10-11 module Aft cell outlet fittings - removal).
5. Collapse aft upper edge of cell downward and inward.
6. With cell held in this position, remove four bolts (9).
7. Disconnect four vent hoses from vent cover (1).
8. Position two webbing straps around cell. Run straps vertically around cell.
9. Tighten straps and remove cell from rear access opening.
10. Cover cell openings and restore to original shape. Store cell in heated area if ambient temperature is below 65°F
(18°C).
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G6AB0322A
28-10-13
Page 2
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G6AB0323A
28-10-13
Page 3
E-AB412-PT6T-2
G6AB0355A
Figure 2. Center aft cell (helicopters codes [A][B])
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E-AB412-PT6T-2
3. CENTER AFT CELL - INSTALLATION
MATERIALS REQUIRED
NUMBER NOMENCLATURE
C-408 TALCUM POWDER
CAUTION

BELOW 65°F (18°C).
1. Inspect cell cavity for cleanliness and smoothness of interior surfaces.
2. Apply talcum powder (C-408) to interior surfaces of cell cavity.
3. Collapse and fold cell. Secure with suitable webbing straps to a bundle which can pass through rear access opening of
cavity.
4. Carefully insert cell into cavity. Remove straps and arrange in approximate position.
5. Install outlet fittings (3 and 7, figure 2) (module 28-10-11 paragraph "3. Aft cell outlet fittings - installation").
6. Coat packings (4) with assembly fluid (C-024) and place packings in groove of two interconnection ports at sides of
cell. Ensure packings are still in place on mating fitting of right aft and left aft cells.
7. Install bolts (6) with washers (5). On right side of cell, position mount of fuel quantity probe (8) under head of bolts.
Torque bolts (6) 50 to 100 in.-lbs. (5,65 to 11,30 Nm).
8. Install vent cover (1) (module 28-10-08 paragraph "3. Center aft cell vent cover - installation").
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E-AB412-PT6T-2
4. CENTER AFT CELL - CLEANING
MATERIALS REQUIRED
NUMBER NOMENCLATURE
C-339 ETHYL ALCOHOL
CAUTION

TEMPERATURE SHALL BE LIMITED TO 160°F (71°C). DO NOT USE SOAPS
REACT WITH FUEL TO FORM A COMPOUND WHICH CAN PLUG FUEL
FILTERS.
2. If fungus is observed in cell cavity, wipe cell cavity with clean cloths moistened with ethyl alcohol (C-339).
5. CENTER AFT CELL - INSPECTION
1. Inspect cell for cracks and scuffing. Cracks and severe scuffing are not acceptable.
2. Inspect threaded inserts for damaged threads. Damaged threads which can be detected visually are not acceptable.
28-10-13
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28-10-14 FUEL STORAGE AND DISTRIBUTION SYSTEM (HELICOPTERS CODES [C][D]) - LOWER FORWARD CELLS
28-10-14
[C][D]) - LOWER FORWARD CELLS
1. LOWER FORWARD CELLS - DESCRIPTION
Two lower forward cells (1 and 28, figure 1) are located under cabin floor below W.L. 22, outboard of each main longitudinal
beam (at left B.L. 14 and right B.L. 14), and between F.S. 84,5 and 102. Each lower forward cell has a vent port on upper
front side and interconnect ports on inboard and aft sides. A sump opening on bottom provides access for installation and
maintenance of internally mounted components.
NOTE
Maintenance procedures for left and right forward cells are the same.
2. LOWER FORWARD CELLS - REMOVAL
MATERIALS REQUIRED
NUMBER NOMENCLATURE
C-428 CAPS AND/OR PLUGS
CAUTION
DO NOT HANDLE CELL WHEN AMBIENT TEMPERATURE IS BELOW 65°F

(18°C).
3. Remove cabin floor panels above cell to be removed. Remove access doors on underside of helicopter directly below
respective lower forward cell.
4. Remove sump assembly (6, figure 1) (module 28-20-28 paragraph "2. Lower main cell sump assemblies - removal").
NOTE
Check valve (4) and hose (3) can remain connected to interconnect fitting and be
removed with fitting.
5. Remove interconnect fitting (5) (module 28-10-17 paragraph "2. Lower forward cell/lower middle cell interconnect
fitting - removal").
6. Remove interconnect fitting (9) (module 28-10-16 paragraph "2. Lower forward cell interconnect hose and fitting -
removal").
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E-AB412-PT6T-2
7. Remove vent hose (7) (module 28-10-15 paragraph "2. Lower forward cell vent hoses - removal").
8. Remove nylon cord from hangers around top of cell and cell cavity.
9. While holding the setscrew (10) with an allen key, remove the nut (11) and washer (12).
10. With the allen key, remove the setscrew (10).
3. LOWER FORWARD CELLS - INSTALLATION
MATERIALS REQUIRED
NUMBER NOMENCLATURE
C-408 TALCUM POWDER
C-480 NYLON CORD
CAUTION
DO NOT HANDLE CELLS WHEN AMBIENT TEMPERATURE IS BELOW

65F (18C).
1. Remove protective caps, plugs, and covers. Inspect cell cavity for clean, smooth condition of surfaces.
2. Apply talcum powder (C-408) to cavity surfaces.
3. Place cell in cavity and align interconnect port with port on lower middle cell and bulkhead opening.
4. With an allen key, install the setscrew (10, figure 1) in the lower forward cell (1) through the bulkhead.
5. Make four turns of the setscrew (10) with the allen key.
6. While holding the setscrew (10) in place with the allen key, install the washer (11) and nut (12). Tighten the nut.
7. Install forward cell interconnect fitting (9) (module 28-10-16 paragraph "3. Lower forward cell interconnect hose and
fitting - installation")
8. Install vent hose (8) (module 28-10-15 paragraph "3. Lower forward cell vent hoses - installation")
9. Install cabin floor panels. Install access doors on under side of helicopter.
(HELICOPTERS CODES [C][D]) - PRESSURE TESTING").
28-10-14
Page 2
E-AB412-PT6T-2
G6AB0364A
Figure 1. Lower forward cell (helicopters codes [C][D])
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Page 3
E-AB412-PT6T-2
4. LOWER FORWARD CELLS - CLEANING
MATERIALS REQUIRED
NUMBER NOMENCLATURE
C-339 ETHYL ALCOHOL
CAUTION
WHEN USING HOT WATER TO CLEAN CELL, WATER TEMPERATURE

SHALL NOT EXCEED 160°F (71°C). DO NOT USE SOAPS OR STRONG
DETERGENTS WHEN CLEANING CELL. CERTAIN STRONG DETERGENTS
ARE HARMFULL TO CELL. SOAPS CAN REACT WITH FUEL TO FORM A
COMPOUND WHICH CAN CLOG FUEL FILTERS.
DO NOT USE MEK OR SIMILAR SOLVENTS FOR CLEANING CELLS.
2. If fungus is observed in cell cavity, wipe cell cavity with clean cloths moistened in ethyl alcohol (C-339).
5. LOWER FORWARD CELLS - INSPECTION
1. Inspect cell for cracks, scuffing, and general condition.
2. Inspect threaded inserts for serviceability. Any defect which can be detected visually is not acceptable.
3. Inspect hoses for damage and deterioration. Any hose which exhibits damage or deterioration shall be replaced.
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28-10-15 FUEL STORAGE AND DISTRIBUTION SYSTEM (HELICOPTERS CODES [C][D]) - LOWER FORWARD CELL VENT HOSES
28-10-15
[C][D]) - LOWER FORWARD CELL VENT HOSES
1. LOWER FORWARD CELL VENT HOSES - DESCRIPTION
Vent hoses are attached to vent ports on upper forward side of each lower forward cell. These vent hoses connect lower
forward cells into forward venting system. Fume tight boots are installed over hose connections to lower forward cell to
prevent escape of fumes into surrounding areas.
NOTE
Maintenance procedures for left and right lower forward cell vent hoses are the
same.
2. LOWER FORWARD CELL VENT HOSES - REMOVAL
3. Remove cabin floor panel.
4. Loosen and slip clamp (11, figure 1) back on hose assembly (3).
6. Loosen retainer (10) and slip back on hose assembly (3).
7. Loosen boot (9) and work back on hose assembly (3).
8. Remove bolts (8), washers (7), retainer (6), and spacers (5).
9. Remove hose assembly (3) and packing (4). Discard packing.
10. Install protective covers over cell opening and hose assembly.
28-10-15
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E-AB412-PT6T-2
3. LOWER FORWARD CELL VENT HOSES - INSTALLATION
MATERIALS REQUIRED
NUMBER NOMENCLATURE
1. Remove protective caps and covers.
2. Install packing (4, figure 1) on end of hose assembly (3). If required, apply assembly fluid (C-024) to hold packing in
place.
NOTE
When installing new hose assembly (3), ensure boot (9), retainer (10), and clamp
(11) are on hose assembly in proper order, and pushed back on hose assembly for
access to end of hose.
3. Hold end of hose assembly (3) close to vent port of cell.
4. Install bolts (8), washers (7), retainer (6), spacers (5), and hose assembly (3) on face of cell vent port. Tighten bolts (8).
5. Slip boot (9) and retainer (10) in place over end of hose assembly (3). Install screws (1), washers (2), retainer (10), and
boot (9) on vent port of cell.
6. Slip clamp (11) over back end of boot (9) and tighten around hose assembly (3).
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Page 2
E-AB412-PT6T-2
G6AB0365A
Figure 1. Lower forward cell vent hose (helicopters codes [C][D])
28-10-15
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E-AB412-PT6T-2
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28-10-16 FUEL STORAGE AND DISTRIBUTION SYSTEM (HELICOPTERS CODES [C][D]) - LOWER FORWARD CELL INTERCONNECT HOSE AND FITTING
28-10-16
[C][D]) - LOWER FORWARD CELL INTERCONNECT HOSE AND FITTING
1. LOWER FORWARD CELL INTERCONNECT HOSE AND FITTING - DESCRIPTION
A fitting is connected directly to the inboard interconnect port of left lower forward cell. An interconnect hose is attached
to one port of fitting and to inboard interconnect port of right lower forward cell. An interconnect hose is attached to
remaining port of fitting and to upper forward center cell output port.
NOTE
Both the interconnect hose and fitting are included in removal and installation
procedures. If both are not to be removed and/or installed, perform only applicable
steps.
2. LOWER FORWARD CELL INTERCONNECT HOSE AND FITTING - REMOVAL
MATERIALS REQUIRED
NUMBER NOMENCLATURE
3. Remove cabin floor panels above left and right lower forward cells.
4. Remove strap (9, figure 1) from boot (5).
6. Loosen retainer (6) and slide back on hose assembly (2).
7. Loosen boot (5) and slide back on hose assembly (1).
9. Remove hose assembly (2) from cell interconnect port. Remove and discard packing (1).
10. Remove straps (10 and 12).
11. Slip boot (11) over connection and back on hose (2).
12. Remove bolts (13), washers (16), and nuts (17).
28-10-16
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E-AB412-PT6T-2
14. Remove straps (33 and 34).
15. Slip boot (35) over connection and back on hose assembly.
16. Remove bolts (18), washers (24), and nuts (25).
17. Remove hose assembly (26) and packing (23) from fitting (15). Discard packing.
18. Remove strap (36).
19. Remove screws (37), washers (40), nuts (41), and doubler (38).
20. Slip the boot (39) forward on the hose assembly (26).
21. Remove the bolts (42), washers (43) and nuts (44).
22. Remove the hose assembly (26) and the packing (45) from the hose assembly (46). Discard the packing.
23. Remove strap (28).
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Page 2
E-AB412-PT6T-2
G6AB0366A
Figure 1. Lower forward cell interconnect hose and fitting (helicopters codes [C][D]) (sheet 1 of 3)
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Page 3
E-AB412-PT6T-2
G6AB0367A
28-10-16
Page 4
E-AB412-PT6T-2
G6AB0368A
28-10-16
Page 5
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25. Loosen retainer (29) and boot (30), and slide both back on fitting (15) for access to cell connection.
26. Remove bolts (19), washers (20), retainers (22), and spacers (21).
27. Remove fitting (15) and packing (27) from interconnect port of cell. Discard packing.
28. Install protective caps and/or plugs (C-428) over cell opening and open end of fitting (15).
3. LOWER FORWARD CELL INTERCONNECT HOSE AND FITTING - INSTALLATION
MATERIALS REQUIRED
NUMBER NOMENCLATURE
C-308 ADESIVE SEALANT
2. Place packing (27) and fitting (15) on left forward cell interconnect port.
3. Place retainer (29), and boot (30) on fitting (15), and slide back on body of fitting.
4. Install bolts (19), washers (20), retainers (22), spacers (21), and fitting (15). Tighten bolts.
5. Apply sealant (C-308) to face of boot (30).
6. Slide boot (30) over end of fitting (15).
7. Install screws (32) and washers (31). Tighten screws.
8. Remove excess sealant (C-308) from around boot (30).
9. Install strap (28) on boot (30).
10. On the aft end of hose assembly (26), slide the doubler (38) and then the boot (39) on the hose assembly.
11. Put the hose assembly (26) in position in the helicopter.
12. Apply assembly fluid (C-024) to packing (45).
13. Place the packing (45) and flange of hose assembly (26) on the flange of hose assembly (46).
14. Install the bolts (42), washers (43) and nuts (44). Tighten the nuts.
15. Apply sealant (C-308) to face of boot (39).
16. Install boot (39) with doubler (38), screws (37), washers (40) and nuts (41). Tighten the nuts.
17. Remove the excess sealant from around the boot (39).
18. Install the strap (36) on the boot (39).
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19. On the forward end of the hose assembly (26), slide the boot (35) on the hose assembly.
21. Place packing (23) and flange of hose assembly (26) on flange of fitting (15).
22. Install bolts (18), washers (24) and nuts (25). Tighten bolts.
23. Slide the boot (35) forward over the hose assembly (26) to the fitting (15) connection.
24. Install straps (33 and 34) on boots (35).
25. Lubricate packing (14) with assembly fluid (C-024).
26. Ensure boot (11) is slid back on hose assembly (2).
27. Place packing (14) and flange of hose assembly (2) on flange of fitting (15).
28. Install bolts (13), washers (16) and nuts (17). Tighten bolts.
29. Slip end of boot (11) over connection and secure with strap (12).
30. Install strap (10) on other end of boot (11).
31. Ensure retainer (6) and boot (5) are over end of hose assembly (2) in proper order.
33. Place packing (1) and flange of hose assembly (2) on surface of right lower forward cell interconnect port.
34. Install bolt (4) and washers (3). Tighten bolts.
35. Apply adhesive sealant (C-308) to face of boot (5).
36. Slip boot (5) in place over connection. Place retainer (6) over flat mounting surface of boot (5).
38. Remove excess sealant from around boot (5).
39. Install strap (9) on boot (5).
28-10-16
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28-10-16
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28-10-17 FUEL STORAGE AND DISTRIBUTION SYSTEM (HELICOPTERS CODES [C][D]) - LOWER FORWARD CELL/LOWER MIDDLE CELL INTERCONNECT FITTING
28-10-17
[C][D]) - LOWER FORWARD CELL/LOWER MIDDLE CELL INTERCONNECT
FITTING
1. LOWER FORWARD CELL/LOWER MIDDLE CELL INTERCONNECT FITTING -

DESCRIPTION
A lower forward cell/lower middle cell interconnect fitting is located on aft interconnect port of each lower forward cell.
The fitting provides interconnection between lower forward and lower middle cells and serves as a mounting point for the
lower forward cell check valve.
NOTE
Maintenance procedures for left and right lower forward cell/lower middle cell
interconnect fitting are the same.

REMOVAL
MATERIALS REQUIRED
NUMBER NOMENCLATURE
3. Remove cabin floor access panels and access doors on underside of helicopter below the applicable lower forward and
lower middle cells.
4. Remove lower forward cell sump assembly (module 28-20-18 paragraph "2. Lower forward cell sump assemblies -
removal").
5. Remove lower middle cell sump assembly (module 28-20-23 paragraph "2. Lower middle cell sump assemblies -
removal").
6. In lower middle cell, disconnect tube (4, figure 1) from union (3).
7. Remove union (3) and packing (2). Discard packing.
8. In lower forward cell, remove forward cell check valve (module 28-10-21 paragraph "3. Lower forward cell/lower
middle cell interconnect fitting - installation").
10. Partially collapse cell (8) and cell (1) for hand access.
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11. Remove packing (5), interconnect fitting (6), and packing (7). Discard packings.
12. Install protective caps and/or plugs (C-428) and covers over cell openings.
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INSTALLATION
MATERIALS REQUIRED
NUMBER NOMENCLATURE
1. Remove protective covers from cell openings.
2. Coat packings (5 and 7, figure 1) with assembly fluid (C-024).
3. Place packings (5 and 7) on each side of interconnect fitting (6).
4. Align fitting with packings (5 and 7) between cell (8) and cell (1) walls, and in hole in bulkhead between.
5. From inside the lower forward fuel cell (8), install bolts (9) and seal (10).
7. Install packing (2) on union (3)
8. Install union (3) into the interconnect fitting (6).
9. Connect hose (4) to union (3).
10. Install lower forward cell check valve (4, figure 2) (module 28-20-22 paragraph "3. Lower forward cell check valves
- installation").
11. Install lower middle cell sump assembly (module 28-20-23 paragraph "3. Lower middle cell sump assemblies -
installation").
12. Install lower forward cell sump assembly (module 28-20-18 "FUEL STORAGE AND DISTRIBUTION SYSTEM
(HELICOPTERS CODES [C][D]) - LOWER FORWARD CELL SUMP ASSEMBLIES").
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G6AB0378A
Figure 1. Lower forward cell/lower middle cell interconnect fitting (helicopters codes [C][D])
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G6AB0379A
Figure 2. Lower forward cell check valve (helicopters codes [C][D])
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28-10-18 FUEL STORAGE AND DISTRIBUTION SYSTEM (HELICOPTERS CODES [C][D]) - LOWER MIDDLE CELLS AND LOWER MAIN CELLS
28-10-18
[C][D]) - LOWER MIDDLE CELLS AND LOWER MAIN CELLS
1. LOWER MIDDLE CELLS AND LOWER MAIN CELLS - DESCRIPTION
Lower middle cells are located under the cabin floor below W.L. 22, outboard of each main longitudinal beam (at left B.L.
14 and right B.L. 14), and between F.S. 102 and front side of lower main cells. Each lower middle cell has a vent port on the
upper outboard side and interconnect ports on the inboard, forward, and aft sides. A sump opening on the bottom provides
access for installation and maintenance of internally mounted components.
Two lower main cells are located under the cabin floor below W.L. 22, outboard of each main longitudinal beam (at left B.L.
14 and right B.L. 14), and between the aft sides of the lower middle cells and F.S. 155. Each lower main cell has a vent port
on the upper inboard side and interconnect ports on the inboard, forward, and aft sides. A sump opening on the bottom
provides access for installation and maintenance of internally mounted components.
NOTE
Lower left middle cell and lower left main cell are connected together by a lower
middle cell/lower main cell interconnect fitting prior to installation, and are removed
and installed together. The lower right middle cell and lower right main cell are
connected together by a lower middle cell/lower main cell interconnect fitting prior
to installation, and are removed and installed together. Removal and installation
procedures for left and right installations are the same.
2. LOWER MIDDLE CELLS AND LOWER MAIN CELLS - REMOVAL
MATERIALS REQUIRED
NUMBER NOMENCLATURE
3. Remove cabin floor panels above the cells to be removed.
4. Remove access doors on underside of helicopter below all lower cells on side having cells to be removed.
5. Remove lower forward cell sump assembly for access (module 28-20-18 paragraph "2. Lower forward cell sump
assemblies - removal").
removal").
7. Remove lower main cell sump assembly (module 28-20-28 paragraph "2. Lower main cell sump assemblies -
removal").
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8. Remove lower forward cell/lower middle cell interconnect fitting (module 28-10-21 paragraph "2. Lower middle cell/
lower main cell interconnect fittings - removal").
9. Remove lower main cell inlet/outlet fitting (module 28-10-22 paragraph "2. Lower main cell inlet/outlet fittings -
removal").
10. Remove lower middle cell vent hose (module 28-10-19 paragraph "2. Lower middle cell vent hoses - removal").
11. Remove lower main cell vent hose (module 28-20-26 paragraph "2. Lower main cell vent valves and hoses - removal").
12. Remove lower middle cell interconnect fitting (23, figure 1) and interconnect hose (24) from lower middle cell (1)
(module 28-10-17 paragraph "2. Lower forward cell/lower middle cell interconnect fitting - removal").
13. Remove lower main interconnect hose (8) from cell (6) (module 28-20-27 paragraph "2. Lower main cell interconnect
hoses - removal").
14. Install protective caps and/or plugs (C-428) on all open end fittings, and install protective covers over cell openings.
15. While holding the setscrews (27) with an allen key, remove the nuts (29) and the washers (28).
16. With the allen key, remove the setscrew (27).
17. Remove nylon cord from hangers around top of cells and top of cell cavity.
18. Partially collapse cells. Lift cells evenly from cell cavity.
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G6AB0369A
Figure 1. Lower middle cell/lower main cell (helicopters codes [C][D]) (sheet 1 of 2)
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1. Check valve 10. Seal drain port

2. Packing 11. Spirolox retaining ring
3. Packing 12. Pump cover
4. Allen screw 13. Pump cover packing
5. Locking bar 14. Inlet seal packing
6. Cartridge 15. Impeller
7. Discharge port 16. Impeller key
8. Retaining ring 17. Inlet seal
9. Cartridge drain port
NOTE
1 Arrows must align within ± 3° for cartridge installation.
G6AB0370B
Figure 1. Lower middle cell/lower main cell (helicopters codes [C][D]) (sheet 2 of 2)
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3. LOWER MIDDLE CELLS AND LOWER MAIN CELLS - INSTALLATION
MATERIALS REQUIRED
NUMBER NOMENCLATURE
C-408 TALCUM POWDER
C-480 NYLON CORD
CAUTION
DO NOT HANDLE CELLS WHEN AMBIENT TEMPERATURE IS BELOW

65°F (18°C).
1. Remove protective caps, plugs, and covers. Inspect entire cell cavity for clean, smooth condition of all surfaces.
2. Apply talcum powder (C-408) to cell cavity surfaces.
3. Place interconnected lower middle cell (1, figure 1) and lower main cell (6) in cell cavity.
4. Align lower forward cell and lower middle cell interconnect parts with opening in bulkhead.
5. With an allen key, install the setscrews (27) in the lower middle fuel cell (6), through the bulkhead.
6. Make four turns of the setscrews (27) with the allen key.
7. While holding the setscrews (27) in place with the allen key, install the washers (28) and nuts (29). Tighten the nuts.
8. Install lower main cell inlet/outlet fitting (12) (module 28-10-22 paragraph "3. Lower main cell inlet/outlet fittings -
installation").
9. Install lower forward cell/lower middle cell interconnect fitting (module 28-10-21 paragraph "3. Lower middle cell/
lower main cell interconnect fittings - installation") and lower forward cell check valve (module 28-20-22 paragraph
"3. Lower forward cell check valves - installation").
10. Ensure all internal cell components are tightly mounted and all internal hose and tube connections have been tightened.
11. Install lower forward cell sump assembly (3, figure 2) (module 28-20-18 paragraph "3. Lower forward cell sump
assemblies - installation").
12. Install lower main cell sump assembly (15, figure 1) (module 28-20-28 paragraph "3. Lower main cell sump
13. Install lower middle cell sump assembly (3) (module 28-20-23 paragraph "3. Lower middle cell sump assemblies -
installation").
14. Install lower middle cell interconnect fitting (23) or hose (24) (module 28-10-21 paragraph "3. Lower middle cell/
lower main cell interconnect fittings - installation").
15. Install lower main cell interconnect hose (8) (module 28-20-27 paragraph "3. Lower main cell interconnect hoses -
installation").
16. Install lower middle cell vent hose (19).
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17. Install lower main cell vent hose (5) (module 28-20-26 "FUEL STORAGE AND DISTRIBUTION SYSTEM
(HELICOPTERS CODES [C][D]) - LOWER MAIN CELL VENT VALVES AND HOSES").
18. Lace and tie a single length of nylon cord (C-480) between hangers around top of cells and cell cavity (figure 1).
19. Install cabin floor panels. Install access doors on underside of helicopter.
21. Service fuel system.
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G6AB0371A
Figure 2. Lower forward cell sump assembly (helicopters codes [C][D]) (sheet 1 of 2)
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NOTE:
Configuration for right lower forward cell. AFTER COMPLIANCE WITH
1 THERMISTOR INSTALLATION MODIFICATION
1. Lower forward cell 10. Fitting

2. Packing 11. Deleted
3. Sump assembly 12. Hose
4. Electrical connector 13. Transfer pump
5. Retainer 14. Electrical connector (internal)
6. Washer 15. Nut
7. Bolt 16. Clamp
8. Drain valve 17. Fuel level sensor thermistor
9. Packing 18. Bracket
G6AB0372B
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4. LOWER MIDDLE CELLS AND LOWER MAIN CELLS - CLEANING
MATERIALS REQUIRED
NUMBER NOMENCLATURE
C-339 ETHYL ALCOHOL
CAUTION
WHEN USING HOT WATER TO CLEAN CELL, WATER TEMPERATURE

SHALL NOT EXCEED 160°F (71°C). DO NOT USE SOAPS OR STRONG
DETERGENTS WHEN CLEANING CELLS. CERTAIN STRONG
DETERGENTS ARE HARMFUL TO CELLS. SOAPS CAN REACT WITH FUEL
TO FORM A COMPOUND WHICH CAN PLUG FUEL FILTERS.
DO NOT USE MEK OR SIMILAR SOLVENTS TO CLEAN CELLS.
1. Remove all fungus growth from cells by hand or with a soft bristled scrub brush using warm or hot water.
2. If fungus is observed in cell cavity, wipe cell cavity with clean cloths moistened in ethyl alcohol (C-339).
3. Inspect other cells for presence of fungus growth. Remove and clean, if required.
5. LOWER MIDDLE CELLS AND LOWER MAIN CELLS - INSPECTION
1. Inspect cells for cracks, scuffing, and general condition.
2. Inspect threaded inserts for serviceability. Damage which can be detected visually requires replacement of insert.
3. Inspect hoses for damage and deterioration. Damage which can be detected visually requires replacement of hose.
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28-10-19 FUEL STORAGE AND DISTRIBUTION SYSTEM (HELICOPTERS CODES [C][D]) - LOWER MIDDLE CELL VENT HOSES
28-10-19
[C][D]) - LOWER MIDDLE CELL VENT HOSES
1. LOWER MIDDLE CELL VENT HOSES - DESCRIPTION
Vent hoses are attached to vent ports on upper outboard side of each lower middle cell. The vent hoses connect the lower
middle cells into the forward venting system. Fume tight boots are installed over hose connections to lower middle cells to
prevent escape of fumes into surrounding cell areas.
NOTE
Maintenance procedures for left and right lower middle cell vent hoses are the same.
2. LOWER MIDDLE CELL VENT HOSES - REMOVAL
3. Remove floor panel above cell.
4. Loosen clamp (11, figure 1) and slide forward on hose assembly (1).
6. Loosen and move retainer (8) forward on hose assembly (1).
7. Loosen boot (7) and slide over hose assembly (1) end connector and forward on hose assembly to obtain access to hose
assembly end connector.
8. Remove bolts (6), washers (5), retainer (4) and spacers (3).
9. Remove hose assembly (1) and packing (2) from lower middle cell vent port. Discard packing.
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3. LOWER MIDDLE CELL VENT HOSES - INSTALLATION
MATERIALS REQUIRED
NUMBER NOMENCLATURE
NOTE
Ensure clamp (11, figure 1, retainer (8), and boot (7) are on hose assembly (1).
3. Place packing (2) and hose assembly (1) end flange in position on lower middle cell vent port.
4. Install screws (6), washers (5), retainer (4), and spacers (3).
5. Position boot (7) in place over hose assembly (1) end flange.
6. Place retainer (8) in place over boot (7).
7. Install screws (10) and washers (9).
8. Position clamp (11) in place over end of boot (7). Tighten clamp.
13. Install floor panel above cell.
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G6AB0373A
Figure 1. Lower middle cell vent hose (helicopters codes [C][D])
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28-10-20 FUEL STORAGE AND DISTRIBUTION SYSTEM (HELICOPTERS CODES [C][D]) - LOWER MIDDLE CELL INTERCONNECT HOSE AND FITTING
28-10-20
[C][D]) - LOWER MIDDLE CELL INTERCONNECT HOSE AND FITTING
1. LOWER MIDDLE CELL INTERCONNECT HOSE AND FITTING - DESCRIPTION
A fitting (8, figure 1) is connected directly to inboard interconnect port of left lower middle cell. An interconnect hose (2)
is attached to one port of fitting and to inboard interconnect port of right lower middle cell. An interconnect hose (11) is
attached to remaining port of fitting (8) and to upper forward center cell output port.
NOTE
Both interconnect hose and fitting are included in removal and installation
procedures. If both are not to be removed and/or installed, only applicable portions
of procedures need be performed.
2. LOWER MIDDLE CELL INTERCONNECT HOSE AND FITTING - REMOVAL
MATERIALS REQUIRED.
NUMBER NOMENCLATURE
3. Remove cabin floor access panels above lower left and right middle cells.
4. Remove bolts (6, figure 1), washers (5), retainers (4), and spacers (3) from hose assembly (2).
5. Remove nuts (18), washers (19), and bolts (21) from fitting (8).
6. Remove packings (1 and 7) and hose assembly (2). Discard packings.
7. Remove bolts (20), washers (9), and nuts (10) from fitting (8) and hose assembly (11).
8. Remove bolts (22), washers (23) and nuts (24) from hose assemblies (11 and 26).
9. Remove hose assembly (11) packings (12 and 13). Discard packings.
10. Remove bolts (17), washers (16), retainer (15), and spacers (14) from fitting (8).
11. Remove fitting (8) and packings (12 and 13). Discard packings.
12. Install protective caps and/or plugs (C-428) on the fuel cell openings, the open end fittings of the hose assemblies (2
and 11) and on the fittings (8).
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3. LOWER MIDDLE CELL INTERCONNECT HOSE AND FITTING - INSTALLATION
MATERIALS REQUIRED
NUMBER NOMENCLATURE
1. Apply assembly fluid (C-024) to packings (12 and 13, figure 1).
2. Remove protective covers from cell opening and hose end. Place packings (7, 12 and 13) on fitting (8).
3. Install bolts (17), washers (16), retainers (15), and spacers (14). Tighten bolts.
4. Install hose assembly (11), bolts (20), washers (9), and nuts (10). Tighten bolts.
5. Place packing (7) on hose assembly (2).
6. Install bolts (21), washers (19), and nuts (18). Tighten bolts.
7. Place packing (1) on hose assembly (2).
8. Install bolts (6), washers (5), retainers (4), and spacers (3). Tighten bolts.
(HELICOPTERS CODES [C][D]) - LOWER MAIN CELL VENT VALVES AND HOSES").
11. Install cabin floor panels.
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G6AB0374A
Figure 1. Lower middle cell interconnect hose and fitting (helicopters codes [C][D])
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28-10-21 FUEL STORAGE AND DISTRIBUTION SYSTEM (HELICOPTERS CODES [C][D]) - LOWER MIDDLE CELL/LOWER MAIN CELL INTERCONNECT FITTINGS
28-10-21
[C][D]) - LOWER MIDDLE CELL/LOWER MAIN CELL INTERCONNECT
FITTINGS
1. LOWER MIDDLE CELL/LOWER MAIN CELL INTERCONNECT FITTINGS -

DESCRIPTION
A lower middle cell/lower main cell interconnect fitting is located on the aft interconnect port of each forward middle cell.
The fitting provides interconnection between lower middle and lower main cells.
NOTE
Maintenance procedures are the same for both right and left lower middle cell/lower
main cell interconnect fittings.

REMOVAL
MATERIALS REQUIRED
NUMBER NOMENCLATURE
1. Remove floor panel above fitting to be removed.
removal")
3. Remove lower main cell sump (module 28-20-28 paragraph "2. Lower main cell sump assemblies - removal".
4. From the lower main fuel cell (1, figure 1) disconnect hose (2) from interconnect fitting (4).
5. From the lower middle fuel cell (6), disconnect tube (7) from interconnect fitting (4).
6. From the lower middle fuel cell (6), remove bolts (8) and seals (9). Discard seals.
7. Partially collapse lower middle cell (6). Remove fitting (4) and packings (3, 5 and 10). Discard packings.
8. Remove sleeve (12) and packing (11), if installed. Discard packing.
10. Install protective caps and/or plugs (C-428) on the hose assemblies (2 and 7) end fittings.
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INSTALLATION
MATERIALS REQUIRED
NUMBER NOMENCLATURE
2. Remove the protective caps and/or plugs (C-024) from the hose assemblies (2 and 7) end fittings.
3. Coat packings (3 and 5, figure 1) with assembly fluid (C-024).
4. Coat packings (10) and (11), if removed, with assembly fluid (C-024).
5. Install interconnect fitting (4), packings (3 and 5), bolts (8), seals (9) and packings (10) between lower middle cell (6)
and lower main cell (1).
6. Connect hose (2), sleeve (12), if removed, and tube (7) to interconnect fitting (4).
CAUTION
DO NOT PERFORM FUEL SYSTEM PRESSURE TEST, SERVICE, OR

OPERATIONAL CHECK UNTIL COMPLETION OF STEP 6.
7. Install lower middle cell sump assembly (module 28-20-23 paragraph "3. Lower middle cell sump assemblies -
installation").
8. Install lower main cell sump assembly (module 28-20-28 paragraph "3. Lower main cell sump assemblies -
installation").
11. Check for area leaks.
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G6AB0375A
Figure 1. Lower middle cell/lower main cell interconnect fitting (helicopters codes [C][D])
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28-10-2 FUEL STORAGE AND DISTRIBUTION SYSTEM (HELICOPTERS CODES [C][D]) - LOWER MAIN CELL INLET/OUTLET FITTINGS
28-10-22
[C][D]) - LOWER MAIN CELL INLET/OUTLET FITTINGS
1. LOWER MAIN CELL INLET/OUTLET FITTINGS - DESCRIPTION
A fuel inlet/outlet fitting is installed on back of each lower main fuel cell. These fittings provide attachment points for hoses
which transfer fuel from upper left and right fuel cells to lower main fuel cells, respectively. The fittings also provide
attachment points for hoses which connect to fuel boost pumps, allowing fuel transfer from boost pumps to engine fuel feed
lines.
2. LOWER MAIN CELL INLET/OUTLET FITTINGS - REMOVAL
MATERIALS REQUIRED
NUMBER NOMENCLATURE
3. Remove cabin floor access panel located aft of respective lower main cell sump assembly.
NOTE
Refer to steps 4., 5., or 6. for removal procedures for the specific fuel system
installed.
4. For helicopters code [C], remove lower right main cell inlet/outlet fitting (12, figure 1, detail A):
a. Disconnect hoses (3 and 9).
c. Separate inlet/outlet fitting (12) from cell.
d. Disconnect hose (16).
e. Remove unions (2, 8, and 15). Remove and discard packings (1, 7, and 14).
f. Remove inlet/outlet fitting (12) and packing (13) from cell. Discard packing.
g. Install protective caps and/or plugs (C-428) on the hose assemblies (3, 9 and 16) open end fittings.
5. For helicopter code [C], remove lower left main cell inlet/outlet fitting (24, figure 1, detail B):
a. Disconnect hoses (22 and 30).
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d. Disconnect hose (17).
f. Remove inlet/outlet fitting (24) and packing (23) from cell. Discard packing.
g. Install protective caps and/or plugs (C-428) on the hose assemblies (22, 30 and 17) open end fittings.
6. For helicopter code [D], remove lower right or left main cell inlet/outlet fitting (45, figure 1, detail C):
a. Disconnect hoses (33, 40, and 43).
d. Disconnect hoses (48 and 51).
f. Remove elbow (39). Remove and discard packing (37).
g. Remove reducer (47). Remove and discard packing (46).
h. Remove fitting (45) and packing (44) from cell. Discard packing (44).
i. Install protective caps and/or plugs (C-428) on the hose assemblies (33, 40, 43, 48 and 51) open end fittings.
j. Install protective cover over cell opening.
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1. Packing 11. Packing 21. Union

2. Union 12. Inlet/outlet fitting 22. Hose
3. Hose 13. Packing 23. Packing
4. Retainer 14. Packing 24. Inlet/outlet fitting
5. Thin aluminum washer 15. Union 25. Retainer
6. Bolt 16. Hose 26. Thin aluminum washer
7. Packing 17. Hose 27. Bolt
8. Union 18. Union 28. Packing
9. Hose 19. Packing 29. Union
10. Plug 20. Packing 30. Hose
G6AB0376B
Figure 1. Lower main cell inlet/outlet fitting (helicopters code [C]) (sheet 1 of 2)
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31. Packing 42. Union

32. Union 43. Hose
33. Hose 44. Packing
34. Retainer 45. Inlet/outlet fitting
35. Thin aluminum washer 46. Packing
36. Bolt 47. Reducer
37. Packing 48. Hose
38. Nut 49. Packing
39. Elbow 50. Union
40. Hose 51. Hose
41. Packing
G6AB0377B
Figure 1. Lower main cell inlet/outlet fitting (helicopters code [C]) (sheet 2 of 2)
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E-AB412-PT6T-2
3. LOWER MAIN CELL INLET/OUTLET FITTINGS - INSTALLATION
MATERIALS REQUIRED
NUMBER NOMENCLATURE
NOTE
Refer to steps 1., 2., or 3. for installation procedures for the specific fuel system
installed.
1. Remove protective cover from the fuel cell opening.
2. Remove caps and/or plugs from the hose assemblies and fittings.
3. For helicopters code [C], install lower right main cell inlet/outlet fitting (12, figure 1, detail A) as follows:
a. Apply assembly fluid (C-024) to packings (1, 7 and 14).
b. Install packings (1, 7 and 14) on unions (2, 8 and 15).
c. Install unions (2, 8 and 15) in inlet/outlet fitting (12).
d. Place packing (13) in groove around cell port. Packing may be held in place with assembly fluid (C-024).
e. Hold inlet/outlet fitting (12) close to cell port and connect hose (16).
NOTE
Bolts (6) installed in top six holes of fitting (12) are longer than bolts (6) used in
bottom two holes.
f. Position fitting (12) over cell port. Install longer bolts (6), washers (5), and retainers (4) in upper six holes. Install
shorter bolts (6) and washers (5) in two lower holes.
g. Connect hoses (3 and 9).
h. Perform fuel system pressure test (module 28-40-06 "FUEL STORAGE AND DISTRIBUTION SYSTEM
i. Check area for leaks.
4. For helicopters code [C], install lower left main cell fitting (24, figure 1, detail B):
a. Apply assembly fluid (C-024) to packings (19, 20, and 28).
b. install packings (19, 20 and 28) on unions (18, 21 and 29).
c. Install unions (18, 21 and 29) in inlet/outlet fitting (24).
d. Place packing (23) in groove around cell port. Packing may be held in place with assembly fluid (C-024).
e. Hold fitting (24) close to cell port and connect hose (17).
NOTE
Bolts (27) used in the top six holes of the fitting (24) are longer than bolts (27) used
in two bottom holes.
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f. Position fitting (24) over cell port. Install longer bolts (27), washers (26), and retainers (25) in the upper six
holes. Install shorter bolts (27) and washers (26) in two lower holes.
g. Connect hoses (22 and 30).
h. Perform fuel system pressure test (module 28-40-06 "FUEL STORAGE AND DISTRIBUTION SYSTEM
i. Check area for leaks.
5. For helicopters code [D], install the lower left or right main cell inlet/outlet fitting (24, figure 1 detail C):
a. Apply assembly fluid (C-024) to the packings (31, 37, 41, 46 and 49).
b. Install the packing (31, 41 and 49) on the unions (32, 42 and 50).
c. Install the packing (37) on the elbow (39).
d. Install the packing (46) on the reducer (47).
e. Install the unions (32, 42 and 50), elbow (39), and reducer (47) in the inlet/outlet fitting (45).
f. Place the packing (44) in the groove around the cell port. The packing may be held in place with assembly fluid
(C-024).
g. Hold fitting (45) close to cell port and connect hoses (48 and 51).
NOTE
Bolts (36) used in the top six holes of fitting (45) are longer than bolts (36) used in
two bottom holes.
h. Position fitting (45) over cell port. Install longer bolts (36), washers (35), and retainers (34) in upper six holes
and shorter bolts (36) and washers (35) in two lower bolt holes.
i. Connect hoses (33, 40, and 43).
j. Perform fuel system pressure test (module 28-40-06 "FUEL STORAGE AND DISTRIBUTION SYSTEM
k. Check area for leaks.
l. Repeat steps 6.a. through 6.j. to install opposite fitting (45).
28-10-22
Page 6 Rev. 2
E-AB412-PT6T-2
28-10-23 FUEL STORAGE AND DISTRIBUTION SYSTEM (HELICOPTERS CODES [C][D]) - UPPER FORWARD CENTER CELL
28-10-23
[C][D]) - UPPER FORWARD CENTER CELL
1. UPPER FORWARD CENTER CELL - DESCRIPTION
The upper forward center cell is located above W.L. 22, between the two main longitudinal beams (at left B.L. 14 and right
B.L. 14), and between F.S. 155 and 178. The upper forward center cell has a vent port on top and interconnect ports on the
bottom, left, right, and aft sides. Internal access is provided by openings at top and bottom of cell.
2. UPPER FORWARD CENTER CELL - REMOVAL
CAUTION

BELOW 65°F (18°C).
3. Remove large access door on underside of helicopter below upper aft center cell.
4. Remove smaller access doors on underside of helicopter below upper forward center cell.
5. Remove access panels in engine compartment floor above upper forward cell, upper aft cell, upper left cell, and upper
right cell.
6. Remove upper forward center cell bottom cover (short standpipe) assembly (7, figure 1) (module 28-10-14
paragraph "2. Lower forward cells - removal").
7. Remove upper forward center cell bottom cover (tall standpipe) assembly (8) (module 28-10-25 paragraph "2. Upper
forward center cell bottom cover (tall standpipe) assembly - removal").
8. Remove upper aft center cell (module 28-10-28 paragraph "2. Upper aft center cell - removal").
9. Remove large access panel on bulkhead between upper aft center cell cavity and upper forward center cell cavity.
10. Remove upper left cell and upper right cell top cover assemblies for access (module 28-10-34 paragraph "2. Upper left
cell and upper right cell top cover assemblies - removal").
11. Working through top vent port of upper left cell, remove lockwire, large nut, and packing from interconnect fitting (6)
(module 28-10-26 paragraph "2. Upper forward center cell interconnect fittings - removal"). Discard packing.
12. Working through top vent port of upper right cell, remove lockwire, large nut, and packing from fitting (2)
(module 28-10-26 paragraph "2. Upper forward center cell interconnect fittings - removal"). Discard packing.
28-10-23
Rev. 2 Page 1
E-AB412-PT6T-2
1. Upper forward center cell

2. Interconnect fitting
3. Top cover assembly
4. Support assemblies
7. Bottom cover (short standpipe) assembly
8. Bottom cover (tall standpipe) assembly
HELICOPTERS CODE
HELICOPTERS CODE
HELICOPTERS CODE
G6AB0380B
Figure 1. Upper forward center fuel cell (helicopters codes [C][D])
28-10-23
Page 2 Rev. 2
E-AB412-PT6T-2
13. Remove upper forward center cell top cover assembly (3) and support assembly (4) (module 28-10-27
paragraph "2. Upper forward center cell top cover assembly - removal").
14. Cover exposed cell openings and cap or plug open lines, except upper forward center cell openings.
15. Collapse aft upper edge of upper forward center cell downward and inward. Ensure fittings (2, 5, and 6) are clear of
bulkhead openings.
16. Position two webbing straps vertically around cell. Tighten straps to compress cell to pass through access openings.
17. Remove cell from upper forward center cell cavity through large access opening in bulkhead between upper forward
and upper aft cell cavities, and through large access opening on underside of helicopter below upper aft center cell.
18. Restore cell to original shape. Cover cell openings.
19. Install protective covers on upper forward center cell openings.
CAUTION
STORE CELL IN A HEATED AREA IF AMBIENT TEMPERATURE IS BELOW

65°F (18°C).
3. UPPER FORWARD CENTER CELL - INSTALLATION
MATERIALS REQUIRED
NUMBER NOMENCLATURE
C-405 LOCKWIRE
C-408 TALCUM POWDER
CAUTION

BELOW 65°F (18°C).
4. Collapse cell and position two webbing straps vertically around cell. Tighten straps to compress cell sufficiently to
pass through access openings.
5. Carefully pass cell through large access opening below upper aft cell cavity, through large access opening in bulkhead
between upper aft center cell and upper forward center cell cavities, and into upper forward center cell cavity.
6. Remove webbing straps and arrange cell in approximate position in cell cavity.
28-10-23
Rev. 2 Page 3
E-AB412-PT6T-2
7. Align interconnect ports and bottom outlet ports with matching cell ports and fuselage openings.
NOTE
In following steps: ensure nut (8, figure 2) contacts packing (7) before contacting
fuel cell (6). To prevent deforming of packing (7) between nut (8) and fuel cell (6)
do not apply excessive torque to nut (8). Nut (8) is sufficiently tight when there is a
0.20 to 0.030 in gap between nut (8) and fuel cell (5).
8. Lubricate packings (7) with assembly fluid (C-024).
9. Working through top vent port of upper left cell (6), install the packing (7) and the nut (8) on the interconnect fitting
(3). Tighten the nut.
10. Secure the nut (8) to the interconnect fitting (3) with lockwire (C-405).
11. Working through the top vent cover of the upper right cell, install the packing (7) and the nut (8) on the interconnect
fitting (3). Tighten the nut.
12. Secure the nut (8) to the interconnect fitting (3) with lockwire (C-405).
13. Install upper left cell and upper right cell top cover assemblies (module 28-10-34 paragraph "3. Upper left cell and
upper right cell top cover assemblies - installation").
14. Install upper forward center cell top cover assembly (module 28-10-27 paragraph "3. Upper forward center cell top
cover assembly - installation").
15. Install upper forward center cell bottom cover (tall standpipe) assembly (module 28-10-25 paragraph "3. Upper
forward center cell bottom cover (tall standpipe) assembly - installation").
16. Install upper forward center cell bottom cover (short standpipe) assembly (module 28-10-23 paragraph "3. Upper
forward center cell bottom cover (short standpipe) assembly - installation").
17. Install large access panel on bulkhead between upper forward center cell cavity and upper aft center cell cavity.
18. Install upper aft center cell (module 28-10-28 paragraph "3. Upper aft center cell - installation").
23. Install access panels and doors.
28-10-23
Page 4 Rev. 2
E-AB412-PT6T-2
1
LOCKWIRE (C-405)
NOTE:
1 Lubricate with assembly fluid (C-024).

2. Packing
3. Fitting
4. Bolt
5. Bulkhead
6. Upper left cell
7. Packing
8. Nut
9. Pin
G6AB0381B
Figure 2. Upper forward center cell interconnect fittings (helicopters codes [C] [D])
28-10-23
Rev. 2 Page 5
E-AB412-PT6T-2
4. UPPER FORWARD CENTER CELL - CLEANING
MATERIALS REQUIRED
NUMBER NOMENCLATURE
C-339 ETHYL ALCOHOL
CAUTION

TEMPERATURE SHALL NOT EXCEED 160F (71C). DO NOT USE SOAPS
REACT WITH FUEL TO FORM A COMPOUND WHICH CAN CLOG FUEL
FILTERS.
DO NOT USE MEK OR SIMILAR SOLVENTS TO CLEAN FUEL CELLS.
1. Remove all fungus growth from cell by hand or with a soft scrub brush using warm or hot water.
2. If fungus is observed in cell cavity, wipe cell cavity with a clean cloth moistened with ethyl alcohol (C-339).
3. Inspect other fuel cells for presence of fungus growth. Remove and clean cells, if required.
5. UPPER FORWARD CENTER CELL - INSPECTION
CAUTION

BELOW 65F (18C).
2. Inspect threaded inserts for damage. Damage to threads which is visually detectable is not acceptable.
28-10-23
Page 6 Rev. 2
E-AB412-PT6T-2
28-10-24 FUEL STORAGE AND DISTRIBUTION SYSTEM (HELICOPTERS CODES [C][D]) - UPPER FORWARD CENTER CELL BOTTOM COVER (SHORT STANDPIPE) ASSEMBLY
28-10-24
[C][D]) - UPPER FORWARD CENTER CELL BOTTOM COVER (SHORT
STANDPIPE) ASSEMBLY
1. UPPER FORWARD CENTER CELL BOTTOM COVER (SHORT STANDPIPE)

ASSEMBLY - DESCRIPTION
A bottom cover (short standpipe) assembly (figure 1) is installed on left bottom interconnect port. Two fittings mounted on
bottom cover (short standpipe) assembly provide attachment points for interconnecting hoses from upper aft center cell and
upper left cell, and an interconnecting hose to input port of input/output fitting on aft side of left lower main cell.

ASSEMBLY - REMOVAL
MATERIALS REQUIRED
NUMBER NOMENCLATURE
3. Remove lower fuselage access doors below short standpipe assembly.
4. Remove the screws (5, figure 1) washers (6) and packing (7) from the fitting (8). Discard the packing.
5. Remove the screws (11), washers (10) and packing (7). Discard the packing.
6. Remove the screws (15), washers (16) and packing (18). Discard the packing.
7. Remove the screws (14), washers (13), fitting (8) and packing (3) and packing (3) Discard the packing.
8. Remove bolts (19), washers (20), retainers (21), cover (2), and packing (1). Discard packing.
10. Install protective caps and/or plugs (C-428) on hose assembly (4, 12 and 17).
28-10-24
Page 1
E-AB412-PT6T-2

ASSEMBLY - INSTALLATION
MATERIALS REQUIRED
NUMBER NOMENCLATURE
2. Remove protective caps and/or plugs from the hose assemblies (4, 12 and 17, figure 1) end fittings.
3. Apply assembly fluid (C-024) to packing (1)
4. Place packing (1) on cover (2).
5. Install bolts (19), washers (20) and retainers (21).
7. Install packing (3), screws (14), and washers (13).
8. Remove protective covers from hose assemblies (4 and 12).
9. Apply assembly fluid (C-024) to packings (7 and 9).
10. Install hose assemblies (4 and 12) and packings (7 and 9) with screws (5 and 11) and washers (6 and 10).
11. Remove protective cover from hose assembly (17).
13. Install hose assembly (17) and packing (18) with screws (15) and washers (16).
18. Install lower fuselage access door.
28-10-24
Page 2
E-AB412-PT6T-2
HELICOPTERS CODE D
HELICOPTERS CODE C
G6AB0395A
Figure 1. Upper forward center cell bottom cover (short standpipe) assembly (helicopters codes [C][D])
28-10-24
Page 3
E-AB412-PT6T-2
28-10-24
Page 4
E-AB412-PT6T-2
28-10-25 FUEL STORAGE AND DISTRIBUTION SYSTEM (HELICOPTERS CODES [C][D]) - UPPER FORWARD CENTER CELL BOTTOM COVER (TALL STANDPIPE) ASSEMBLY
28-10-25
[C][D]) - UPPER FORWARD CENTER CELL BOTTOM COVER (TALL
STANDPIPE) ASSEMBLY
1. UPPER FORWARD CENTER CELL BOTTOM COVER (TALL STANDPIPE)

ASSEMBLY - DESCRIPTION
A bottom cover (tall standpipe) assembly (figure 1) is installed on right bottom interconnect port. Two fittings mounted on
bottom cover (tall standpipe) assembly provide attachment points for interconnecting hoses from upper aft center cell bottom
fitting and upper right cell outlet fitting, and an interconnecting hose to input port of inlet/outlet fitting on aft side of right
lower main cell.

ASSEMBLY - REMOVAL
MATERIALS REQUIRED
NUMBER NOMENCLATURE
3. Remove lower fuselage access door below tall standpipe assembly.
4. Remove the screws (6 and 17, figure 1), washers (5 and 18), hose assemblies (7 and 16) and packings (8 and 15).
Discard packings.
5. Remove the screws (13), washers (14), fitting (4) and packing (3). Discard the packing.
6. Remove screws (12), washers (11), hose assembly (10) and packing (9). Discard the packing.
7. Remove the bolts (19), washers (20), retainers (21), cover (2) and packing (1). Discard packing.
8. Install protective cover over the hose assembly opening.
10. Install protective caps and/or plugs (C-428) on the hose assemblies (7, 10 and 16) open end fittings.
28-10-25
Page 1
E-AB412-PT6T-2

ASSEMBLY - INSTALLATION
MATERIALS REQUIRED
NUMBER NOMENCLATURE
2. Remove protective caps and/or plugs from hose assemblies (7, 10 and 16, figure 1). End fittings.
3. Apply assembly fluid (C-024) to packing (1). Place packing on cover (2)
4. Install cover (2) and packing (1) with bolts (19), washers (20) and retainers (21).
5. Apply assembly fluid (C-024) to packing (3). place packing on fitting (4).
6. Install fitting (4) and packing (3) with screws (13) and washers (14).
8. Install hose assemblies (7 and 16) and packings (8 and 15) with screws (6 and 17) and washers (5 and 18).
10. Install hose assembly (10) with packing (9), screws (12) and washers (11).
15. Install lower fuselage access door.
28-10-25
Page 2
E-AB412-PT6T-2
HELICOPTERS CODE C
HELICOPTERS CODE D
G6AB0396A
Figure 1. Upper forward center cell bottom cover (tall standpipe) assembly (helicopters codes [C][D])
28-10-25
Page 3
E-AB412-PT6T-2
28-10-25
Page 4
E-AB412-PT6T-2
28-10-26 FUEL STORAGE AND DISTRIBUTION SYSTEM (HELICOPTERS CODES [C][D]) - UPPER FORWARD CENTER CELL INTERCONNECT FITTINGS
28-10-26
[C][D]) - UPPER FORWARD CENTER CELL INTERCONNECT FITTINGS
1. UPPER FORWARD CENTER CELL INTERCONNECT FITTINGS - DESCRIPTION
NOTE
Maintenance procedures are the same for the three upper forward center cell
interconnect fittings.
2. UPPER FORWARD CENTER CELL INTERCONNECT FITTINGS - REMOVAL
1. Remove upper right cell top cover assembly (module 28-10-34 paragraph "2. Upper left cell and upper right cell top
cover assemblies - removal").
2. Remove upper left cell top cover assembly (module 28-10-34 paragraph "2. Upper left cell and upper right cell top
cover assemblies - removal").
3. Remove upper aft center cell top cover assembly (module 28-10-31 paragraph "2. Upper aft center cell top cover
assembly - removal").
4. Remove lockwire, nut (8, figure 1) and packing (7). Discard packing.
5. Partially collapse upper forward center cell (1) to gain access to fitting (3).
6. Remove bolts (4), fitting (3), and packing (2). Discard packing.
7. Install protective covers over cell openings.
28-10-26
Rev. 2 Page 1
E-AB412-PT6T-2
3. UPPER FORWARD CENTER CELL INTERCONNECT FITTINGS - INSTALLATION
MATERIALS REQUIRED
NUMBER NOMENCLATURE
C-383 CEMENT
C-405 LOCKWIRE
1. Remove protective covers from cell openings.
2. Apply assembly fluid (C-024) to packing (2, figure 1). Place packing (2) between upper forward center cell (1) and
fitting (3).
3. Install bolts (4). Tighten bolts.
4. Install fitting (3) through bulkhead (5) and upper cell (6).
5. Apply assembly fluid (C-024) to packing (7). Place packing (7) on fitting (3).
NOTE
In following step: Ensure nut (8) contacts packing (7) before contacting fuel cell (6).
To prevent deforming of packing (7) between nut (8) and fuel cell (6) do not apply
excessive torque to nut (8). Nut (8) is sufficiently tight when there is a 0.20 to
0.030 in gap between nut (8) and fuel cell (6).
6. Install nut (8) and secure with lockwire (C-405).
7. Install upper right cell top cover assembly (module 28-10-34 paragraph "3. Upper left cell and upper right cell top
cover assemblies - installation").
8. Install upper left cell top cover assembly (module 28-10-34 paragraph "3. Upper left cell and upper right cell top cover
9. Install upper aft cell top cover assembly (module 28-10-31 paragraph "3. Upper aft center cell top cover assembly -
installation").
28-10-26
Page 2 Rev. 2
E-AB412-PT6T-2
1
LOCKWIRE (C-405)
NOTE:
1 Lubricate with assembly fluid (C-024).

2. Packing
3. Fitting
4. Bolt
5. Bulkhead
6. Upper left cell
7. Packing
8. Nut
9. Pin
G6AB0381B
Figure 1. Upper forward center cell interconnect fittings (helicopters codes [C] [D])
28-10-26
Rev. 2 Page 3
E-AB412-PT6T-2
28-10-26
Page 4 Rev. 2
E-AB412-PT6T-2
28-10-27 FUEL STORAGE AND DISTRIBUTION SYSTEM (HELICOPTERS CODES [C][D]) - UPPER FORWARD CENTER CELL TOP COVER ASSEMBLY
28-10-27
[C][D]) - UPPER FORWARD CENTER CELL TOP COVER ASSEMBLY
1. UPPER FORWARD CENTER CELL TOP COVER ASSEMBLY - DESCRIPTION
An upper forward center cell top cover assembly is installed over top port of upper forward center cell. Five fittings are
mounted on top cover assembly which provide attachment points for connection of aft vent system hoses.
2. UPPER FORWARD CENTER CELL TOP COVER ASSEMBLY - REMOVAL
MATERIALS REQUIRED
NUMBER NOMENCLATURE
3. Remove access door above upper forward center cell top cover assembly.
4. Remove screws (3, figure 1) and washers (2).
5. Remove bolts (4) and washers (5), securing support assembly (1) to cover assembly (20).
6. Disconnect hose assemblies (7, 8, 11, 21, and 24).
7. Remove remaining bolts (4) and washers (5). Lift cover assembly (20) and remove packing (19). Discard packing.
8. To remove elbow (6), remove nut (14), washer (13), and packing (12). Discard packing.
9. To remove elbows (9, 10, 22, and 23), remove nuts (16), washers (17), and packing (18). Discard packing.
10. Install protective cover over cell opening and cap or cover hose assembly openings.
11. Install protective caps and/or plugs (C-428) on hose assemblies (7, 8,11, 21 and23) open end fittings.
28-10-27
Page 1
E-AB412-PT6T-2
3. UPPER FORWARD CENTER CELL TOP COVER ASSEMBLY - INSTALLATION
MATERIALS REQUIRED
NUMBER NOMENCLATURE
1. Remove protective cover and caps from cell opening and hose assemblies.
2. Lubricate packing (18, figure 1) with assembly fluid (C-024).
3. Install elbows (9, 10, 22 and 23) through cover assembly (20).
4. Install packings (18) on elbows (9, 10, 22 and 23) with washers (17) and nuts (16).
5. Lubricate packing (12) with assembly fluid (C-024).
6. Install elbow (6) through cover assembly (20).
7. Install packing (12) on elbow (6) with washer (13) and nut (14).
8. Install support assembly (1) on cover assembly (20) with bolts (4) and washers (5).
9. Apply assembly fluid (C-024) to packing (19). Place packing in position on upper forward cell (15).
10. Install remaining screws (4) and washers (5).
11. Connect hose assemblies (7, 8, 11, 21 and 24). Tighten the hose assemblies end fittings.
28-10-27
Page 2
E-AB412-PT6T-2
G6AB0397A
Figure 1. Upper forward center cell top cover assembly (helicopters codes [C][D])
28-10-27
Page 3
E-AB412-PT6T-2
28-10-27
Page 4
E-AB412-PT6T-2
28-10-28 FUEL STORAGE AND DISTRIBUTION SYSTEM (HELICOPTERS CODES [C][D]) - UPPER AFT CENTER CELL
28-10-28
[C][D]) - UPPER AFT CENTER CELL
1. UPPER AFT CENTER CELL - DESCRIPTION
The upper aft center cell (figure 1) is located above W.L. 22, between the two main longitudinal beams (at left B.L. 14, and
right B.L. 14), and between F.S. 178 and 200. The upper aft center cell has a vent port on top side, and interconnect ports on
bottom, left, right, and forward sides.
2. UPPER AFT CENTER CELL - REMOVAL
MATERIALS REQUIRED
NUMBER NOMENCLATURE
CAUTION

BELOW 65F (18C).
3. Remove large access door on underside of helicopter below upper aft center cell.
4. Remove access panel in engine compartment floor above cell.
5. Remove bottom cover and fitting (module 28-10-29 paragraph "2. Upper aft center cell bottom cover assembly and
fitting - removal").
6. Remove fitting (5, figure 1) (module 28-10-30 paragraph "3. Upper aft center cell bottom fitting - installation").
7. Remove supports (2), and cover assembly (6) (module 28-10-31 paragraph "2. Upper aft center cell top cover assembly
- removal").
8. Working through top vent port of cell, disconnect interconnect fitting (4) (module 28-10-26 paragraph "2. Upper
forward center cell interconnect fittings - removal").
9. Partially collapse cell. Remove cell through large access opening in bottom of cell cavity and bottom of helicopter.
10. Install protective cover over cell openings and cap or plug open fuel lines.
28-10-28
Rev. 2 Page 1
E-AB412-PT6T-2
CAUTION
STORE CELL IN A HEATED AREA IF AMBIENT TEMPERATURE IS BELOW

66°F (18°C).
11. Install protective caps and/or plugs (C-428) on hose assemblies open end fittings.
3. UPPER AFT CENTER CELL - INSTALLATION
MATERIALS REQUIRED
NUMBER NOMENCLATURE
C-408 TALCUM POWDER
CAUTION

BELOW 65F (18C).
4. Insert upper aft center cell (1, figure 1) into cell cavity through large access opening under cell cavity on underside of
helicopter. Align cell ports with matching ports and fuselage openings. Align interconnect port to slip over end of
upper forward center cell interconnect fitting (4).
5. Working through top vent port, connect interconnect fitting (4) (module 28-10-26 paragraph "3. Upper forward center
cell interconnect fittings - installation").
6. Install top cover assembly (6, figure 1) and support assembly (2) (module 28-10-27 paragraph "3. Upper forward
center cell top cover assembly - installation").
7. Install bottom cover and fitting (3) (module 28-10-29 paragraph "3. Upper aft center cell bottom cover assembly and
fitting - installation").
8. Install fitting (5) (module 28-10-30 module Upper aft center cell bottom fitting - installation).
9. Perform fuel system pressure test (module 28-40-06 FUEL STORAGE AND DISTRIBUTION SYSTEM
(HELICOPTERS CODES [C][D]) - PRESSURE TESTING).
13. Install access panel and door.
28-10-28
Page 2 Rev. 2
E-AB412-PT6T-2
4. UPPER AFT CENTER CELL - INSPECTION
CAUTION

BELOW 65F (18C).
2. Inspect threaded inserts for damage. Damage to threads that is visually detectable is not acceptable.
5. UPPER AFT CENTER CELL - CLEANING
MATERIALS REQUIRED
NUMBER NOMENCLATURE
COMMERCIAL BRUSH
COMMERCIAL CLOTH
C-339 METHYL ALCOHOL
CAUTION

TEMPERATURE SHALL NOT EXCEED 160°F (71°C). DO NOT USE SOAPS
REACT WITH FUEL TO FORM A COMPOUND WHICH CAN TO PLUG FUEL
FILTERS. DO NOT USE METHYL-ETHYL-KETONE OR SIMILAR
SOLVENTS FOR CLEANING FUEL CELLS.
1. Remove all fungus growth from cell by hand or with a soft brush using warm water.
2. If fungus is observed in cell cavity, wipe the cell with a clean cloth moinstened with alcohol (C-339).
28-10-28
Rev. 2 Page 3
E-AB412-PT6T-2
1. Upper aft center

2. Support assembly
3. Bottom cover and fitting
5. Bottom fitting
G6AB0398B
Figure 1. Upper aft center cell (helicopters codes [C][D])
28-10-28
Page 4 Rev. 2
E-AB412-PT6T-2
28-10-29 FUEL STORAGE AND DISTRIBUTION SYSTEM (HELICOPTERS CODES [C][D]) - UPPER AFT CENTER CELL BOTTOM COVER ASSEMBLY AND FITTING
28-10-29
[C][D]) - UPPER AFT CENTER CELL BOTTOM COVER ASSEMBLY AND
FITTING
1. UPPER AFT CENTER CELL BOTTOM COVER ASSEMBLY AND FITTING -

DESCRIPTION
A bottom cover and fitting assembly is mounted on the larger bottom port of upper aft center cell. The fitting provides an
attachment point for outlet hose that connects upper aft center cell to left outlet fitting on bottom of upper forward center cell.

REMOVAL
3. Remove access door on underside of helicopter below aft center cell.
5. Remove screws (9), washers (8), and retainers (7). Remove fitting (6) and packing (5). Discard packing.
6. Remove screws (4), and washers (3). Remove cover (2) and gasket (1). Discard gasket.
7. Install protective cover over cell opening and cap or plug open fuel lines.
28-10-29
Page 1
E-AB412-PT6T-2

INSTALLATION
MATERIALS REQUIRED
NUMBER NOMENCLATURE
2. Apply assembly fluid (C-024) to gasket (1, figure 1).
3. Place gasket (1) on cover (2). Place cover (2) and gasket (1) on flat surface of larger outlet port on bottom of aft center
cell.
5. Apply assembly fluid (C-024) to packing (5). Place packing (5) on fitting (6).
6. Position fitting (6) on cover (2). Install screws (9), washers (8), and retainers (7). Tighten screws.
7. Connect hose assemblies (10).
28-10-29
Page 2
E-AB412-PT6T-2
G6AB0399A
Figure 1. Upper aft center cell bottom cover and fitting (helicopters codes [C][D])
28-10-29
Page 3
E-AB412-PT6T-2
28-10-29
Page 4
E-AB412-PT6T-2
28-10-30 FUEL STORAGE AND DISTRIBUTION SYSTEM (HELICOPTERS CODES [C][D]) - UPPER AFT CENTER CELL BOTTOM FITTING
28-10-30
[C][D]) - UPPER AFT CENTER CELL BOTTOM FITTING
1. UPPER AFT CENTER CELL BOTTOM FITTING - DESCRIPTION
A bottom fitting is installed on the smaller bottom port of upper aft center cell. This fitting provides an attachment point for
hose connecting upper aft center cell to right outlet fitting on bottom of upper forward center cell.
2. UPPER AFT CENTER CELL BOTTOM FITTING - REMOVAL
3. Remove access door on underside of helicopter below aft center cell.
5. Remove screws (4), washers (5), and retainers (3). Remove fitting (2) and packing (1). Discard packing.
3. UPPER AFT CENTER CELL BOTTOM FITTING - INSTALLATION
MATERIALS REQUIRED
NUMBER NOMENCLATURE
2. Apply assembly fluid (C-024) to packing (1, figure 1). Install packing (1) in groove of fitting (2).
3. Position fitting (2) and packing (1) over outlet port on bottom of cell and install screws (4), washers (5), and retainers
(3). Tighten screws.
4. Connect hose assembly (6).
28-10-30
Page 1
E-AB412-PT6T-2
9. Install access door.
G6AB0400A
Figure 1. Upper aft center cell bottom fitting (helicopters codes [C][D])
28-10-30
Page 2
E-AB412-PT6T-2
28-10-31 FUEL STORAGE AND DISTRIBUTION SYSTEM (HELICOPTERS CODES [C][D]) - UPPER AFT CENTER CELL TOP COVER ASSEMBLY
28-10-31
[C][D]) - UPPER AFT CENTER CELL TOP COVER ASSEMBLY
1. UPPER AFT CENTER CELL TOP COVER ASSEMBLY - DESCRIPTION
An upper aft center cell top cover assembly (figure 1) is mounted over the top port of upper aft center cell. Five fittings are
mounted on top cover assembly which provide attachment points for connection of aft vent system hoses.
2. UPPER AFT CENTER CELL TOP COVER ASSEMBLY - REMOVAL
3. Remove access panel in engine compartment floor above aft center cell.
4. Remove bolts (3, figure 1) and washers (2) holding supports (9 and 28) to helicopter structure.
5. Remove bolts (4 and 7) and washers (5 and 8) to remove the supports (9 and 28) from the cover (25).
6. Remove hose assembly (1) from elbow (6).
9. Remove hose assembly (13) from union (12).
11. Remove the remaining bolts (4 and 7) and washers (5 and 8).
12. Remove cover assembly (25) and packing (17) from cell. Discard packing.
13. Install protective cover over cell opening and cap or plug all open fuel lines.
14. Remove elbows (6 and 10) from the cover assembly (25) by removing the nut (16), washer (15) and packing (14).
Discard packing.
NOTE
Packing, washer and nut for elbows (6 and 10) are shown only once on illustration
for clarity.
15. Remove the elbow (24) from the cover assembly (25) by removing nut (18), washer (19) and packing (20). Discard
packing.
28-10-31
Page 1
E-AB412-PT6T-2
NOTE
Packing, washer, and nut for unions (12 and 27) are shown only once on illustration
for clarity.
16. Remove the unions (12 and 27) from the cover assembly (25) by removing the nuts (21), washers (22) and packings
(26).
3. UPPER AFT CENTER CELL TOP COVER ASSEMBLY - INSTALLATION
MATERIALS REQUIRED
NUMBER NOMENCLATURE
1. Remove the protective covers from the cell opening.
2. Remove the protective caps and/or plugs from the fuel lines.
3. To install the unions (12 and 27, figure 1), do the following:
a. Apply assembly fluid (C-024) to the packings (26).
b. Install the packings (26) on the unions (12 and 27).
c. Put the unions (12 and 27) in position on the cover assembly (25) and install the washers (22) and the nuts (21).
Tighten the nuts.
4. To install the elbow (24), do the following:
a. Put the elbow (24) in position on the cover assembly (25).
b. Apply assembly fluid (C-024) to the packing (20) and install the packing on the elbow (24).
NOTE
Make sure that the elbow (24) is properly aligned with the hose assembly (23) before
tightening the nut (18).
c. Install the washer (19) and the nut (18) on the elbow (24). Tighten the nut.
5. To install the elbows (6 and 10), do the following:
a. Put the elbows (6 and 10) in position on the cover assembly (25).
b. Apply assembly fluid (C-024) to the packings (14) and install the packings on the elbows (6 and 10).
NOTE
tightening the nut (16).
tightening the nut (16)
c. Install the washers (15) and nuts (16) on the elbows (6 and 10). Tighten the nuts.
28-10-31
Page 2
E-AB412-PT6T-2
6. Apply assembly fluid (C-024) to the packing (17).
7. Put the top cover assembly (25) and packing (17) in position on the upper aft center cell.
NOTE
Make sure that the mounting holes for bolts (3) in the support (9 and 28) are lined up
with the mounting holes in the helicopter structure before tightening the bolts (4 and
7).
8. Install the support (9) with the bolt (7) and washer (8). Tighten the bolt.
9. Install the support (28) with the bolt (4) and washers (5). Tighten the bolt.
10. Install the remaining bolts (7) and washers (8) on the cover assembly (25). Tighten the bolts.
11. Connect the hose assembly (11) to the elbow (10). Tighten the end fitting.
12. Connect the hose assembly (13) to the (12). Tighten the end fitting.
14. Connect the hose assembly (29) to the union (27). Tighten the end fitting.
16. Install the bolts (3) and washers (2) through the helicopter structure and the support (9 and 28). Tighten the bolts.
28-10-31
Page 3
E-AB412-PT6T-2
G6AB0401A
Figure 1. Upper aft center cell top cover assembly (helicopters codes [C][D])
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Page 4
E-AB412-PT6T-2
28-10-32 FUEL STORAGE AND DISTRIBUTION SYSTEM (HELICOPTERS CODES [C][D]) - UPPER LEFT CELL AND UPPER RIGHT CELL
28-10-32
[C][D]) - UPPER LEFT CELL AND UPPER RIGHT CELL
1. UPPER LEFT CELL AND UPPER RIGHT CELL - DESCRIPTION
The upper left and upper right cells are located above W.L. 22, outboard of the two main longitudinal beams (at left B.L.
14 and right B.L. 14), and between F.S. 166 and 178. The upper left and the upper right cells have vent ports on the top
side and interconnect ports on the bottom and inboard sides. The upper right cell has a port on outboard side for filler cap
and adapter assembly.
NOTE
Maintenance procedures for upper left cell and upper right cell are the same, except
filler cap and adapter assembly procedures are applicable for upper right cell only.
2. UPPER LEFT CELL AND UPPER RIGHT CELL - REMOVAL
CAUTION

BELOW 65°F (18°C).
3. Remove access door on underside of helicopter below cell (1, figure 1).
4. Remove engine compartment floor panel above cell (1).
5. Remove outlet fitting (4) (module 28-10-33 paragraph "2. Upper left cell and upper right cell outlet fittings - removal").
6. Remove support assemblies (2) and top cover assembly (6) (module 28-10-34 paragraph "2. Upper left cell and upper
right cell top cover assemblies - removal").
7. If removing upper right cell (1), remove filler cap and adapter assembly (module 28-20-35 paragraph "2. Filler cap and
adapter assembly - removal" or module 28-20-36 paragraph "2. Improved filler cap and adapter assembly - removal").
8. Working through top vent port of cell, disconnect interconnect fitting (5) (module 28-10-26 paragraph "2. Upper
forward center cell interconnect fittings - removal").
9. Partially collapse cell (1). Lift cell from cell cavity.
10. Install protective cover over cell openings and caps and/or plugs (C-428) on open fuel lines.
28-10-32
Rev. 2 Page 1
E-AB412-PT6T-2
1. Upper left cell (or upper right cell)

2. Support assemblies
3. Fuel quantity probe
4. Outlet fitting
5. Upper forward center cell interconnect fitting
G6AB0402B
Figure 1. Upper left cell and upper right cell (helicopters codes [C][D])
28-10-32
Page 2 Rev. 2
E-AB412-PT6T-2
3. UPPER LEFT CELL AND UPPER RIGHT CELL - INSTALLATION
MATERIALS REQUIRED
NUMBER NOMENCLATURE
C-408 TALCUM POWDER
CAUTION

BELOW 65°F (18°C).
2. Inspect cell cavity for presence of any foreign objects and/or rough interior surfaces. Remove foreign objects from cell
and repair rough surfaces prior to cell installation.
3. Apply talcum powder (C-408) to all interior surfaces of cell cavity.
4. Insert cell (1, figure 1) into cell cavity through opening above cell in engine compartment floor. Use care to avoid
damage to cell. Align cell ports with matching ports and fuselage openings. Align interconnect port to slip over end of
upper forward center cell interconnect fitting (5).
5. Working through vent port, connect the upper forward center cell interconnect fitting (5) (module 28-10-26 paragraph
"3. Upper forward center cell interconnect fittings - installation").
6. If installing the upper right cell, install the filler cap and adapter assembly (module 28-20-35 paragraph "3. Filler cap
and adapter assembly - installation" or module 28-20-36 paragraph "3. Improved filler cap and adapter assembly -
installation").
7. Install top cover assembly (module 28-10-31 paragraph "3. Upper aft center cell top cover assembly - installation").
8. Install outlet fitting (5, figure 2) (module 28-10-33 paragraph "3. Upper left cell and upper right cell outlet fittings -
installation").
11. Perform operational check of fuel quantity indicating system (Chapter 96).
12. Check for leaks.
13. Install access panels and doors.
28-10-32
Rev. 2 Page 3
E-AB412-PT6T-2
1. Hose 11. Bolt

2. Union 12. Thin aluminum washer
3. Packing 13. Bolt
4. Packing 14. Hose
5. Outlet fitting 15. Packing
6. Packing 16. Thin aluminum washer
7. Cover 17. Bolt
8. Thin aluminum washer 18. Cap
9. Bolt 19. Adapter
10. Thin aluminum washer 20. Packing
G6AB0403B
Figure 2. Upper left cell and upper right cell outlet fittings (helicopters codes [C][D])
28-10-32
Page 4 Rev. 2
E-AB412-PT6T-2
4. UPPER LEFT CELL AND UPPER RIGHT CELL - CLEANING
MATERIALS REQUIRED
NUMBER NOMENCLATURE
C-339 ETHYL ALCOHOL
CAUTION

TEMPERATURE SHALL NO EXCEED 160°F (71°C). DO NOT USE SOAPS OR
STRONG DETERGENTS WHEN CLEANING FUEL CELL. CERTAIN STRONG
DETERGENTS ARE HARMFUL TO FUEL CELL. SOAPS CAN REACT WITH
FUEL TO FORM A COMPOUND WHICH CAN PLUG FUEL FILTERS.
DO NOT USE MEK OR SIMILAR SOLVENTS FOR CLEANING FUEL CELLS.
1. Remove all fungus growth from cell by hand or with a soft scrub brush using warm or hot water.
2. If fungus is observed in cell cavity, wipe the cell cavity with a clean cloth moistened with ethyl alcohol (C-339).
5. UPPER LEFT CELL AND UPPER RIGHT CELL - INSPECTION
CAUTION

BELOW 65°F (18°C).
2. Inspect threaded inserts for damage.
3. Damage to threads that is visually detectable is not acceptable.
28-10-32
Rev. 2 Page 5
E-AB412-PT6T-2
28-10-32
Page 6 Rev. 2
E-AB412-PT6T-2
28-10-3 FUEL STORAGE AND DISTRIBUTION SYSTEM (HELICOPTERS CODES [C][D]) - UPPER LEFT CELL AND UPPER RIGHT CELL OUTLET FITTINGS
28-10-33
[C][D]) - UPPER LEFT CELL AND UPPER RIGHT CELL OUTLET FITTINGS
1. UPPER LEFT CELL AND UPPER RIGHT CELL OUTLET FITTINGS - DESCRIPTION
An outlet fitting (figure 1) is installed on bottom port of upper left cell and upper right cell. These fittings provide hose
attachment points for transfer of fuel from upper left cell and upper right cell to lower main cell on same side of helicopter.
NOTE
Maintenance procedures for upper left cell outlet fitting and upper right cell outlet
fittings are the same.
2. UPPER LEFT CELL AND UPPER RIGHT CELL OUTLET FITTINGS - REMOVAL
3. Remove lower access doors.
4. Remove bolts (13, figure 1), washers (12), hose (14), and packing (15). Discard packing.
7. Remove bolts (17), washers (16), adapter (19), and packing (20). Discard packing.
8. Remove bolts (9), washers (8), cover (7), and packing (6). Discard packing.
9. Remove bolts (11), washers (10), fitting (5), and packing (4). Discard packing.
28-10-33
Page 1
E-AB412-PT6T-2
3. UPPER LEFT CELL AND UPPER RIGHT CELL OUTLET FITTINGS - INSTALLATION
MATERIALS REQUIRED
NUMBER NOMENCLATURE
1. Remove protective cover and caps or plugs.
2. Apply assembly fluid (C-024) to packings (3, 4, 6, 15, and 20, figure 1).
3. Position packing (4) and fitting (5) on bottom outlet port of cell.
4. Install bolts (11) and thin aluminum washers (10). Tighten the bolts.
5. Install cover (7), packing (6), washers (8), and bolts (9).
6. Install union (2) and packing (3).
8. Install cap (18), adapter (19), packing (20), washers (16), and bolts (17).
9. Install packing (15), hose (14), washers (12), and bolts (13).
13. Check for leaks.
14. Install access panel in engine compartment floor.
28-10-33
Page 2
E-AB412-PT6T-2
G6AB0403A
Figure 1. Upper left cell and upper right cell outlet fittings (helicopters codes [C][D])
28-10-33
Page 3
E-AB412-PT6T-2
28-10-33
Page 4
E-AB412-PT6T-2
28-10-34 FUEL STORAGE AND DISTRIBUTION SYSTEM (HELICOPTERS CODES [C][D]) - UPPER LEFT CELL AND UPPER RIGHT CELL TOP COVER ASSEMBLIES
28-10-34
[C][D]) - UPPER LEFT CELL AND UPPER RIGHT CELL TOP COVER
ASSEMBLIES
1. UPPER LEFT CELL AND UPPER RIGHT CELL TOP COVER ASSEMBLIES -
DESCRIPTION
A top cover assembly is installed on top port of each upper left and upper right cells. Each top cover assembly includes two
fittings which provide attachment points for vent hoses.
NOTE
Maintenance procedures for upper left cell and upper right cell top cover assemblies
are the same.
REMOVAL
3. Remove access panel in engine compartment floor above upper left and upper right cells.
4. Disconnect electrical connector from fuel quantity probe (29, figure 1). Cap electrical connector.
5. Remove fuel quantity probe (29) (module 28-40-08 paragraph "5-2. Upper left and upper right cell fuel quantity probes
- removal").
8. Remove screws (3 and 8) and washers (2 and 7).
9. Remove bolts (4 and 10) and washers (5 and 9) and remove support assemblies (1 and 6).
10. Remove bolts (16) and washers (17). Remove top cover assembly (18) and packing (19). Discard packing.
11. Remove nut (23) and washer (21). Remove elbow (12) and packing (13) from top cover assembly (18). Discard
packing.
12. Remove nut (24) and washer (25). Remove union (27) and packing (26). Discard packing.
13. Remove nut (22) and washer (20). Remove plug (14) and packing (15). Discard packing.
14. Install protective cover over cell opening and caps and/or plugs on all open fuel lines.
28-10-34
Page 1
E-AB412-PT6T-2
INSTALLATION
MATERIALS REQUIRED
NUMBER NOMENCLATURE
1. Remove protective covers and caps or plugs.
2. Apply assembly fluid (C-024) to packings (13, 15, 19, and 26, figure 1).
3. Place packing (15) on plug (14) and install in mounting hole of top cover assembly (18).
4. Install washer (20) and nut (22) on plug (14). Tighten nut.
5. Place packing (26) on union (27) and install in top cover assembly (18).
6. Install washer (25) and nut (24) on union (27). Tighten nut.
7. Place packing (13) on elbow (12) and install in top cover assembly (18).
8. Install washer (21) and nut (23) on elbow (23). Tighten nut.
9. Install packing (19) in groove around cell vent opening.
10. Place top cover assembly (18) on cell vent opening. Install bolts (16) and washers (17). Tighten bolts.
11. Place support assembly (6) on top cover assembly (18). Install bolts (10) and washers (9). Tighten bolts.
12. Place support assembly (1) on top cover assembly (18). Install bolts (4) and washers (5). Tighten bolts.
15. Connect hose assembly (11) to elbow (12). Tighten the end fitting of hose assembly.
16. Connect hose assembly (28) to union (27). Tighten the end fitting of hose assembly.
17. Install fuel quantity probe (29) (module 28-40-08 paragraph "5-3. Upper left and upper right cell fuel quantity probes
- installation"). Connect fuel quantity indicating system connector.
20. Perform fuel quantity system operational check (Chapter 96).
22. Install access panel in engine compartment floor above cell area.
28-10-34
Page 2
E-AB412-PT6T-2
G6AB0404A
Figure 1. Upper left cell and upper right cell top cover assembly (helicopters codes [C][D])
28-10-34
Page 3
E-AB412-PT6T-2
28-10-34
Page 4
E-AB412-PT6T-2
28-20-01 FUEL STORAGE AND DISTRIBUTION SYSTEM (HELICOPTERS CODES [A][B]) - FORWARD INTERCONNECT VALVE
28-20-01
[A][B]) - FORWARD INTERCONNECT VALVE
1. FORWARD INTERCONNECT VALVE - DESCRIPTION
The electrically controlled forward interconnect valve (31, figure 1) is installed in an interconnect line between the forward
compartments of the forward fuel cells. This valve is normally closed, but can be opened to permit crossflow between cells
when fuel level becomes low.
2. FORWARD INTERCONNECT VALVE - REMOVAL
3. Remove cabin floor panel.
4. Disconnect electrical connector (1, figure 2).
5. Remove bolts (6 and 9).
6. Separate forward interconnect valve (2) from support (5). Remove flanges (7 and 16), packings (10, 11, and 17), and
fitting (12).
Discard packings.
7. Cap or plug openings.
3. FORWARD INTERCONNECT VALVE - INSTALLATION
MATERIALS REQUIRED
NUMBER NOMENCLATURE
1. Apply assembly fluid (C-024) to new packings (10, 11, and 17, figure 2).
2. Position packings (10 and 11) in forward interconnect valve (2) and position packing (17) in groove of fitting (12).
3. Fitting (12) has a plug installed in one side. Locate plug on bottom when installing fitting.
4. Place fitting (12) on forward interconnect valve (2) with packing (17) outboard.
5. Remove protective caps or plugs from hoses (8 and 15).
6. Place flanges (7 and 16) on hoses (8 and 15) with flange slots facing aft. Align mounting holes in parts and install two
bolts (9), washers (13), and nuts (14). Do not tighten nuts at this time.
28-20-01
Page 1
E-AB412-PT6T-2
7. Position forward interconnect valve (2) in support (5). Install two bolts (6), washers (4), and nuts (3). Tighten nuts (3
and 14).
9. Install cabin floor panel.
12. Perform operational check of INTCON switch and forward and aft interconnect valves (Chapter 96).
28-20-01
Page 2
E-AB412-PT6T-2
G6AB0322A
28-20-01
Page 3
E-AB412-PT6T-2
G6AB0323A
28-20-01
Page 4
E-AB412-PT6T-2
G6AB0325A
Figure 2. Forward interconnect valve (helicopters codes [A][B])
28-20-01
Page 5
E-AB412-PT6T-2
28-20-01
Page 6
E-AB412-PT6T-2
28-20-02 FUEL STORAGE AND DISTRIBUTION SYSTEM (HELICOPTERS CODES [A][B]) - AFT INTERCONNECT VALVE
28-20-02
[A][B]) - AFT INTERCONNECT VALVE
1. AFT INTERCONNECT VALVE - DESCRIPTION
The electrically controlled aft interconnect valve (24, figure 1) is installed in an interconnect line between aft compartments
of aft fuel cells. This valve is normally closed, but may be opened to permit crossflow between cells.
2. AFT INTERCONNECT VALVE - REMOVAL
3. Remove access door from underside of fuselage.
5. Disconnect hoses (5 and 11).
6. Remove bolts (12).
7. Remove aft interconnect valve (8), connectors (6 and 10), and packings (7 and 9). Discard packings.
3. AFT INTERCONNECT VALVE - INSTALLATION
MATERIALS REQUIRED
NUMBER NOMENCLATURE
2. Place packings (7 and 9) and connectors (6 and 10) on valve (8).
3. Place aft interconnect valve (8) and connectors (6 and 10) on bracket (2). Install bolts (12), washers (3) and nuts (4).
4. Connect hoses (5 and 11).
6. Perform fuel system pressure test (Refer to module 28-40-01 "FUEL STORAGE AND DISTRIBUTION SYSTEM
28-20-02
Page 1
E-AB412-PT6T-2
8. Perform operational check of interconnect valve (8).
9. Check area for fuel leaks.
28-20-02
Page 2
E-AB412-PT6T-2
G6AB0322A
28-20-02
Page 3
E-AB412-PT6T-2
G6AB0323A
28-20-02
Page 4
E-AB412-PT6T-2
G6AB0326A
Figure 2. Aft interconnect valve (helicopters codes [A][B])
28-20-02
Page 5
E-AB412-PT6T-2
28-20-02
Page 6
E-AB412-PT6T-2
28-20-03 FUEL STORAGE AND DISTRIBUTION SYSTEM (HELICOPTERS CODES [A][B]) - SUMP ASSEMBLIES
28-20-03
[A][B]) - SUMP ASSEMBLIES
1. SUMP ASSEMBLIES - DESCRIPTION
A sump assembly is mounted in openings on underside of aft compartment of each forward cell (16 and 28, figure 1).
Removal of sump assembly permits access for maintenance of boost pump, flow switch, defueling valve, sump drain valve,
low fuel level warning switch, and sump interconnect valve. The boost pump and sump drain valve may be removed without
removing sump assembly.
NOTE
Maintenance procedures are the same for both sump assemblies.
2. SUMP ASSEMBLIES - REMOVAL
3. Disconnect electrical leads at terminal block (9, figure 2) and fuel quantity probe connectors (8) on bottom of sump
assembly (2).
5. Separate hose (14) from fitting (10). Remove and discard packing (13). Remove bonding strap from sump assembly
(2).
6. Remove bolts (4) and retainers (6).
7. Lower sump assembly (2) enough to reach through cell sump opening.
10. Disconnect wires from fuel quantity probe connectors (8).
11. Remove packing (1) from cell. Discard packing.
12. Cover fuel cell sump opening.
28-20-03
Page 1
E-AB412-PT6T-2
G6AB0322A
28-20-03
Page 2
E-AB412-PT6T-2
G6AB0323A
28-20-03
Page 3
E-AB412-PT6T-2
G6AB0800A
Figure 2. Sump assembly (helicopters codes [A][B])
28-20-03
Page 4
E-AB412-PT6T-2
3. SUMP ASSEMBLIES - INSTALLATION
MATERIALS REQUIRED
NUMBER NOMENCLATURE
1. Remove protective covering from fuel cell sump opening.
2. Coat packing (1, figure 2) with assembly fluid (C-024) and place in groove around fuel cell sump opening.
3. Hold sump assembly (2) slightly below fuel cell sump opening.
4. Connect hose (15) to flow switch (17).
5. Connect hose (3) to fuel outlet fitting (7).
6. Connect wires to fuel quantity probe connectors (8).
NOTE
Retainers (6) are installed on bolts (4) at each side and each end of sump assembly
(2).
7. Install bolts (4), washers (5), and retainers (6). Torque bolts 50 to 100 in.lbs. (5,65 to 11,30 Nm).
8. Connect hose (14) to fitting (10) with packing (13), screws (11), and washers (12).
9. Connect electrical leads at terminal block (9) and fuel quantity probe connectors (8) on bottom of sump assembly (2).
11. Perform operational check of the fuel quantity indicating system before servicing the system (Chapters 95 and 96).
4. SUMP ASSEMBLIES - INSPECTION
1. Inspect area where sump assembly mates with cell for damage and cleanliness. Inspect packing groove.
2. Inspect components for security of mounting.
3. Inspect hoses, union, and fittings for contamination and thread damage. Contamination shall be removed. Thread
damage that can be detected visually is not acceptable, part shall be replaced.
4. Inspect electrical leads and connectors for condition.
5. Replace unserviceable components.
28-20-03
Page 5
E-AB412-PT6T-2
28-20-03
Page 6
E-AB412-PT6T-2
28-20-04 FUEL STORAGE AND DISTRIBUTION (HELICOPTERS CODES [A][B]) - DEFUELING VALVES
28-20-04
DEFUELING VALVES
1. DEFUELING VALVES - DESCRIPTION
Each sump assembly is provided with a crash-resistant defuel valve which is manually operated by insertion of an AN815-12
union to provide gravity defueling of cells.
NOTE
Maintenance procedures for defueling valve in each sump assembly are the same.
2. DEFUELING VALVES - REMOVAL
2. Remove nut (1, figure 1), valve body (3), and packing (2). Discard packing.
3. DEFUELING VALVES - INSTALLATION
MATERIALS REQUIRED
NUMBER NOMENCLATURE
C-405 LOCKWIRE
1. Place packing (2, figure 1) on valve body (3).
2. Insert valve body (3) through sump assembly (4). Install and tighten valve nut (1). Apply lockwire (C-405) to valve
body (3).
4. Perform operational check on valve body (3) by verifying fuel gravity drains upon insertion of union and valve body
(3) does not leak following removal of union.
28-20-04
Page 1
E-AB412-PT6T-2
G6AB0328A
Figure 1. Defueling valve (helicopters codes [A][B])
28-20-04
Page 2
E-AB412-PT6T-2
28-20-05 FUEL STORAGE AND DISTRIBUTION SYSTEM (HELICOPTERS CODES [A][B]) - SUMP INTERCONNECT VALVES
28-20-05
[A][B]) - SUMP INTERCONNECT VALVES
1. SUMP INTERCONNECT VALVES - DESCRIPTION
NOTE
Maintenance procedures for the left and right sump interconnect valves are the same.
2. SUMP INTERCONNECT VALVES - REMOVAL
2. Remove valve (1, figure 1).
3. Remove nut (2), washer (3), packing (4), and sump interconnect valve fitting (5). Discard packing. Sump interconnect
valves - installation
3. SUMP INTERCONNECT VALVES - INSTALLATION
1. Install packing (4, figure 1) on interconnect valve fitting (5).
2. Install interconnect valve fitting (5), washer (3), nut (2) and valve (1) in sump (6).
28-20-05
Page 1
E-AB412-PT6T-2
G6AB0331A
Figure 1. Sump interconnect valve (helicopters codes [A][B])
28-20-05
Page 2
E-AB412-PT6T-2
28-20-06 FUEL STORAGE AND DISTRIBUTION SYSTEM (HELICOPTERS CODES [A][B]) - SUMP DRAIN VALVES
28-20-06
[A][B]) - SUMP DRAIN VALVES
1. SUMP DRAIN VALVES - DESCRIPTION
Each sump assembly is provided with a sump drain valve which can be operated manually or electrically to drain off
accumulations of water or other contaminants.
NOTE
Maintenance procedures for left and right sump drain valves are the same.
2. SUMP DRAIN VALVES - REMOVAL
3. Disconnect electrical leads (6, figure 1) from terminal block (7).
4. Remove sump drain valve (5) and packing (4) from sump assembly (8). Discard packing.
5. Install protective cover or plug opening in sump assembly (8).
3. SUMP DRAIN VALVES - INSTALLATION
MATERIALS REQUIRED
NUMBER NOMENCLATURE
C-405 LOCKWIRE
1. Remove protective cover or plug from sump assembly (8).
2. Install new packing (4, figure 1) on sump drain valve (5).
NOTE
Nut (2) is held in place by retainers (1 and 3). Carefully thread sump drain valve (5)
into nut (2). Do not push against nut (2).
3. Install sump drain valve (5). Apply lockwire (C-405) to sump drain valve.
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Rev. 3 Page 1
E-AB412-PT6T-2
28-20-06
Page 2 Rev. 3
E-AB412-PT6T-2
1
2
3
4
8
5
6
7
1. Retainer
2. Nut
3. Retainer
4. Packing
5. Sump drain valve
6. Electrical leads
7. Terminal block
8. Sump assembly
G6AB0332B
Figure 1. Sump drain valve (helicopters codes [A][B])
28-20-06
Rev. 3 Page 3
E-AB412-PT6T-2
28-20-06
Page 4 Rev. 3
E-AB412-PT6T-2
28-20-07 FUEL STORAGE AND DISTRIBUTION SYSTEM (HELICOPTERS CODES [A][B]) - FLOW SWITCHES
28-20-07
[A][B]) - FLOW SWITCHES
1. FLOW SWITCHES - DESCRIPTION
The flow switch is actuated by outlet flow from the boost pump (16 and 28, figure 1). If fuel flow is interrupted, the flow
switch will cause the respective caution panel FUEL BOOST segment to illuminate.
NOTE
Maintenance procedures for left and right flow switches are the same.
2. FLOW SWITCHES - REMOVAL
2. Disconnect tube (4, figure 2) from union (1) and fuel outlet fitting (5).
4. Remove nut (7), washer (8), packing (9), and flow switch (3). Discard packing.
5. Remove unions (1) and packings (2). Discard packings.
6. Install protective cover over sump opening.
3. FLOW SWITCHES - INSTALLATION
MATERIALS REQUIRED
NUMBER NOMENCLATURE
C-405 LOCKWIRE
1. Apply assembly fluid (C-024) to new packings (2, figure 2). Install unions (1) and packings (2).
2. Install packing (9) on flow switch (3).
3. Position flow switch (3) on sump assembly (6). Install washer (8) and nut (7).
Torque nut (7) 40 to 50 in.lbs. (4,52 to 5,65 Nm) and lockwire (C-405) nut (7).
4. Connect tube (4) to union (1) and fuel outlet fitting (5).
6. Install sump assembly (module 28-20-03 paragraph "3. Sump assemblies - installation").
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Figure 2. Flow switch (helicopters codes [A][B])
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28-20-08 FUEL STORAGE AND DISTRIBUTION SYSTEM (HELICOPTERS CODES [A][B]) - AUXILIARY FUEL CAPPED CONNECTOR
28-20-08
[A][B]) - AUXILIARY FUEL CAPPED CONNECTOR
1. AUXILIARY FUEL CAPPED CONNECTOR - DESCRIPTION
NOTE
Maintenance procedures for left and right auxiliary fuel capped connectors are the
same.
2. AUXILIARY FUEL CAPPED CONNECTOR - REMOVAL
3. Remove access door located on fuselage bottom aft of sump access door.
4. Remove two outer screws (1, figure 1).
5. Pull access cover (2) outboard to release clip.
6. Lift access cover (2) up and hold fitting (8). Remove screw (9) to separate access cover (2) from fitting (8).
7. Install protective cap or plug on open fuel line.
8. If required, remove bolts (5) to separate hose (4) from fitting (8). Remove and discard seal (3).
3. AUXILIARY FUEL CAPPED CONNECTOR - INSTALLATION
1. Remove protective cap or plug. Install seal (3, figure 1) using bolts (5).
2. Ensure packing is installed inside fitting (8) and fitting (8) is tightened.
3. Secure access cover (2) to fitting (8) using screw (9).
4. Install access cover (2) by inserting clip on access over under floor panel structure.
5. Install screws (1).
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Figure 1. Auxiliary fuel capped connector (helicopters codes [A][B])
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28-20-09 FUEL STORAGE AND DISTRIBUTION SYSTEM (HELICOPTERS CODES [A][B]) - FLAPPER VALVES
28-20-09
[A][B]) - FLAPPER VALVES
1. FLAPPER VALVES - DESCRIPTION
A flapper valve, consisting of two plates and a valve element, (18 and 30, figure 1) is installed on baffle between front and
aft compartments of forward cells. The flapper valve allows fuel to flow from front compartment to aft compartment but
prevents flow in the opposite direction.
NOTE
Maintenance procedures for left and right flapper valves are the same.
2. FLAPPER VALVES - REMOVAL
2. Remove cabin floor access panel.
3. Remove screws (23, figure 2), cover (22), and packing (21). Discard packing.
4. Remove screws (7), washers (8), and valve element (5).
5. Disconnect hoses (6 and 18). Remove nut (4), union (17), and washer (20).
6. Remove nuts (3, 9, and 11), washers (2, 10, and 12), and bolts (15, 16, and 19). Remove plates (13 and 14).
7. Install protective covers on cell openings.
3. FLAPPER VALVES - INSTALLATION
1. Remove protective covers.
2. Position plates (13 and 14, figure 1) on baffle (1).
3. Install bolts (15, 16, and 19) with washers (2, 10, and 12), and nuts (3, 9, and 11).
4. Install union (17), washer (20), and nut (4).
5. Install valve element (5) with screws (7) and washers (8).
6. Verify valve element (5) works freely and centers over opening in plate (13). If necessary, loosen screws (7) and
reposition valve. Tighten screws.
7. Connect hoses (6 and 18).
8. Install packing (21), cover (22), and screws (23).
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28-20-09
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Figure 2. Flapper valve (helicopters codes [A][B])
9. Install cabin floor access panel.
4. FLAPPER VALVES - INSPECTION
1. Inspect valve element (5, figure 2) for cracks and nicks. Cracks and nicks which will affect valve function are not
acceptable.
2. Inspect plates (13 and 14) for mechanical and corrosion damage. Mechanical damage in excess of a superficial type
and/or any corrosion damage is not acceptable.
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28-20-10 FUEL STORAGE AND DISTRIBUTION SYSTEM (HELICOPTERS CODES [A][B]) - EJECTOR PUMPS
28-20-10
[A][B]) - EJECTOR PUMPS
1. EJECTOR PUMPS - DESCRIPTION
An ejector pump (20 and 32, figure 1) is installed in the forward compartment of each forward cell. The pump is operated
by fuel delivered through a hose from the boost pump.
The ejector pump draws fuel from the forward compartment and returns fuel continuously to aft compartment of forward
cell.
NOTE
2. EJECTOR PUMPS - REMOVAL
3. Remove cabin floor access panel above fuel cell.
4. Remove screws (1, figure 2), cover (2), and packing (3). Discard packing.
7. Remove bolts (7) and washers (6). Remove ejector pump (5).
8. Remove elbow (11), nut (9), and packing (8). Discard packing.
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3. EJECTOR PUMPS - INSTALLATION
1. Remove protective cover.
2. Install elbow (11, figure 2) with packing (8) and nut (9).
3. Position ejector pump (5) on support (12). Install and tighten bolts (7) with washers (6).
4. Connect hose (10) to elbow (11).
5. Install new packing (3), cover (2), and screws (1).
6. Install cabin flow access panel.
9. Perform operational check of ejector pump (Chapter 96).
4. EJECTOR PUMPS - CLEANING
MATERIALS REQUIRED
NUMBER NOMENCLATURE
C-405 LOCKWIRE
1. Remove any obstructions from openings of ejectors pump using compressed air
2. If necessary, clean nozzle opening of ejector pump using lockwire (C-405). Do not enlarge nozzle in cleaning process.
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28-20-10
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28-20-10
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G6AB0337A
Figure 2. Ejector pump (helicopters codes [A][B])
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28-20-1 FUEL STORAGE AND DISTRIBUTION SYSTEM (HELICOPTERS CODES [A][B]) - EJECTOR PUMP SUPPORTS
28-20-11
[A][B]) - EJECTOR PUMP SUPPORTS
1. EJECTOR PUMP SUPPORTS - DESCRIPTION
NOTE
2. EJECTOR PUMP SUPPORTS - REMOVAL
1. Remove ejector pump (module 28-20-10 paragraph "2. Ejector pumps - removal").
2. Disconnect hose (1, figure 1) from forward interconnect valve (module 28-20-01 "FUEL STORAGE AND
DISTRIBUTION SYSTEM (HELICOPTERS CODES [A][B]) - FORWARD INTERCONNECT VALVE").
3. Loosen clamp (3). Disconnect hose (1) from ejector pump support (6).
4. Remove washer (4), seal (5), and packing (2). Discard packing.
5. Remove bolts (9), washers (8), spacers (7), and ejector pump support (6).
6. Install protective covers over cell openings.
3. EJECTOR PUMP SUPPORTS - INSTALLATION
1. Remove protective covers.
2. Position ejector pump support (6, figure 1) to port in cell. Install bolts (9) with washers (8) and spacers (7).
3. Place clamp (3), washers (4), seal (5) (if required), and packing (2) on hose (1). Connect hose (1) to ejector pump
support (6).
4. Position clamp (3) over hex portion of fitting on hose (1) until seal (5) (if installed) is partially compressed. Tighten
clamp (3).
5. Connect hose (1) to forward interconnect valve (module 28-20-01 "FUEL STORAGE AND DISTRIBUTION
SYSTEM (HELICOPTERS CODES [A][B]) - FORWARD INTERCONNECT VALVE").
6. Install ejector pump (module 28-20-10 paragraph "3. Ejector pumps - installation").
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Figure 1. Ejector pump support (helicopters codes [A][B])
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28-20-12 FUEL STORAGE AND DISTRIBUTION SYSTEM (HELICOPTERS CODES [A][B]) - SIPHON BREAKER VALVES
28-20-12
[A][B]) - SIPHON BREAKER VALVES
1. SIPHON BREAKER VALVES - DESCRIPTION
Two siphon breaker valves (check valves) (21, figure 1) are installed in vent tube tees above the engine deck near left shutoff
valve.
NOTE
Maintenance procedures for left and right siphon breaker valves are the same.
2. SIPHON BREAKER VALVES - REMOVAL
3. Remove access door in left side of pylon support in cabin.
4. Remove siphon breaker valve (2 or 4, figure 2) with packing (1 or 3). Discard packing.
5. Install protective cap or plug in open fuel line.
3. SIPHON BREAKER VALVES - INSTALLATION
1. Remove protective cap or plug. Install siphon breaker valve (2 or 4, figure 2) using packing (1 or 3).
4. Check fuel system for leaks.
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Figure 2. Siphon breaker valve (helicopters codes [A][B])
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28-20-13 FUEL STORAGE AND DISTRIBUTION SYSTEM (HELICOPTERS CODES [A][B]) - SHUTOFF VALVES
28-20-13
[A][B]) - SHUTOFF VALVES
1. SHUTOFF VALVES - DESCRIPTION
Two motor-operated shutoff valves (40, figure 1), connected in main fuel pressure lines to engine power sections, are located
on front of lower forward engine firewall. The valves are electrically controlled by ENGINE 1 FUEL and ENGINE 2 FUEL
switches and have manual override handles which are also position indicators. Thermal relief valves are incorporated for
internal bypass of trapped fuel when the system is inoperative.
NOTE
Maintenance procedures for left and right shutoff valves are the same.
2. SHUTOFF VALVES - REMOVAL
3. Open engine cowling.
4. Remove access door on side of pylon support in cabin.
6. Disconnect tubes (1 and 14).
7. Remove tee reducer (2) if connector (4) is to be replaced.
9. Remove four screws (12) and washers (11).
10. Remove shutoff valve (6), connectors (4 and 7), and packings (9 and 10). Discard packings.
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3. SHUTOFF VALVES - INSTALLATION
MATERIALS REQUIRED
NUMBER NOMENCLATURE
1. Remove protective caps or plugs.
3. Position packings (9 and 10) and connectors (4 and 7) on body of shutoff valve (6). Insert two upper screws (12) with
washers (11).
NOTE
Screws (13) securing mounting bracket (3) to deck may be loosened as necessary to
provide clearance for installation of shutoff valve (6).
4. Position shutoff valve (6) between mounting bracket (3) and firewall.
5. Start upper screws (12) into firewall nutplates.
6. Install two lower screws (12) with washers (11). Tighten all four screws (12).
7. Tighten screws (13) if previously loosened.
8. If not previously accomplished, install tee reducer (2).
9. Connect tubes (1 and 14).
10. Connect tube (8).
14. Perform operational check on shutoff valve (Chapter 96).
16. Close engine cowling and install sump access door.
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G6AB0343A
Figure 2. Shutoff valve (helicopters codes [A][B])
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28-20-13
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28-20-14 FUEL STORAGE AND DISTRIBUTION SYSTEM (HELICOPTERS CODES [A][B]) - CROSSFEED VALVE
28-20-14
[A][B]) - CROSSFEED VALVE
1. CROSSFEED VALVE - DESCRIPTION
The crossfeed valve (4, figure 1) is located above and between the shutoff valves. Under normal conditions the crossfeed
valve is closed and fuel is supplied to each power section from lower cell on same side of helicopter. However, if boost pump
in either cell ceases to function, the crossfeed valve opens to permit flow from operating pump to both power sections.
2. CROSSFEED VALVE - REMOVAL
3. Remove transmission cowling.
5. Disconnect tubes (1 and 8).
6. Remove screws (7).
7. Remove crossfeed valve (11), packings (5 and 10), and connectors (4 and 9). Discard packings.
3. CROSSFEED VALVE - INSTALLATION
MATERIALS REQUIRED
NUMBER NOMENCLATURE
3. Position packings (5 and 10) and connectors (4 and 9) on crossfeed valve (11). Install two forward screws (7), washers
(3), and nuts (2). Do not tighten nuts (2) at this time.
4. Position crossfeed valve (11) and connectors (4 and 9) in bracket (6). Install two aft screws (7), washers (3), and nuts
(2). Tighten four nuts (2).
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9. Perform operational check of crossfeed valve (Chapter 96).
11. Install transmission cowling and sump access door.
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Figure 2. Crossfeed valve (helicopters codes [A][B])
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28-20-15 FUEL STORAGE AND DISTRIBUTION SYSTEM (HELICOPTERS CODES [A][B]) - GOVERNOR BLEED LINE CHECK VALVES
28-20-15
[A][B]) - GOVERNOR BLEED LINE CHECK VALVES
1. GOVERNOR BLEED LINE CHECK VALVES - DESCRIPTION
Two directional flow check valves (figure 1) are installed in the center aft cell rear cover. The check valves are connected
to governor bleed lines which return excess fuel from each power section fuel control to the center aft cell.
NOTE
Maintenance procedures are the same for both governor bleed line check valves.
2. GOVERNOR BLEED LINE CHECK VALVES - REMOVAL
1. Remove center aft cell rear cover (module 28-20-10 paragraph "1. Center aft cell rear cover - removal").
2. Remove nut (2, figure 1), washer (3), packing (4), and check valve (5). Discard packing.
3. GOVERNOR BLEED LINE CHECK VALVES - INSTALLATION
MATERIALS REQUIRED
NUMBER NOMENCLATURE
1. Remove protective cover and cap from cell opening and tube.
3. Install check valve (5), packing (4), washer (3), and nut (2).
4. Install center aft cell rear cover (module 28-20-10 paragraph "2. Center aft cell rear cover - installation").
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G6AB0350A
Figure 1. Governor bleed line check valve (helicopters codes [A][B])
28-20-15
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28-20-16 FUEL STORAGE AND DISTRIBUTION SYSTEM (HELICOPTERS CODES [A][B]) - FILLER CAP AND ADAPTER ASSEMBLY (HELICOPTERS NOT EQUIPPED WITH PUMP P/N 206-062-687-101)
28-20-16
[A][B]) - FILLER CAP AND ADAPTER ASSEMBLY (HELICOPTERS NOT
EQUIPPED WITH PUMP P/N 206-062-687-101)
1. FILLER CAP AND ADAPTER ASSEMBLY (HELICOPTERS NOT EQUIPPED WITH

PUMP P/N 206-062-687-101) - DESCRIPTION
The filler cap and adapter assembly (2, figure 1) is located on the right aft cell. A spring-loaded plate inside assembly serves
as a seal in event cap opens accidentally.

PUMP P/N 206-062-687-101) - REMOVAL
3. Remove screws (2, figure 2), washers (3), retainer (4), filler cap and adapter assembly (5), and packing (6). Discard
packing.
4. Install protective cover over cell opening if not immediately replacing filler cap and adapter assembly (5).

PUMP P/N 206-062-687-101) - INSTALLATION
MATERIALS REQUIRED
NUMBER NOMENCLATURE
2. Coat packing (6, figure 2) with assembly fluid (C-024). Place packing (6) in groove around cell opening.
3. Taking care not to disturb packing (6), assemble filler cap and adapter assembly (5) and retainer (4) to cell (1) as shown
in view A.
4. Install screws (2) with washers (3), installing ground strip at hole location indicated in figure 2. Torque screws (2) 50
to 100 in.lbs. (5,65 to 11,30 Nm).
5. Pressure test fuel system (module 28-40-01 "FUEL STORAGE AND DISTRIBUTION SYSTEM (HELICOPTERS
CODES [A][B]) - PRESSURE TESTING").
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28-20-16
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Figure 2. Filler cap and adapter assembly (helicopters codes [A][B])
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28-20-17 FUEL STORAGE AND DISTRIBUTION SYSTEM (HELICOPTERS CODES [A][B]) - IMPROVED FILLER CAP AND ADAPTER ASSEMBLY (EQUIPPED WITH PUMP P/N 206-062-687-101)
28-20-17
[A][B]) - IMPROVED FILLER CAP AND ADAPTER ASSEMBLY (EQUIPPED
WITH PUMP P/N 206-062-687-101)
1. IMPROVED FILLER CAP AND ADAPTER ASSEMBLY (EQUIPPED WITH PUMP P/N
206-062-687-101) - DESCRIPTION
The improved filler cap and adapter assembly (figure 1) is located on the right aft cell. This cap incorporates a spring-loaded
closure which retains cap minimizes fuel loss in the event cap is not secured.
206-062-687-101) - REMOVAL
3. Remove screws (1, figure 1), washers (2), four retainers (4), filler cap and adapter assembly (5), and packing (6).
Discard packing.
4. Install protective cover over cell opening if not immediately replacing filler cap and adapter assembly (5).
206-062-687-101) - INSTALLATION
MATERIALS REQUIRED.
NUMBER NOMENCLATURE
1. Remove protective cover. Coat packing (6, figure 1) with assembly fluid (C-024). Place packing (6) in groove around
cell opening.
2. Taking care not to disturb packing (6), install cap and adapter assembly (5), with retainers (4), washers (2) and screws
(1). Locate retainers (4) at the 2, 4, 8, and 10 o’clock position as shown in detail B.
3. Connect ground strip (3) at the one o’clock position.
4. Torque all screws (1) 50 to 100 in.lbs. (5,65 to 11,30 Nm).
CODES [A][B]) - PRESSURE TESTING").
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Figure 1. Improved filler cap and adapter assembly
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28-20-18 FUEL STORAGE AND DISTRIBUTION SYSTEM (HELICOPTERS CODES [C][D]) - LOWER FORWARD CELL SUMP ASSEMBLIES
28-20-18
[C][D]) - LOWER FORWARD CELL SUMP ASSEMBLIES
1. LOWER FORWARD CELL SUMP ASSEMBLIES - DESCRIPTION
Sump assemblies (10 and 29, figure 1) are mounted over the opening on bottom of each lower forward cell. Removal of
sump assembly provides access for maintenance of transfer pump, drain valve, and internally mounted components
including check valve, fuel quantity probe, and fuel level sensor. The transfer pump and drain valve can both be removed
without removing sump assembly.
NOTE
Maintenance procedures are the same for both lower forward cell sump assemblies
except as noted in figure 2, sheet 2.
2. LOWER FORWARD CELL SUMP ASSEMBLIES - REMOVAL
MATERIALS REQUIRED
NUMBER NOMENCLATURE
3. Remove sump access door.
5. Disconnect transfer pump electrical leads (22).
6. Remove bolts (7), washers (6), and retainers (5).
7. Lower the lower forward cell sump assembly (3) for access.
NOTE
Ensure hardware stack-up is retained
9. Remove nuts (13), washers (14), spacers (16) and bolts (18).
10. Remove fuel level sensor (thermistor) (19) from clamp (15) and lay fuel level sensor (thermistor) on the lower forward
cell sump assembly (3).
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11. Remove the bolts (24), washers (25) and spacers (26) from the mounting bracket (27).
12. Remove the fuel level transmitter (23) and lay on the lower forward fuel cell sump assembly (3).
13. Remove the lower forward cell sump assembly (3), fuel level sensor (19) and fuel level transmitter (23).
14. Install protective caps and/or plugs (C-428) and covers over cell openings.
3. LOWER FORWARD CELL SUMP ASSEMBLIES - INSTALLATION
MATERIALS REQUIRED
NUMBER NOMENCLATURE
2. Coat packing (2, figure 2) with assembly fluid (C-024). Place packing (2) in groove around sump opening of lower
forward cell (1).
3. Install fuel level sensor (thermistor) (19) in clamp (15).
4. Hold lower forward cell sump assembly (3) below sump opening of lower forward cell (1).
5. Install fuel level sensor (thermistor) (19) and clamp (15) in bracket (17) using nuts (13), washers (14), spacers (16) and
bolts (18).
6. Install the bolts (24) through the fuel level transmitter mounting brackets (27).
7. Install the spacers (26) and the washers (25) on the bolts (24).
8. Install the fuel level transmitter (23) on the inboard wall of the lower forward fuel cell (1). Tighten the bolts (24).
9. Connect hose (12) to fitting (10).
10. Connect internal electrical connector (14).
11. Position lower forward cell sump assembly (3) in place over sump opening on bottom of lower forward cell (1).
12. Install mounting bolts (7), washers (6), and retainers (5).
13. Connect electrical connector (4) on bottom of lower forward cell sump assembly (3).
17. Check installation area for leaks.
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THERMISTOR INSTALLATION MODIFICATION
G6AB0802A
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4. LOWER FORWARD CELL SUMP ASSEMBLIES - INSPECTION
1. Inspect area where sump assembly (3) mates with cell for damage and cleanliness. Inspect packing groove.
2. Inspect components for security of mounting.
3. Inspect hoses and fittings for contamination. Contamination shall be removed. Damage which can be detected visually
necessitates replacement.
4. Inspect electrical wiring and connectors for condition.
5. Replace any components which fails to meet inspection requirements.
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28-20-19 FUEL STORAGE AND DISTRIBUTION SYSTEM (HELICOPTER CODES [C][D]) - TRANSFER PUMPS
28-20-19
FUEL STORAGE AND DISTRIBUTION SYSTEM (HELICOPTER CODES
[C][D]) - TRANSFER PUMPS
1. TRANSFER PUMPS - DESCRIPTION
A transfer pump (figure 1) is mounted on sump assembly of each lower forward cell. The transfer pumps provide fuel
pressures required to transfer fuel from lower forward cells to lower main cells. The transfer pumps are electrically operated,
and controlled by separate FUEL TRANS switches located on engine and fuel control panel and by fuel level sensors in
lower forward cell fuel quantity probes.
NOTE
Maintenance procedures for the left and right transfer pumps are the same.
2. TRANSFER PUMPS - REMOVAL
3. Drain any trapped fuel through sump drain valve (10, figure 1).
4. Disconnect transfer pump electrical leads (6).
5. Remove bolt (11), washer (12), packings (13 and 15), and retainer (14). Discard packings.
7. Remove transfer pump (5) and gasket (4) from sump assembly (3).
8. Remove plug (16) and packing (17). Discard packing.
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3. TRANSFER PUMPS - INSTALLATION
MATERIALS REQUIRED
NUMBER NOMENCLATURE
C-405 LOCKWIRE
1. Remove protective cover over cell opening.
2. Apply assembly fluid (C-024) to packing (17, figure 1). Place packing (17) on plug (16). Install plug (16).
3. Apply assembly fluid (C-024) to packings (13 and 15). Place washer (12), packing (13), retainer (14), and packing (15)
on bolt (11).
4. Coat gasket (4) with assembly fluid (C-024). Place gasket (4) on transfer pump (5).
5. Align transfer pump (15) with fitting (18). Install bolt (11) and apply lockwire (C-405).
6. Install bolts (8), washers (7), transfer pump (5), and gasket (4) on sump assembly (3).
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G6AB0804A
Figure 1. Transfer pump (helicopters codes [C][D])
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28-20-20 FUEL STORAGE AND DISTRIBUTION SYSTEM (HELICOPTERS CODES [C][D]) - CANNISTER TYPE TRANSFER PUMPS
28-20-20
[C][D]) - CANNISTER TYPE TRANSFER PUMPS
1. CANNISTER TYPE TRANSFER PUMPS - DESCRIPTION
The cannister type transfer pumps (figure 1) incorporate an integral cartridge pumping element.
NOTE
Maintenance procedures for left and right cannister type transfer pumps are the
same.
2. CANNISTER TYPE TRANSFER PUMPS - REMOVAL
3. Drain any trapped fuel through sump drain.
4. Disconnect transfer pump electrical leads (2, figure 1).
5. Remove bolt (9), washer (8), packings (5 and 7), and plug (6).
7. Remove transfer pump (12) and gasket (1) from sump assembly (13).
28-20-20
Page 1
E-AB412-PT6T-2
3. CANNISTER TYPE TRANSFER PUMPS - INSTALLATION
MATERIALS REQUIRED
NUMBER NOMENCLATURE
C-008 PETROLATUM
C-383 CEMENT
C-405 LOCKWIRE
2. Apply petrolatum (C-008) to packing (11, figure 1) and install on plug (10). Install plug (10).
3. Apply petrolatum (C-008) to packings (5 and 7) and install on plug (6).
4. Install washer (8) on bolt (9). Insert bolt (9) through plug (6) and into discharge port of pump.
5. Coat gasket (1) with cement (C-383). Place gasket (1) on pump (12).
6. Position transfer pump (12) on sump assembly (13). Align transfer pump (12) with fitting (14). Tighten bolt (9) and
ensure fitting seats in discharge port.
8. Connect electrical leads (2).
9. Secure plug (10) and bolt (9) with lockwire (C-405).
12. Perform operational check on transfer pump (Chapter 96).
4. CANNISTER TYPE TRANSFER PUMPS - CARTRIDGE
For removal, cleaning and installation procedures, refer to module 28-20-30 "FUEL STORAGE AND DISTRIBUTION
SYSTEM (HELICOPTERS CODES [C][D]) - CANISTER TYPE BOOST PUMP".
28-20-20
Page 2
E-AB412-PT6T-2
G6AB0389A
Figure 1. Cannister type transfer pump (helicopters codes [C][D])
28-20-20
Page 3
E-AB412-PT6T-2
28-20-20
Page 4
E-AB412-PT6T-2
28-20-21 FUEL STORAGE AND DISTRIBUTION SYSTEM (HELICOPTERS CODES [C][D]) - SUMP DRAIN VALVES
28-20-21
[C][D]) - SUMP DRAIN VALVES
A manually operated sump drain valve is mounted on each lower forward cell sump assembly. These valves provide for
draining of any possible accumulation of moisture or other contamination.
NOTE
Maintenance procedures for sump drain valve installed on each lower forward cell
sump assembly are the same.
4. Remove lockwire from outer flange of sump drain valve (8, figure 1).
5. Remove sump drain valve (8) and packing (9) from sump assembly (3). Discard packing.
6. Install protective cover or plug opening.
28-20-21
Rev. 1 Page 1
E-AB412-PT6T-2
MATERIALS REQUIRED
NUMBER NOMENCLATURE
C-008 PETROLATUM
C-405 LOCKWIRE
1. Remove protective cover from opening.
2. Apply petrolatum (C-008) to packing (9, figure 1). Place packing on sump drain valve (8).
3. Install sump drain valve and lockwire (C-405).
28-20-21
Page 2 Rev. 1
E-AB412-PT6T-2
G6AB0371A
28-20-21
Rev. 1 Page 3
E-AB412-PT6T-2
NOTE:
AFTER COMPLIANCE WITH
1 Configuration for right lower forward cell. THERMISTOR INSTALLATION MODIFICATION
1. Lower forward cell 10. Fitting

2. Packing 11. Deleted
3. Sump assembly 12. Hose
4. Electrical connector 13. Transfer pump
5. Retainer 14. Electrical connector (internal)
6. Washer 15. Nut
7. Bolt 16. Clamp
8. Drain valve 17. Fuel level sensor thermistor
9. Packing 18. Bracket
G6AB0372B
28-20-21
Page 4 Rev. 1
E-AB412-PT6T-2
28-20-2 FUEL STORAGE AND DISTRIBUTION SYSTEM (HELICOPTERS CODES [C][D]) - LOWER FORWARD CELL CHECK VALVES
28-20-22
[C][D]) - LOWER FORWARD CELL CHECK VALVES
1. LOWER FORWARD CELL CHECK VALVES - DESCRIPTION
Check valves are installed in the output hoses of the transfer pumps. These valves permit forward flow of fuel from lower
forward cells to lower middle cells when transfer pumps are operating, but prevent back flow of fuel during shutdown.
NOTE
Maintenance procedures for left and right lower forward cell check valves are the
same.
2. LOWER FORWARD CELL CHECK VALVES - REMOVAL
MATERIALS REQUIRED
NUMBER NOMENCLATURE
3. Remove access door on underside of helicopter directly under applicable lower forward cell.
4. Remove sump assembly (module 28-20-18 paragraph "2. Lower forward cell sump assemblies - removal") to obtain
internal access to cell.
6. Remove check valve (4) and packing (3). Discard packing.
7. Install protective caps and/or plugs (C-0428) and covers over cell opening.
28-20-22
Page 1
E-AB412-PT6T-2
3. LOWER FORWARD CELL CHECK VALVES - INSTALLATION
MATERIALS REQUIRED
NUMBER NOMENCLATURE
1. Remove protective cover over cell opening.
3. Place packing (3) on check valve (4) with arrow on side of check valve pointing toward packing (3).
4. Install check valve (4) with arrow pointing toward forward cell/lower middle cell interconnect fitting (2).
6. Install sump assembly (module 28-20-18 paragraph "3. Lower forward cell sump assemblies - installation")
28-20-22
Page 2
E-AB412-PT6T-2
G6AB0379A
Figure 1. Lower forward cell check valve (helicopters codes [C][D])
28-20-22
Page 3
E-AB412-PT6T-2
28-20-22
Page 4
E-AB412-PT6T-2
28-20-23 FUEL STORAGE AND DISTRIBUTION SYSTEM (HELICOPTERS CODES [C][D]) - LOWER MIDDLE CELL SUMP ASSEMBLIES
28-20-23
[C][D]) - LOWER MIDDLE CELL SUMP ASSEMBLIES
1. LOWER MIDDLE CELL SUMP ASSEMBLIES - DESCRIPTION
A sump assembly is mounted over opening on bottom of each lower middle cell. Removal of sump assembly provides access
for maintenance of ejector pump, drain valve, and fuel quantity probe. The drain valve can be removed without removing
sump assembly.
NOTE
Maintenance procedures are the same for both left and right lower middle cell sump
assemblies.
2. LOWER MIDDLE CELL SUMP ASSEMBLIES - REMOVAL
MATERIALS REQUIRED
NUMBER NOMENCLATURE
5. Remove bolts (7) with washers (8) and four retainers (9).
6. Lower sump assembly (3) as needed for access.
7. Remove the bolts (11), washers (12) and spacers (13) from the mounting brackets (14).
8. Remove the fuel quantity transmitter (10) and lay it on the sump assembly (3).
9. Remove sump assembly (3) with fuel quantity transmitter (10) and packing (2). Discard packing.
28-20-23
Page 1
E-AB412-PT6T-2
3. LOWER MIDDLE CELL SUMP ASSEMBLIES - INSTALLATION
MATERIALS REQUIRED
NUMBER NOMENCLATURE
2. Coat packing (2, figure 1) with assembly fluid (C-024). Place packing in groove around lower middle cell (1) sump
opening.
3. Connect internal electrical wiring.
4. Hold lower middle cell sump assembly in position over sump opening in lower middle cell (1).
5. Install the bolts (11) and washers (12) through the mounting brackets (14) of the fuel quantity transmitter (10).
6. Place the spacers (13) on the bolts (11), between the mounting brackets (14) and the lower middle cell (1) inboard wall.
Tighten the bolts.
7. Install bolts (7), washers (8), and retainers (9).
9. Apply assembly fluid (C-024) to packing (4). Install drain valve (5) and packing (4) on sump assembly (3).
10. Install packing (4) on drain valve (5).
11. Install drain valve (5) on sump assembly (3).
4. LOWER MIDDLE CELL SUMP ASSEMBLIES - INSPECTION AND REPAIR
1. Inspect area where sump assembly mates with cell for damage and cleanliness. Inspect packing groove for rough edges
or nicks.
2. Inspect sump assembly for security of mounting.
3. Inspect drain valve for security.
4. Inspect electrical leads and connector for condition.
5. Repair or replace components which fail to meet inspection requirements.
28-20-23
Page 2
E-AB412-PT6T-2
G6AB0382A
Figure 1. Lower middle cell sump assembly (helicopters codes [C][D])
28-20-23
Page 3
E-AB412-PT6T-2
28-20-23
Page 4
E-AB412-PT6T-2
28-20-24 FUEL STORAGE AND DISTRIBUTION SYSTEM (HELICOPTERS CODES [C][D]) - EJECTOR PUMPS
28-20-24
[C][D]) - EJECTOR PUMPS
1. EJECTOR PUMPS - DESCRIPTION
An ejector pump is mounted internally in each lower middle cell. The pumps are operated by fuel flow through hoses
attached to output ports of transfer pumps. The ejector pumps transfer fuel from lower middle cells to lower main cells. The
pumps cease operation when fuel flow from transfer pumps cease.
NOTE
Maintenance procedures for lower middle cell ejector pumps are the same.
2. EJECTOR PUMPS - REMOVAL
MATERIALS REQUIRED
NUMBER NOMENCLATURE
removal") to gain access to ejector pump.
2. Disconnect hoses (1 and 3, figure 1) from ejector pump (2).
3. Remove bolts (4) and washers (5) from bracket (6).
4. Remove ejector pump (2) with bracket (6).
5. Remove bolts (8) and washers (7) securing bracket to pump.
7. Install caps and/or plugs (C-428) on hose assemblies (1 and 5) end fittings and on fuel ejector pump (3) ports.
28-20-24
Page 1
E-AB412-PT6T-2
3. EJECTOR PUMPS - INSTALLATION
2. Remove protective caps and/or plugs from hoses (1 and 3, figure 1) end fittings and from ejector pump (2) ports.
3. Install mounting bracket (6) on ejector pump (2) with bolts (8) and washers (7).
4. Place ejector pump (2) and mounting bracket (6) over mounting bosses in cell. Install bolts (4) and washers (5).
5. Connect hoses (1 and 3). Tighten end fittings.
6. Install sump assembly (module 28-20-23 paragraph "3. Lower middle cell sump assemblies - installation").
4. EJECTOR PUMPS - CLEANING
1. Remove any obstructions from openings of ejector pump using compressed air.
CAUTION
DO NOT ENLARGE NOZZLE OPENING OF EJECTOR PUMP WHILE

CLEANING.
2. If necessary, clean nozzle opening of ejector pump using lockwire.
5. EJECTOR PUMPS - INSPECTION
1. Inspect ejector pump for mechanical damage, corrosion, looseness of parts and threads for condition.
2. Inspect ejector pump for contamination
28-20-24
Page 2
E-AB412-PT6T-2
G6AB0383A
Figure 1. Ejector pump (helicopters codes [C][D])
28-20-24
Page 3
E-AB412-PT6T-2
28-20-24
Page 4
E-AB412-PT6T-2
28-20-25 FUEL STORAGE AND DISTRIBUTION SYSTEM (HELICOPTER CODES [C][D]) - SUMP DRAIN VALVES
28-20-25
FUEL STORAGE AND DISTRIBUTION SYSTEM (HELICOPTER CODES
A manually operated sump drain valve is mounted on sump assembly of each lower middle cell. The sump drain valves
provide for draining off any possible moisture accumulation or other contamination.
NOTE
Maintenance procedures for lower middle cell drain valves are the same.
MATERIALS REQUIRED
NUMBER NOMENCLATURE
3. Remove drain valve (5, figure 1) and packing (4). Discard packing.
28-20-25
Page 1
E-AB412-PT6T-2
MATERIALS REQUIRED
NUMBER NOMENCLATURE
3. Install packing (4) and drain valve (5)
4. Install drain valve (5) into sump assembly (3).
28-20-25
Page 2
E-AB412-PT6T-2
G6AB0382A
Figure 1. Lower middle cell sump assembly (helicopters codes [C][D])
28-20-25
Page 3
E-AB412-PT6T-2
28-20-25
Page 4
E-AB412-PT6T-2
28-20-26 FUEL STORAGE AND DISTRIBUTION SYSTEM (HELICOPTERS CODES [C][D]) - LOWER MAIN CELL VENT VALVES AND HOSES
28-20-26
[C][D]) - LOWER MAIN CELL VENT VALVES AND HOSES
1. LOWER MAIN CELL VENT VALVES AND HOSES - DESCRIPTION
Vent hoses are attached to vent ports on upper inboard side of each lower main cell. The vent hoses connect lower main cells
to upper cell common venting system. Fume tight boots are installed over hose connections to lower main cells to prevent
escape of fumes into surrounding cell areas.
NOTE
Maintenance procedures are the same for both right and left lower main cell vent
valves.
2. LOWER MAIN CELL VENT VALVES AND HOSES - REMOVAL
MATERIALS REQUIRED
NUMBER NOMENCLATURE
3. Remove cabin floor access panels above lower right and lower left main cells.
5. Remove nut (6) and washers (5).
7. Remove vent valve (2) and packing (1) from lower main cell (8). Discard packing.
8. Cover cell opening to prevent cell contamination. Cap hose (7).
9. Install protective caps and/or plugs (C-428) on open end of hose (7).
28-20-26
Page 1
E-AB412-PT6T-2
3. LOWER MAIN CELL VENT VALVES AND HOSES - INSTALLATION
MATERIALS REQUIRED
NUMBER NOMENCLATURE
1. Remove protective cover from lower main cell (8, figure 1) and cap from hose (7).
2. Apply assembly fluid (C-024) to packing (1). Place packing (1) and vent valve (2) on lower main cell (8).
4. Install washers (5) and nut (6).
8. Perform fuel system operational test (Chapter 96).
10. Install cabin floor access panel.
28-20-26
Page 2
E-AB412-PT6T-2
G6AB0384A
Figure 1. Lower main cell vent valve and hose (helicopters codes [C][D])
28-20-26
Page 3
E-AB412-PT6T-2
28-20-26
Page 4
E-AB412-PT6T-2
28-20-27 FUEL STORAGE AND DISTRIBUTION SYSTEM (HELICOPTERS CODES [C][D]) - LOWER MAIN CELL INTERCONNECT HOSES
28-20-27
[C][D]) - LOWER MAIN CELL INTERCONNECT HOSES
1. LOWER MAIN CELL INTERCONNECT HOSES - DESCRIPTION
An interconnect hose is attached directly to inboard interconnect port of each lower main cell. The other end of each
interconnect hose is attached to a port on interconnect valve.
NOTE
Maintenance procedures are the same for both right and left lower main cell
interconnect hoses.
2. LOWER MAIN CELL INTERCONNECT HOSES - REMOVAL
MATERIALS REQUIRED
NUMBER NOMENCLATURE
3. Remove floor panels above hose to be removed.
4. Remove interconnect valve (module 28-20-34 paragraph "2. Interconnect valve - removal").
5. Remove bolts (8, figure 1), washers (7), retainer (6), and spacers (5).
28-20-27
Page 1
E-AB412-PT6T-2
3. LOWER MAIN CELL INTERCONNECT HOSES - INSTALLATION
MATERIALS REQUIRED
NUMBER NOMENCLATURE
1. Remove protective cover and cap from cell opening and hose assembly end.
2. Install interconnect valve (module 28-20-34 paragraph "3. Interconnect valve - installation").
NOTE
Do not perform fuel system pressure test, service, or operational check at this time.
3. Apply assembly fluid (C-024) to packing (4, figure 1). Install hose assembly (3), packing (4), bolts (8), washers (7),
retainer (6), and spacers (5).
28-20-27
Page 2
E-AB412-PT6T-2
G6AB0385A
Figure 1. Lower main cell interconnect hose (helicopters codes [C][D])
28-20-27
Page 3
E-AB412-PT6T-2
28-20-27
Page 4
E-AB412-PT6T-2
28-20-28 FUEL STORAGE AND DISTRIBUTION SYSTEM (HELICOPTERS CODES [C][D]) - LOWER MAIN CELL SUMP ASSEMBLIES
28-20-28
[C][D]) - LOWER MAIN CELL SUMP ASSEMBLIES
1. LOWER MAIN CELL SUMP ASSEMBLIES - DESCRIPTION
A sump assembly is mounted over the opening on the bottom of each lower main cell. Removal of sump assembly provides
access for maintenance of boost pump, drain valve, defueling valve, flow switch check valve, fuel quantity probe, and input/
output fitting. The boost pump and drain valve can both be removed without removing sump assembly.
NOTE
Maintenance procedures are the same for left and right lower main cell sump
assemblies.
2. LOWER MAIN CELL SUMP ASSEMBLIES - REMOVAL
MATERIALS REQUIRED
NUMBER NOMENCLATURE
2. Defuel sump system (Chapter 12).
5. Remove bolts (8), washers (7), and retainers (6).
6. Lower sump assembly (3) for access.
7. Remove bolts (23), washers (24) and spacers (26) from the mounting brackets (25) of the fuel quantity probe (22).
8. Remove the fuel quantity probe (22) from the lower main cell (1) inboard the wall and lay it on the sump assembly (3).
9. For helicopters code [C], perform the following: disconnect hoses (11) and (18).
10. For helicopters code [D], perform the following: disconnect hoses (18, 19, and 21).
11. Remove sump assembly (3), with the fuel quantity probe (22) and packing (2). Discard packing.
12. Install protective covers on lower main cell (1) openings.
13. Install protective caps and/or plugs (C-428) on the applicable hose assemblies (11, 16, 17 and 19) open end fittings.
28-20-28
Page 1
E-AB412-PT6T-2
3. LOWER MAIN CELL SUMP ASSEMBLIES - INSTALLATION
MATERIALS REQUIRED
NUMBER NOMENCLATURE
1. Remove the protective covers, caps and/or plugs from the lower main cell (1, figure 1) opening and the applicable hose
assemblies (11, 16, 17 and 19) end fittings.
2. Coat the packing (2) with assembly fluid (C-024). Place the packing in groove around sump opening in lower main
fuel cell.
3. Install the bolts (23) with the washers (24) through the mounting brackets (25) of the fuel quantity probe (22).
4. Install the spacers (26) on the bolts (23) between the inboard wall of the lower main cell (1) and the fuel quantity probe
(22) mounting bracket (25). Tighten the bolts.
5. Hold the sump assembly (3) below the lower main cell (1) sump opening.
6. For helicopters code [C], perform the following:
a. Connect the hose assembly (11) to the flow switch check valve (4).
7. For helicopters code [D], perform the following:
a. Connect the hose assemblies (17 and 19) to the flow switch check valve (4)
8. Connect the hose assembly (16) to the fitting (14).
9. Put the sump assembly (3) in position on the opening of the lower main cell (1).
10. Install the bolts (8), washers (7) and retainers (6).
11. Connect the electrical connector (5) on the bottom of the sump assembly (3).
(HELICOPTERS CODES [C][D]) - LOWER MAIN CELL SUMP ASSEMBLIES").
13. Service the fuel system (Chapter 12).
14. Perform the fuel system operational check (Chapter 96).
28-20-28
Page 2
E-AB412-PT6T-2
4. LOWER MAIN CELL SUMP ASSEMBLIES - INSPECTION
1. Inspect area where sump assembly mates with cell for damage and cleanliness. Inspect packing groove.
2. Inspect sump assembly for security of mounting.
3. If installed, inspect drain valve for security.
4. Inspect electrical leads and connector for condition.
5. Repair or replace components failing to meet inspection requirements.
28-20-28
Page 3
E-AB412-PT6T-2
HELICOPTERS CODE D
G6AB0386A
Figure 1. Lower main cell sump assembly (helicopters codes [C][D]) (sheet 1 of 2)
28-20-28
Page 4
E-AB412-PT6T-2
G6AB0387A
Figure 1. Lower main cell sump assembly (helicopters codes [C][D]) (sheet 2 of 2)
28-20-28
Page 5
E-AB412-PT6T-2
28-20-28
Page 6
E-AB412-PT6T-2
28-20-29 FUEL STORAGE AND DISTRIBUTION SYSTEM (HELICOPTERS CODES [C][D]) - BOOST PUMPS
28-20-29
[C][D]) - BOOST PUMPS
1. BOOST PUMPS - DESCRIPTION
A boost pump is mounted on sump assembly of each lower main cell. The boost pumps provide a positive pressure in lines
suppling fuel to each power section.
NOTE
Maintenance procedures for left and right lower main cell boost pumps are the same.
2. BOOST PUMPS - REMOVAL
MATERIALS REQUIRED
NUMBER NOMENCLATURE
3. Drain any trapped fuel through drain valve (10, figure 1).
4. Remove bolt (11), washer (12), packings (13 and 15) and retainer (14). Discard packings..
5. Remove bolts (8), washers (7), and grounding wire.
6. Disconnect electrical leads (6) from pump (5).
7. Remove boost pump (5) from sump assembly (3).
8. Remove plug (16), and packing (17). Discard packing.
9. Remove drain valve (10) and packing (9). Discard packing.
11. Install protective caps and/or plugs (C-428) on open end of fittings (2).
28-20-29
Page 1
E-AB412-PT6T-2
3. BOOST PUMPS - INSTALLATION
MATERIALS REQUIRED
NUMBER NOMENCLATURE
C-405 LOCKWIRE
1. Remove the protective cover, caps and/or plugs, from the fuel cell opening and the fitting (2, figure 1)
2. Apply assembly fluid (C-024) to packings (9, 13, 15 and 17).
3. Place packing (9) on pump drain valve (10). Install pump drain valve.
4. Install plug (16) and packing (17).
5. Install washer (12) on bolt (11). Install packings (13 and 15) on retainer (14).
6. Install retainer (14) on bolt (11).
8. Coat gasket (4) with assembly fluid (C-024). Install gasket (4) on boost pump (5).
9. Insert pump (5) into sump assembly (3).
10. Align pump (5) with fitting (2) and install bolt (11) and apply lockwire (C-405).
11. Install ground wire on nearest bolt (8).
28-20-29
Page 2
E-AB412-PT6T-2
G6AB0388A
Figure 1. Boost pump (helicopters codes [C][D])
28-20-29
Page 3
E-AB412-PT6T-2
28-20-29
Page 4
E-AB412-PT6T-2
28-20-30 FUEL STORAGE AND DISTRIBUTION SYSTEM (HELICOPTERS CODES [C][D]) - CANISTER TYPE BOOST PUMP
28-20-30
[C][D]) - CANISTER TYPE BOOST PUMP
1. CANISTER TYPE BOOST PUMP - DESCRIPTION
The canister type boost pumps are electrically operated by 28 Vdc circuits controlled by separate switches. Each pump
incorporates an integral cartridge pumping element. These pumps are applicable to helicopter equipped with canister type
pumps P/N 206-062-687-101.
NOTE
Maintenance procedures for left and right canister type boost pumps are the same.
2. CANISTER TYPE BOOST PUMP - REMOVAL
MATERIALS REQUIRED
NUMBER NOMENCLATURE
3. Remove sump access cover.
4. Drain trapped fuel through drain plug (10, figure 1).
5. Disconnect electrical leads (2) from boost pump (12).
6. Remove bolt (9), washer (8), packings (5 and 7) and plug (6). Discard packings.
7. Remove bolts (4) and washers (3). Remove boost pump (12) and gasket (1) from sump assembly (13). Discard gasket.
8. Install protective covers over cell opening and protective caps and/or plugs (C-428) on the open end of the fitting (14).
28-20-30
Rev. 3 Page 1
E-AB412-PT6T-2
3. CANISTER TYPE BOOST PUMP - INSTALLATION
MATERIALS REQUIRED
NUMBER NOMENCLATURE
C-405 LOCKWIRE
1. Remove the protective covers from the cell opening and protective caps and/or plugs from the fitting (14, figure 1).
2. Apply assembly fluid (C-024) to packing (11) and install on plug (10).
3. Install plug (10) in base of pump at cartridge drain point.
4. Lubricate packings (5 and 7) with assembly fluid (C-024) and install on plug (6).
5. Install washer (8) on bolt (9). Insert bolt through plug (6) and into discharge port of pump.
6. Coat gasket (1) with assembly fluid (C-024). Install gasket (1) on boost pump (12).
7. Position boost pump (12) on sump assembly (13). Align pump (12) with fitting (14). Tighten bolt (9) and ensure fitting
(14) seats in discharge port.
10. Secure plug (10) and bolt (9) with lockwire (C-405).
12. Service fuel system, (Chapter 12).
13. Perform operational check on boost pump (12) (Chapter 96).
15. Install sump access cover.
28-20-30
Page 2 Rev. 3
E-AB412-PT6T-2
1. Gasket
2. Electrical leads
3. Washer
4. Bolt
5. Packing
6. Plug
7. Packing
8. Washer
9. Bolt
10. Plug
11. Packing
12. Boost pump
13. Sump assembly
14. Fitting
15. Hose
G6AB0389B
Figure 1. Canister type boost pump (helicopters codes [C] [D])
28-20-30
Rev. 3 Page 3
E-AB412-PT6T-2
28-20-30
Page 4 Rev. 3
E-AB412-PT6T-2
28-20-31 FUEL STORAGE AND DISTRIBUTION SYSTEM (HELICOPTERS CODES [C][D]) - CANISTER TYPE BOOST PUMP CARTRIDGE
28-20-31
[C][D]) - CANISTER TYPE BOOST PUMP CARTRIDGE
1. CANISTER TYPE BOOST PUMP CARTRIDGE - DESCRIPTION
The canister type boost pump incorporates an integral cartridge pumping element. Replacement of element reduces damage
to fuel cell components and eliminates need to break cell-to-pump seal during routine maintenance.
2. CANISTER TYPE BOOST PUMP CARTRIDGE - REMOVAL
NUMBER NOMENCLATURE
T75 CARTRIDGE REMOVAL TOOL
2. Remove lockwire.
CAUTION
KEEP THE SPRING (12, FIGURE 1) DEPRESSED DURING REMOVAL OF

THE SCREW (10). THIS IS TO PREVENT DAMAGE TO VALVE STEM (13).
3. Put thumb on valve arm (9) above spring (12). Press valve arm (9) in toward pump housing and remove screw (10).
4. Disconnect black (+) positive lead from cartridge terminal and remove cable assembly (8).
5. Rotate valve arm (9) away from cartridge (4).
6. Remove drain plug, with packing, from cartridge center drain port (6) and allow trapped fuel to drain. Discard packing.
7. Using a small screwdriver, pry end of retaining ring (11) from seat in pump housing (7). Put screwdriver tip between
retaining ring and pump housing. Rotate pump housing counterclockwise to remove retaining ring.
8. Install cartridge removal tool (5) (T75) in drain port (6) and secure with check nut. Slide hammer of cartridge removal
tool (5) against bolt head to remove cartridge (4) from fuel boost pump. Remove tool from cartridge.
9. Use a wooden or plastic probe to remove packings. Do not use a screwdriver or other sharp metal tool. Remove three
packings (2 and 3) from pump cartridge (4). Discard packings.
28-20-31
Rev. 3 Page 1
E-AB412-PT6T-2
NOTE
For cartridge repair, return to: Airborne, Aviation Products Group, 711 Taylor Street,
Elyria, Ohio 44035.
10. Install protective cover on cartridge opening.
3. CANISTER TYPE BOOST PUMP CARTRIDGE - INSTALLATION
MATERIALS REQUIRED
NUMBER NOMENCLATURE
C-008 PETROLATUM
C-405 LOCKWIRE
1. Remove protective cover from cartridge opening.
2. Apply a thin coat of petrolatum (C-008) to packings (2 and 3, figure 1). Install smaller packing into top groove, and
remaining packings in lower two grooves of cartridge (4).
CAUTION
DO NOT USE CARTRIDGE REMOVAL TOOL FOR CARTRIDGE

INSTALLATION. USE THUMB PRESSURE ONLY.
3. Install cartridge (4) half way into pump housing (7). Align matchmarks on pump housing and cartridge. Using thumb
pressure only, push firmly on cartridge until it is fully seated on housing.
4. Install one end of retaining ring (11) into ring groove in pump housing (7). Hold end of retaining ring in groove. Use
index finger to spiral retaining ring into groove, a little at a time.
5. Install drain plug in cartridge drain port (6) with new packing.
CAUTION
KEEP THE SPRING (12, FIGURE 1), DEPRESSED DURING INSTALLATION

OF THE SCREW (10). THIS IS TO PREVENT DAMAGE TO VALVE STEM (13).
6. Put thumb on valve arm (9) above spring (12). Press and rotate valve arm (9) over cartridge and in line with minus (-)
terminal. Insert white (-) negative lead terminal under bar and secure both with screw (10).
7. Connect black (+) positive lead terminal to (+) terminal on cartridge, do not overtorque.
8. Secure drain plugs, fitting through bolt, and allen screw with lockwire (C-405).
9. Perform boost pump operational check (Chapter 96).
28-20-31
Page 2 Rev. 3
E-AB412-PT6T-2
CAUTION
CARTRIDGE PUMPS ARE COOLED AND LUBRICATED BY FUEL WHICH

EXITS THROUGH TOP UMBRELLA CHECK VALVE (1) ON PUMP/
CARTRIDGE HOUSING. DO NOT RUN DRY.
10. Ensure pumps are covered with fuel. Refuel helicopter, as required.
11. Check cartridge/pump for leakage.
12. Install sump access cover.
4. CANISTER TYPE BOOST PUMP CARTRIDGE - CLEANING
1. Remove all foreign matter from cartridge bore, retaining ring groove in pump housing, and from retaining ring.
5. CARTRIDGE PUMP COVER PACKING - REPLACEMENT
MATERIALS REQUIRED
NUMBER NOMENCLATURE
1. Remove cartridges from housing (paragraph "2. Canister type boost pump cartridge - removal").
CAUTION
KEEP PUMP COVER (15, FIGURE 1) END UP AT ALL TIMES AS THE

IMPELLER (18) COULD DROP OFF THE END OF THE MOTOR SHAFT IF
THE IMPELLER KEY (19) BECOMES DISLODGED. THE IMPELLER KEY
CANNOT BE INSTALLED WITHOUT COMPLETE MOTOR DISASSEMBLY.
2. Remove Spirolox retaining ring (14).
3. Install suitable fitting in threaded hole of pump cover (15) to permit removal of pump cover by pulling straight out of
housing bore.
CAUTION
THE INLET SEAL PACKING (17) SHOULD REMAIN IN THE HOUSING

BORE. DO NOT DISTURB. THE INLET SEAL IS BRITTLE CARBON AND
CRACKS EASILY.
4. Remove and replace the pump cover packing (16) only.
28-20-31
Rev. 3 Page 3
E-AB412-PT6T-2
NOTE
The inlet seal packing (17) will not need to be replaced as its function does not effect
pump leakage.
5. Coat the pump cover packing (16) and housing bore with assembly fluid (C-024) and press the pump cover (15) into
the housing bore using thumb pressure only. Make sure that the Spirolox retaining ring (14) groove is exposed above
the cover.
6. If the cover will not go into the bore deep enough to expose the retaining ring groove, the inlet seal (20) has become
cocked. Remove the cover and correct the seating position of the inlet seal before proceeding.
7. With the pump cover (14) installed in its proper position, install the Spirolox retaining ring (14).
8. Install the cartridge in the pump housing (paragraph "3. Canister type boost pump cartridge - installation").
28-20-31
Page 4 Rev. 3
E-AB412-PT6T-2
1 B
BOOST PUMP WITH CARTRIDGE
REMOVAL TOOL INSTALLED
2 4 6
13
3
9 7
10 B
A
8
PRESS
HERE 9 1. Check valve
10 MATCHMARKS 2. Packing
12 3. Packing
4. Cartridge
5. Cartridge removal tool (T75)
6 6. Drain port
7. Pump housing
8. Cable assembly
9. Valve arm
10. Screw
11. Retaining ring
12. Spring
11 13. Valve stem
4
POSITIVE
TERMINAL
G6AB1048A
Figure 1. Boost pump cartridge (sheet 1 of 2)
28-20-31
Rev. 3 Page 5
E-AB412-PT6T-2
2
3
20
14
15
19
16 17 SECTION B-B
18
CAUTION:
Keep this end up during disassembly,

handling while disassembled, and
reassembly to prevent impeller falling off end
of shaft. If impeller falls off, the key cannot be
reinstalled without complete disassembly.
LOCKWIRE (C-405)
14. Spirolox retaining ring

15. Pump cover
16. Pump cover packing
17. Inlet seal packing
18. Impeller
19. Impeller key
20. Inlet seal
G6AB0391C
Figure 1. Boost pump cartridge (sheet 2 of 2)
28-20-31
Page 6 Rev. 3
E-AB412-PT6T-2
28-20-32 FUEL STORAGE AND DISTRIBUTION SYSTEM (HELICOPTERS CODES [C][D]) - FLOW SWITCH CHECK VALVES
28-20-32
[C][D]) - FLOW SWITCH CHECK VALVES
1. FLOW SWITCH CHECK VALVES - DESCRIPTION
A flow switch check valve is mounted on sump assembly of each lower main cell and is attached to the end of hose from
output port of ejector pump. The flapper type check valve prevents backflow of fuel from lower main cell to lower middle
cell, but allows forward flow of fuel from lower middle cell to lower main cell. The check valve contains a flow switch with
contacts that are closed when no flow exists, and open when fuel flow exists. When switch contacts are closed, the FUEL
TRANS caution lights will be illuminated, provided fuel is present in forward or midtanks.
2. FLOW SWITCH CHECK VALVES - REMOVAL
1. Remove lower main cell sump assembly (module 28-20-28 paragraph "2. Lower main cell sump assemblies -
removal").
2. Remove nut (5, figure 1) and washer (4).
3. Remove flow switch check valve (1) and packing (2) from sump assembly (3). Discard packing.
28-20-32
Rev. 1 Page 1
E-AB412-PT6T-2
3. FLOW SWITCH CHECK VALVES - INSTALLATION
MATERIALS REQUIRED
NUMBER NOMENCLATURE
2. Install flow switch check valve (1) and packing (2) through sump assembly (3).
3. Install washer (4) and nuts (5). Tighten the nut.
4. For helicopters code [D], make sure that the directional arrow on the flow switch check valve (1) points towards the
aft of the helicopter.
NOTE
Ensure directional arrow is positioned properly and flow switch check valve
operates correctly before returning sump assembly to service.
5. Install lower main cell sump assembly (module 28-20-28 paragraph "3. Lower main cell sump assemblies -
installation").
28-20-32
Page 2 Rev. 1
E-AB412-PT6T-2
HELICOPTERS CODE D
MODIFIED WITH FUEL CONNECTION
INTO AFT CENTER CELL.
HELICOPTERS CODE C
1. Flow switch check valve

2. Packing
3. Sump assembly
4. Washer
5. Nut
G6AB0392B
Figure 1. Flow switch check valve (helicopters codes [C][D])
28-20-32
Rev. 1 Page 3
E-AB412-PT6T-2
28-20-32
Page 4 Rev. 1
E-AB412-PT6T-2
28-20-3 FUEL STORAGE AND DISTRIBUTION SYSTEM (HELICOPTERS CODES [C][D]) - SUMP DRAIN VALVES
28-20-33
An electrically (or mechanically) operated sump drain valve is mounted on the sump assembly of each lower main cell. The
sump drain valve may be electrically operated by pushing a push-button switch, or may be mechanically operated. The sump
drain valves provide for draining off possible moisture or other contamination.
NOTE
Maintenance procedures are the same for both right and left lower main sump drain
valves.
MATERIALS REQUIRED
NUMBER NOMENCLATURE
3. Remove drain valve (10, figure 1) packing (9). Discard packing.
4. Install protective cover, caps and/or plugs (C-428) over cell opening.
MATERIALS REQUIRED
NUMBER NOMENCLATURE
2. Apply assembly fluid (C-024) to packing (9, figure 1) before installation.
3. Install packing (9) and drain valve (10) in sump assembly (3).
28-20-33
Page 1
E-AB412-PT6T-2
28-20-33
Page 2
E-AB412-PT6T-2
DETAIL A
HELICOPTERS CODE D
G6AB0393A
Figure 1. Lower main cell sump assembly (helicopters codes [C][D])
28-20-33
Page 3
E-AB412-PT6T-2
28-20-33
Page 4
E-AB412-PT6T-2
28-20-34 FUEL STORAGE AND DISTRIBUTION SYSTEM (HELICOPTERS CODES [C][D]) - INTERCONNECT VALVE
28-20-34
[C][D]) - INTERCONNECT VALVE
1. INTERCONNECT VALVE - DESCRIPTION
A motor-operated interconnect valve is located in interconnect line between right and left lower main cells. The interconnect
valve is operated by the FUEL INTCON switch on engine and fuel control panel. The valve is normally closed to provide
isolation of the two power section fuel supplies, but may be opened to permit crossflow when fuel levels are low. Valve opens
automatically if low fuel level condition occurs.
2. INTERCONNECT VALVE - REMOVAL
4. Disconnect hoses (5 and 11).
5. Remove screws (12), washers (3), and nuts (4).
6. Remove valve (8), connectors (6 and 10), and packings (7 and 9) from bracket (2). Discard packings.
7. Cap openings or plug openings.
28-20-34
Page 1
E-AB412-PT6T-2
3. INTERCONNECT VALVE - INSTALLATION
MATERIALS REQUIRED
NUMBER NOMENCLATURE
C-024 PETROLATUM
1. Remove the protective caps and/or plugs from the hose assemblies (5 and 11, figure 1).
3. Place packings (7 and 9) and connectors (6 and 10) on interconnect valve (8).
4. Position the interconnect valve (8) and connectors (6 and 10) on bracket (2). Install screws (12), thin aluminum
washers (3) and nuts (4). Tighten the nuts.
28-20-34
Page 2
E-AB412-PT6T-2
G6AB0394A
Figure 1. Interconnect valve (helicopters codes [C] [D])
28-20-34
Page 3
E-AB412-PT6T-2
28-20-34
Page 4
E-AB412-PT6T-2
28-20-35 FUEL STORAGE AND DISTRIBUTION SYSTEM (HELICOPTERS CODES [C][D]) - FILLER CAP AND ADAPTER ASSEMBLY
28-20-35
[C][D]) - FILLER CAP AND ADAPTER ASSEMBLY
1. FILLER CAP AND ADAPTER ASSEMBLY - DESCRIPTION
NOTE
The following maintenance procedures are for helicopters code [C] not equipped
with filler cap P/N 412-061-668-101.
The fuel system filler cap and adapter assembly is mounted on the upper outboard side of upper right cell. A spring-loaded
plate on inside of assembly serves as a fuel seal in event cap opens accidentally.
2. FILLER CAP AND ADAPTER ASSEMBLY - REMOVAL
3. Remove screws (1, figure 1), washers (2), retainer (3), filler cap and adapter assembly (4), and packing (5). Discard packing.
3. FILLER CAP AND ADAPTER ASSEMBLY - INSTALLATION
MATERIALS REQUIRED
NUMBER NOMENCLATURE
3. Install filler cap and adapter assembly (4) and retainer (3) on cell opening.
4. Install screws (1), washers (2), and ground strap (located at second screw hole).
28-20-35
Page 1
E-AB412-PT6T-2
G6AB0405A
Figure 1. Filler cap and adapter assembly
28-20-35
Page 2
E-AB412-PT6T-2
28-20-36 FUEL STORAGE AND DISTRIBUTION SYSTEM (HELICOPTERS CODES [C][D]) - IMPROVED FILLER CAP AND ADAPTER ASSEMBLY
28-20-36
[C][D]) - IMPROVED FILLER CAP AND ADAPTER ASSEMBLY
1. IMPROVED FILLER CAP AND ADAPTER ASSEMBLY - DESCRIPTION
NOTE
The following maintenance procedures apply to helicopters code [D] and code [C]
equipped with filler cap P/N 412-061-668-101.
The improved filler cap and adapter assembly is located on the right aft cell. This filler cap incorporates a spring-loaded
hinge which will minimize fuel and cap loss in the event cap is not locked.
2. IMPROVED FILLER CAP AND ADAPTER ASSEMBLY - REMOVAL
3. Remove screws (1, figure 1), washers (2), four retainers (4), filler cap and adapter assembly (5), and packing (6).
Discard packing.
3. IMPROVED FILLER CAP AND ADAPTER ASSEMBLY - INSTALLATION
MATERIALS REQUIRED
NUMBER NOMENCLATURE
3. Taking care not to disturb packing (6), install cap and adapter assembly (5), with four retainers (4), washers (2), and
screws (1). Locate retainers (4) at the 2, 4, 8, and 10 o'clock position as shown in detail B.
4. Connect ground strip (3) at the one o'clock position.
5. Torque all screws (1) 50 to 100 in.-lbs (5,65 to 11,30 Nm).
CODES [C][D]) - PRESSURE TESTING").
28-20-36
Page 1
E-AB412-PT6T-2
G6AB0406A
Figure 1. Improved filler cap and adapter assembly
28-20-36
Page 2
E-AB412-PT6T-2
28-20-37 FUEL STORAGE AND DISTRIBUTION SYSTEM (HELICOPTERS CODES [C][D]) - ENGINE FUEL FEED LINE PRESSURE SWITCHES
28-20-37
[C][D]) - ENGINE FUEL FEED LINE PRESSURE SWITCHES
1. ENGINE FUEL FEED LINE PRESSURE SWITCHES - DESCRIPTION
An engine fuel feed line pressure switch is installed in each power section fuel feed line. These switches are located in front
of bulkhead at F.S. 154 contacts are closed when no fuel pressure exists and open when normal fuel pressure is present. The
FUEL BOOST caution lights illuminate when switch contacts are closed.
NOTE
Maintenance procedures for left and right power section fuel feed line pressure
switches (fuel pressure switches) are the same.
2. ENGINE FUEL FEED LINE PRESSURE SWITCHES - REMOVAL
3. Remove access door over cargo hook opening on bottom of helicopter, if installed.
5. Remove fuel pressure switch (3) and packing (2) from bushing (1). Discard packing.
6. Cap or plug open fuel lines.
28-20-37
Rev. 1 Page 1
E-AB412-PT6T-2
3. ENGINE FUEL FEED LINE PRESSURE SWITCHES - INSTALLATION
MATERIALS REQUIRED
NUMBER NOMENCLATURE
C-405 LOCKWIRE
1. Remove caps and plugs from open fuel lines. Remove cap from electrical connector (4).
3. Place packing (2) on threaded end of fuel pressure switch (3).
4. Install fuel pressure switch (3).
6. Secure switch (3) and bushing (7) to tee fitting using lockwire (C-405).
9. Perform fuel pressure system operational test (Chapter 96).
11. Install access door over cargo hook opening, if applicable.
28-20-37
Page 2 Rev. 1
E-AB412-PT6T-2
1. Bushing
2. Packing
3. Fuel pressure switch
G6AB0407B
Figure 1. Fuel feed line pressure switch (helicopters codes [C][D])
28-20-37
Rev. 1 Page 3
E-AB412-PT6T-2
28-20-37
Page 4 Rev. 1
E-AB412-PT6T-2
28-20-38 FUEL STORAGE AND DISTRIBUTION SYSTEM (HELICOPTERS CODES [C][D]) - FUEL FEED LINE CHECK VALVES
28-20-38
[C][D]) - FUEL FEED LINE CHECK VALVES
1. FUEL FEED LINE CHECK VALVES - DESCRIPTION
A check valve (figure 1), with internal orifices for thermal relief, is installed in each of power section fuel feed lines. These
valves are located in front of bulkhead at F.S. 154, (forward of upper forward center cell).
NOTE
Maintenance procedures for left and right feed line check valves are the same.
2. FUEL FEED LINE CHECK VALVES - REMOVAL
MATERIALS REQUIRED
NUMBER NOMENCLATURE
3. Remove access door over cargo hook opening on bottom of helicopter, if installed.
4. Loosen first mounting clamp on fuel feed line below and above check valve (2, figure 1).
5. Disconnect tube assembly (1) from engine fuel feed line check valve (2).
6. Disconnect tube assembly (3) from engine fuel feed line check valve (2).
7. Remove engine fuel feed line check valve (2).
8. Install caps and/or plugs (C-428) on open fuel lines.
28-20-38
Page 1
E-AB412-PT6T-2
3. FUEL FEED LINE CHECK VALVES - INSTALLATION
1. Remove protective caps and plugs.
2. Hold check valve (2, figure 1) in place near tube assembly (1) and tube assembly (3), with large flow arrow on side of
check valve (2) pointing up.
3. Connect the tube assembly (1) on top of threaded portion of engine fuel feed line check valve (2). Tighten nut.
4. Connect the tube assembly (3) on bottom threaded portion of engine fuel feed line check valve (2). Tighten nut.
5. Tighten first mounting clamps above and below check valve.
9. Install access door over cargo hook opening, if applicable
28-20-38
Page 2
E-AB412-PT6T-2
G6AB0408A
Figure 1. Fuel feed line check valve (helicopters codes [C][D])
28-20-38
Page 3
E-AB412-PT6T-2
28-20-38
Page 4
E-AB412-PT6T-2
28-20-39 FUEL STORAGE AND DISTRIBUTION SYSTEM (HELICOPTERS CODES [C][D]) - SHUTOFF VALVES
28-20-39
[C][D]) - SHUTOFF VALVES
1. SHUTOFF VALVES - DESCRIPTION
A motor-operated shutoff valve (figure 1) is installed in each fuel feed line above fuel feed line check valves. These valves
are located on front of lower forward engine firewall. The shutoff valves are controlled by ENGINE 1 and ENGINE 2 FUEL
switches on engine and fuel control panel. The valves have manual override handles which also serve as valve position
indicators. Thermal relief valves are incorporated for internal bypass of trapped fuel when system is inoperative.
NOTE
Maintenance procedures for left and right shutoff valves are the same.
2. SHUTOFF VALVES - REMOVAL
MATERIALS REQUIRED
NUMBER NOMENCLATURE
3. Remove access door on side of pylon support in cabin.
5. Disconnect tubes (1 and 14) from the tee reducer (2).
6. Remove the tee reducer (2) if connector (4) is to be replaced.
7. Disconnect tube (8) from connector (7).
9. Remove valve (6), connectors (4 and 7), and packings (9 and 10). Discard packings.
10. Install caps and/or plugs (C-428) on open ends of tubes (1, 8, and 14).
28-20-39
Page 1
E-AB412-PT6T-2
3. SHUTOFF VALVES - INSTALLATION
MATERIALS REQUIRED
NUMBER NOMENCLATURE
2. Position packings (9 and 10) and connectors (4 and 7) on body of valve (6).
NOTE
Screws (13) securing bracket (3) to deck can be loosened as necessary to provide
clearance for installation of shutoff valve (6).Install fuel pressure switch (3).
3. Position shutoff valve (6) between bracket (3) and firewall.
4. Insert two upper screws (12) and washers (11). Start upper screws into firewall nutplates.
5. Install two lower screws (12) and washers (11). Tighten all four screws (12).
6. Tighten screws (13), if loosened.
7. Install tee reducer (2), if removed.
8. Connect tubes (1 and 14) to the tee reducer (2).
9. Connect tube (8) to connector.
13. Perform operational check on shutoff valve (Chapter 96).
28-20-39
Page 2
E-AB412-PT6T-2
G6AB0409A
Figure 1. Shutoff valve (helicopters codes [C][D])
28-20-39
Page 3
E-AB412-PT6T-2
28-20-39
Page 4
E-AB412-PT6T-2
28-20-40 FUEL STORAGE AND DISTRIBUTION SYSTEM (HELICOPTERS CODES [C][D]) - CROSSFEED VALVE
28-20-40
[C][D]) - CROSSFEED VALVE
1. CROSSFEED VALVE - DESCRIPTION
A crossfeed valve (figure 1) is located above and between shutoff valves on front of lower forward engine firewall. This
valve is normally closed so fuel is supplied to each power section from the isolated lower main cell on the same side of the
helicopter. If boost pump in either lower main cell ceases to function, the crossfeed valve opens automatically and fuel flows
from remaining operating boost pump to both power sections.
2. CROSSFEED VALVE - REMOVAL
MATERIALS REQUIRED
NUMBER NOMENCLATURE
2. Remove transmission cowling.
4. Disconnect tubes (1 and 8) from connectors (4 and 9).
5. Remove screws (7), nuts (2) and thin aluminum washers (3).
6. Remove crossfeed valve (11), connectors (4 and 9) and packings (5 and 10). Discard packings.
7. Install protective caps and/or plugs (C-428) to the tubes (1 and 8) open end fittings.
28-20-40
Page 1
E-AB412-PT6T-2
3. CROSSFEED VALVE - INSTALLATION
MATERIALS REQUIRED
NUMBER NOMENCLATURE
1. Apply assembly fluid (C-024) to packing (5 and 10, figure 1).
2. Put the packings (5 and 10) and the connectors (4 and 9) in position on the crossfeed valve (11).
3. Install two forward screws (7), thin aluminum washers (3) and nuts (2). Do not tighten the screws at this time.
4. Put the crossfeed valve (11) and the connectors (4 and 9) in position on the bracket (6).
5. Install two aft screws (7), thin aluminum washers (3) and nuts (2). Tighten the four screws.
6. Connect tubes (1 and 8) to connectors (4 and 9).
8. Perform operational check of crossfeed valve (11) (Chapter 96).
12. Install transmission cowling
28-20-40
Page 2
E-AB412-PT6T-2
G6AB0410A
Figure 1. Crossfeed valve (helicopters codes [C][D])
28-20-40
Page 3
E-AB412-PT6T-2
28-20-40
Page 4
E-AB412-PT6T-2
28-20-41 FUEL STORAGE AND DISTRIBUTION SYSTEM [C] [D] - FUEL PRESSURE TRANSMITTERS
28-20-41
FUEL STORAGE AND DISTRIBUTION SYSTEM [C] [D] - FUEL PRESSURE
TRANSMITTERS
1. FUEL PRESSURE TRANSMITTERS - DESCRIPTION
An electrical fuel pressure transmitter (figure 1) is connected in each power section fuel feed line. The fuel pressure
transmitters are sensor units for the fuel pressure indicating system, which provide indicator readings of fuel pressure. The
transmitters are mounted on left and right sides of upper forward engine firewall.
NOTE
Maintenance procedures for left and right fuel pressure transmitters are the same.
2. FUEL PRESSURE TRANSMITTERS - REMOVAL
4. Disconnect electrical connector, (1, figure 1).
7. Remove nut (9) and corrosion resistant steel washer (8).
8. Remove pressure transmitter (4). Remove plug (2) and packing (3). Discard packing.
9. Cap or plug tube (12) and electrical connector (1).
28-20-41
Page 1
E-AB412-PT6T-2
3. FUEL PRESSURE TRANSMITTERS - INSTALLATION
MATERIALS REQUIRED
NUMBER NOMENCLATURE
C-008 PETROLATUM
2. Apply petrolatum (C-008) to packing (3, figure 1) before installation. Install plug (2) and packing (3).
3. Position pressure transmitter (4) on bracket (7). Install corrosion resistant steel washer (8) and nut (9).
4. Apply petrolatum lubricant (C-008) to packing (10) before installation. Install packing (10) and union (11).
9. Perform operational check (Chapter 96).
28-20-41
Page 2
E-AB412-PT6T-2
G6AB0411A
Figure 1. Left and right fuel pressure transmitter (helicopters codes [C] [D])
28-20-41
Page 3
E-AB412-PT6T-2
28-20-41
Page 4
E-AB412-PT6T-2
28-40-01 FUEL STORAGE AND DISTRIBUTION SYSTEM (HELICOPTERS CODES [A][B]) - PRESSURE TESTING
28-40-01
[A][B]) - PRESSURE TESTING
1. PRESSURE TESTING - DESCRIPTION
CAUTION
ENSURE FUEL CELL ACCESS PANELS ARE INSTALLED PRIOR TO

APPLYING INFLATION PRESSURE.
NOTE
For field pressure test of the fuel system, fill the helicopter fuel cells with fuel.
Inspect fuel system and the area affected by the work accomplished for leaks. Repeat
the inspection procedures several times as the fuel cells are being filled.
2. Use regulated, low pressure, filtered, compressed nitrogen or compressed air source with a manometer or accurate
pressure gage and a shutoff valve.
CAUTION
DO NOT APPLY MORE THAN 1,0 PSIG (6,9 KPA) PRESSURE TO FUEL
SYSTEM. SEVERE DAMAGE TO CELLS AND STRUCTURE MAY RESULT.
3. Apply 0,5 to 1,0 psig (3,5 to 6,9 kPa) pressure to all cells and tubing of the fuel system. Shut off pressure source. Verify
pressure does not decrease after 15 minutes.
4. If leakage is detected, apply a soap and water solution to all repaired areas and to areas suspected of leaking. Make
repairs and repeat pressure test until no leaks are indicated.
NOTE
For field pressure test of the fuel system, fill the helicopter fuel cells with fuel.
Inspect fuel system and the area affected by the work accomplished for leaks. Repeat
the inspection procedures several times as the fuel cells are being filled.
5. Upon satisfactory conclusion of test, remove soap residue and remove all caps and plugs used to close off system.
28-40-01
Page 1
E-AB412-PT6T-2
28-40-01
Page 2
E-AB412-PT6T-2
28-40-02 FUEL STORAGE AND DISTRIBUTION SYSTEM (HELICOPTERS CODES [A][B]) - FUEL PRESSURE TRANSMITTERS
28-40-02
[A][B]) - FUEL PRESSURE TRANSMITTERS
1. FUEL PRESSURE TRANSMITTERS - DESCRIPTION
Two electrical fuel pressure transmitters (3 and 6, figure 1) for the fuel pressure indicating system are connected to main fuel
lines to the engine power sections. The transmitters are mounted on left and right rear sides of forward engine firewall.
NOTE
Maintenance procedures for left and right fuel pressure transmitters are the same.
2. FUEL PRESSURE TRANSMITTERS - REMOVAL
4. Disconnect electrical connector (1, figure 2) from pressure transmitter (4) located on cabin bulkhead.
7. Remove nut (9) and washer (8).
8. Remove pressure transmitter (4). Remove plug (2) and packing (3). Discard packing.
3. FUEL PRESSURE TRANSMITTERS - INSTALLATION
MATERIALS REQUIRED
NUMBER NOMENCLATURE
C-008 PETROLATUM
1. Apply petrolatum (C-008) to packing (3, figure 2).
2. Remove protective caps or plugs. Install plug (2) and packing (3).
3. Position pressure transmitter (4) on bracket (7). Install washer (8) and nut (9).
4. Install packing (10) and union (11).
28-40-02
Page 1
E-AB412-PT6T-2
28-40-02
Page 2
E-AB412-PT6T-2
G6AB0322A
28-40-02
Page 3
E-AB412-PT6T-2
G6AB0323A
28-40-02
Page 4
E-AB412-PT6T-2
G6AB0345A
Figure 2. Fuel pressure transmitter (helicopters codes [A][B])
28-40-02
Page 5
E-AB412-PT6T-2
28-40-02
Page 6
E-AB412-PT6T-2
28-40-03 FUEL STORAGE AND DISTRIBUTION SYSTEM (HELICOPTERS CODES [A][B]) - FUEL QUANTITY PROBES
28-40-03
[A][B]) - FUEL QUANTITY PROBES
1. FUEL QUANTITY PROBES - DESCRIPTION
Five cell mounted fuel quantity probes (tank units) (1 through 5, figure 1) are used to measure quantity (weight) of fuel in
the system. The probes are variable capacitors in which capacitance varies with changes in dielectric constant of fuel and air
present between tubes (capacitor plates) of probes. The level and density of fuel in cells determine dielectric constant. Probe
capacitance is transmitted to a self-balancing bridge network in the indicator.
Refer to Chapter 52 for locations of doors, panels, cowlings, and covers which must be removed for access to fuel system
components.
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E-AB412-PT6T-2
G6AB0356A
Figure 1. Fuel quantity probes (helicopters codes [A][B])
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E-AB412-PT6T-2
28-40-04 FUEL STORAGE AND DISTRIBUTION SYSTEM (HELICOPTERS CODES [A][B]) - FORWARD CELL FUEL QUANTITY PROBES
28-40-04
[A][B]) - FORWARD CELL FUEL QUANTITY PROBES
1. FORWARD CELL FUEL QUANTITY PROBES - DESCRIPTION
Each compartment of the forward cells contains a fuel quantity probe.
NOTE
Maintenance procedures for forward left and right cell fuel quantity probes are the
same.
2. FORWARD CELL FUEL QUANTITY PROBES - REMOVAL
2. Remove forward fuel quantity probe (1, figure 1) as follows:
a. Remove right or left floor panel as applicable.
b. Remove screws (22) and cover (23).
c. Remove bolt (10), spacers (3 and 9), and washer (4).
d. Remove bolt (7) and washer (5).
e. Route electrical leads (2) over baffle (21) and remove forward fuel quantity probe (1).
f. Remove clamps (6) and (8).
3. Remove aft fuel quantity probe (12) as follows:
a. Remove bolt (20), spacer (14), and washer (15).
b. Remove bolt (18) and washer (16).
NOTE
Verify electrical leads (13) were disconnected when sump assembly was removed.
c. Remove aft fuel quantity probe (12) and clamps (17 and 19).
4. Install protective cover on cell sump opening.
28-40-04
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E-AB412-PT6T-2
G6AB0357A
Figure 1. Forward cell fuel quantity probe (helicopters codes [A][B])
28-40-04
Page 2
E-AB412-PT6T-2
3. FORWARD CELL FUEL QUANTITY PROBES - INSTALLATION
1. Install forward fuel quantity probe (1, figure 1) as follows:
a. Remove protective cover from sump opening. Place clamps (6 and 8) on forward fuel quantity probe (1).
b. Align clamps (6 and 8) over attachment points in cell.
c. Place bolt (10) through clamp on hose (11). Use spacer (9), clamp (8), spacer (3), and washer (5). Install bolt
(10) in cell. Torque bolt (10) 30 to 40 in.-lbs. (3,39 to 4,52 Nm).
d. Place bolt (7) through clamp (6) and washer (5). Install bolt (7) in cell. Torque bolt (7) 30 to 40 in.-lbs. (3,39 to
4,52 Nm).
e. Route electrical leads (2) over baffle (21).
f. Install cover (23) and screws (22).
g. Install floor panel.
2. Install aft fuel quantity probe (12) as follows:
a. Remove protective cover from sump opening. Place clamps (17 and 19) on aft fuel quantity probe (12). Align
clamps (17 and 19) over attachment points in cell.
b. Place bolt (20) through clamp (19), spacer (14), and washer (15). Install bolt (20) in cell. Torque bolt (20) 30 to
40 in.-lbs. (3,39 to 4,52 Nm).
c. Place bolt (18) through clamp (17) and washer (16). Install bolt (18) in cell. Torque bolt (18) 30 to 40 in.-lbs.
(3,39 to 4,52 Nm).
NOTE
Electrical leads (13) will be connected when sump is installed at step 3. below:
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28-40-05 FUEL STORAGE AND DISTRIBUTION SYSTEM (HELICOPTERS CODES [A][B]) - CENTER AFT CELL FUEL QUANTITY PROBE
28-40-05
[A][B]) - CENTER AFT CELL FUEL QUANTITY PROBE
1. CENTER AFT FUEL QUANTITY PROBE - DESCRIPTION
The center aft cell contains a single fuel quantity probe mounted on a support on right wall of cell.
2. CENTER AFT FUEL QUANTITY PROBE - REMOVAL
1. Remove center aft cell rear cover (module 28-10-10 paragraph "1. Center aft cell rear cover - removal"). Do not install
protective cover over cell opening at this time.
2. Remove straps (6, figure 1). Remove fuel quantity probe (2).
3. Remove bolts (3), washers (4), and support (5).
3. CENTER AFT FUEL QUANTITY PROBE - INSTALLATION
2. Position support (5, figure 1) on wall of center aft fuel cell. Install volts (3) and washers (4). Torque bolts (3) 50 to 100
in.-lbs. (5,65 to 11,30 Nm).
3. Position fuel quantity probe (2) in clips (1). Install straps (6).
4. Connect electrical leads to quantity probe and install center aft cell rear cover (module 28-10-10 paragraph "2. Center
aft cell rear cover - installation").
28-40-05
Page 1
E-AB412-PT6T-2
G6AB0358A
Figure 1. Center cell fuel quantity probe (helicopters codes [A][B])
28-40-05
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E-AB412-PT6T-2
28-40-06 FUEL STORAGE AND DISTRIBUTION SYSTEM (HELICOPTERS CODES [C][D]) - PRESSURE TESTING
28-40-06
[C][D]) - PRESSURE TESTING
1. PRESSURE TESTING - DESCRIPTION
NOTE
For field pressure test of the fuel system, an alternate method is to fill the helicopter
fuel cells with fuel. Inspect fuel system and the area affected by the work
accomplished for leaks. Repeat the inspection procedure to check for leaks several
times as the fuel cells are being filled.
CAUTION
ENSURE FUEL CELL ACCESS PANELS ARE INSTALLED PRIOR TO

APPLYING PRESSURE.
2. Use regulated, low pressure, filtered, compressed nitrogen or compressed air source with a manometer or accurate
pressure gage and a shutoff valve.
CAUTION
DO NOT APPLY MORE THAN 1.0 PSIG (6.9 KPA) PRESSURE TO CELLS.
DAMAGE TO CELLS AND STRUCTURE MAY RESULT.
3. Apply 0.5 to 1.0 psig (3.5 to 6.9 kPa) pressure to all cells and tubing of the fuel system. Shut off pressure source. Verify
pressure does not decrease during 15 minute time period.
4. If leakage is detected, apply a soap and water solution to all repaired areas and to areas suspected of leaking. Make
repairs and repeat pressure test until no leaks are indicated.
5. Upon satisfactory conclusion of test, remove soap residue and remove all caps and plugs used to close off system.
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Page 2 Rev. 2
E-AB412-PT6T-2
28-40-07 FUEL STORAGE AND DISTRIBUTION SYSTEM (HELICOPTERS CODES [C][D]) - FORWARD TO MIDDLE FUEL CELL LEAK CHECK
28-40-07
[C][D]) - FORWARD TO MIDDLE FUEL CELL LEAK CHECK
1. FORWARD TO MIDDLE FUEL CELL LEAK - DESCRIPTION
1. Verify zero fuel indicator.
2. Open both middle tank sump drain valves.
3. Open both forward sump drain valves.
4. Push “IN” all fuel circuit breakers.
5. Verify that fuel valve switches, boost pump switches and transfer pump switches are in “OFF” position.
CAUTION
DO NOT TURN BOOST PUMP OR TRANSFER SWITCHES “ON” UNTIL

AFTER MID TANK LEAK CHECK IS COMPLETED.
6. Turn fuel interconnect switch to “OPEN” and verify that crossfeed switch, is on “NORMAL” position.
7. Check that the fuel interconnect light and fuel caution light go out at approximately 450 lb (204 kg) or 70 ga (265 L).
Fuel the helicopter to 700 lb (317,5 kg) or 108 gal (408,8 L).
8. After 5 to 10 minutes, check for fuel leaking out of the middle tank sump drain valves. This checks for leaks between
the middle tanks and main tanks. Close both forward sump drain valves.
9. Fuel the helicopter to 1200 lbs (544,3 kg) or 184 gal (696,5 L).
10. After 5 to 10 minutes, check for fuel leaking out of the middle tank sump drain valves. This checks for leaks between
forward and middle tanks.
28-40-07
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28-40-08 FUEL STORAGE AND DISTRIBUTION SYSTEM (HELICOPTERS CODES [C][D]) - FUEL QUANTITY PROBES
28-40-08
[C][D]) - FUEL QUANTITY PROBES
1. FUEL QUANTITY PROBES - DESCRIPTION
Eight cell mounted fuel quantity probes (tank units) (1 through 8, figure 1) are used to measure quantity (weight) of fuel in
system. The probes are variable capacitors in which capacitance varies with changes in dielectric constant of fuel and air
dielectric material present between tubes (capacitor plates) of probes. The level and density of fuel in cells determine
dielectric constant. Probe capacitance is transmitted to a self-balancing bridge network in the fuel level indicator.
2. FUEL QUANTITY PROBES - LOWER FORWARD CELL FUEL QUANTITY PROBES
2-1. LOWER FORWARD CELL FUEL QUANTITY PROBES - DESCRIPTION
A fuel quantity probe is mounted on inboard wall of each lower forward cell. The base of each probe supports a fuel level
sensor (thermistor) which causes the transfer pump to shut off automatically when cell is emptied. With cell empty, the
thermistor also provides a ground path to the signal conditioner to extinguish the associated “no transfer” (NO 1 FUEL
TRANS or NO 2 FUEL TRANS) caution light segment. When the thermistor is covered with fuel, the ground path is open,
and caution light remains on as long as the flow switch check valve senses there is no transfer flow.
NOTE
Maintenance procedures for lower left forward and lower right forward cell fuel
quantity probes are the same.
2-2. LOWER FORWARD CELL FUEL QUANTITY PROBES - REMOVAL
MATERIALS REQUIRED
NUMBER NOMENCLATURE
1. Remove sump assembly (2, figure 2) (module 28-20-18 paragraph "2. Lower forward cell sump assemblies -
removal").
3. Remove bolts (3), washers (4), and spacers (5).
5. Install protective cover over cell sump opening.
6. Install protective caps and/or plugs (C-428) on the electrical connector (1).
28-40-08
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E-AB412-PT6T-2
2-3. LOWER FORWARD CELL FUEL QUANTITY PROBES - INSTALLATION
1. Remove protective cover from cell sump opening.
2. Insert bolts (3, figure 2) with washers (4) through mounting brackets (7).
3. Place spacers (5) on bolts (3) and position fuel quantity probe (6) onto attaching points on inboard wall of cell. Insert
and tighten bolts (3).
5. Install sump assembly (2) (module 28-20-18 paragraph "3. Lower forward cell sump assemblies - installation").
28-40-08
Page 2
E-AB412-PT6T-2
G6AB0412A
Figure 1. Fuel quantity probes (helicopters codes [C] [D])
28-40-08
Page 3
E-AB412-PT6T-2
G6AB0413A
Figure 2. Lower forward cell fuel quantity probe (helicopters codes [C] [D])
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Page 4
E-AB412-PT6T-2
3. FUEL QUANTITY PROBES - LOWER MIDDLE CELL FUEL QUANTITY PROBES
3-1. LOWER MIDDLE CELL FUEL QUANTITY PROBES - DESCRIPTION
Each lower middle cell contains a fuel quantity probe (tank unit) (figure 3) equipped with a fuel level sensor (thermistor)
which causes associated no transfer (NO 1 FUEL TRANS or NO 2 FUEL TRANS) caution light segment to be extinguished
when fuel flow through flow switch check valve ceases because of cell being empty.
3-2. LOWER MIDDLE CELL FUEL QUANTITY PROBES - REMOVAL
MATERIALS REQUIRED
NUMBER NOMENCLATURE
1. Remove sump assembly (7, figure 4) (module 28-20-23 paragraph "2. Lower middle cell sump assemblies - removal").
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Page 5
E-AB412-PT6T-2
3-3. LOWER MIDDLE CELL FUEL QUANTITY PROBES - INSTALLATION
1. Remove protective caps and/or plugs from the electrical connector (1, figure 4).
3. Insert bolts (3, figure 4) with washers (4) through mounting brackets (2).
4. Place the spacers (5) on bolts (3) and position fuel quantity probe (6) onto attaching points on inboard wall of cell.
Insert and tighten bolts (3).
6. Install sump assembly (7) (module 28-20-23 paragraph "3. Lower middle cell sump assemblies - installation").
28-40-08
Page 6
E-AB412-PT6T-2
G6AB0414A
Figure 3. Lower main cell fuel quantity probe (helicopters codes [C] [D])
28-40-08
Page 7
E-AB412-PT6T-2
G6AB0415A
Figure 4. Lower middle cell fuel quantity probe (helicopters codes [C] [D])
28-40-08
Page 8
E-AB412-PT6T-2
4. FUEL QUANTITY PROBES - LOWER MAIN CELL FUEL QUANTITY PROBES
4-1. LOWER MAIN CELL FUEL QUANTITY PROBES - DESCRIPTION
One fuel quantity probe is mounted on the inboard wall of each lower main cell (figure 3). These probes serve only the
quantity measuring function.
4-2. LOWER MAIN CELL FUEL QUANTITY PROBES - REMOVAL
MATERIALS REQUIRED
NUMBER NOMENCLATURE
1. Remove sump assembly (2, figure 3) (module 28-20-28 paragraph "2. Lower main cell sump assemblies - removal").
4-3. LOWER MAIN CELL FUEL QUANTITY PROBES - INSTALLATION
1. Remove the protective caps and/or plugs from the electrical connector (1, figure 3).
2. Remove protective cover from cell sump opening.
3. Insert bolts (5, ) with washers (6) through mounting brackets (4).
4. Place spacers (7) on bolts (5) and position fuel quantity probe (3) onto attaching points on inboard wall of cell. Insert
and tighten bolts (5).
6. Install sump assembly (2) (module 28-20-28 paragraph "3. Lower main cell sump assemblies - installation").
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E-AB412-PT6T-2
5. FUEL QUANTITY PROBES - UPPER LEFT AND UPPER RIGHT CELL FUEL
QUANTITY PROBES
5-1. UPPER LEFT AND UPPER RIGHT CELL FUEL QUANTITY PROBES - DESCRIPTION
The fuel quantity probe in the upper left cell is connected electrically to signal conditioner No. 1 while probe in upper right
cell is connected to signal conditioner No. 2. Each probe contains a fuel level sensor (thermistor) at its base that signals the
corresponding NO. 1 FUEL LOW or NO. 2 FUEL LOW segment in the caution panel that the cell has become empty.
5-2. UPPER LEFT AND UPPER RIGHT CELL FUEL QUANTITY PROBES - REMOVAL
MATERIALS REQUIRED
NUMBER NOMENCLATURE
3. Remove engine deck panel.
5. Remove bolts (9) and washer (8).
6. Remove fuel quantity probe (7), gaskets (5), and spacer (6).
5-3. UPPER LEFT AND UPPER RIGHT CELL FUEL QUANTITY PROBES - INSTALLATION
MATERIALS REQUIRED
NUMBER NOMENCLATURE
C-405 LOCKWIRE
1. Remove the protective caps and/or plugs from the electrical connector (2, figure 5)
2. Remove protective cover from cell opening
3. Place gasket (5, ), spacer (6), and a second gasket (5) on fuel quantity probe (7). Position these items near mounting
flange (3) of fuel quantity probe (7).
4. Insert fuel quantity probe (7) into cell. Rotate fuel quantity probe (7) so terminal block assembly (4) faces aft.
5. Align holes in mounting flange (3) with those in gasket (5), spacer (6), and vent cover (1).
6. Install bolts (9) with washers (8). Tighten bolts (9).
28-40-08
Page 10
E-AB412-PT6T-2
7. Apply lockwire (C-405) to bolts (9).
13. Install sump access door and engine deck panel.
28-40-08
Page 11
E-AB412-PT6T-2
G6AB0416A
Figure 5. Upper left and upper right cell fuel quantity probe (helicopters codes [C] [D])
28-40-08
Page 12
E-AB412-PT6T-2
CHAPTER 29 - HYDRAULIC POWER

Module Page
Number Title Number
29-00-00 HYDRAULIC POWER
1. Hydraulic systems - general .................................................................................................................... 1
29-01-01 GENERAL MAINTENANCE PRACTICES
1. General maintenance practices - general ................................................................................................ 1

2. General maintenance practices - troubleshooting ................................................................................... 1
3. General maintenance practices - leakage limits....................................................................................... 6
4. General maintenance practices - flushing ............................................................................................... 8
5. General maintenance practices - operational checks .............................................................................. 9
5-1. Operational check (using test stand) .............................................................................................. 9
5-2. Operational check (using helicopter power) ................................................................................ 11
29-11-01 HYDRAULIC SYSTEM COMPONENTS
1. Hydraulic system components - description ........................................................................................... 1
29-11-02 HYDRAULIC SYSTEM COMPONENTS - HYDRAULIC PUMP (HYDRAULIC SYSTEM NO. 1)
1. Hydraulic pump (hydraulic system no. 1) - description ......................................................................... 1

2. Hydraulic pump (hydraulic system no. 1) - removal .............................................................................. 1
3. Hydraulic pump (hydraulic system no. 1) - installation ......................................................................... 1
4. Hydraulic pump (hydraulic system no. 1) - inspection ........................................................................... 2
5. Hydraulic pump (hydraulic system no. 1) - repair .................................................................................. 2
1. Hydraulic pump (hydraulic system no. 2) - description ......................................................................... 1

2. Hydraulic pump (hydraulic system no. 2) - removal .............................................................................. 1
3. Hydraulic pump (hydraulic system no. 2) - installation ......................................................................... 1
4. Hydraulic pump (hydraulic system no. 2) - inspection ........................................................................... 2
5. Hydraulic pump (hydraulic system no. 2) - repair .................................................................................. 2
29-11-04 HYDRAULIC SYSTEM COMPONENTS - HYDRAULIC RESERVOIR
1. Hydraulic reservoir - description ............................................................................................................ 1

2. Hydraulic reservoir - removal ................................................................................................................. 1
3. Hydraulic reservoir - installation ............................................................................................................ 1
4. Hydraulic reservoir - inspection ............................................................................................................. 2
5. Hydraulic reservoir - repair ..................................................................................................................... 2
29-11-05 HYDRAULIC SYSTEM COMPONENTS - VALVES
1. Integrated valve and filter assembly - description .................................................................................. 1

2. Integrated valve and filter assembly - removal ....................................................................................... 1
3. Integrated valve and filter assembly - installation .................................................................................. 2
4. Integrated valve and filter assembly - inspection ................................................................................... 2
29-Index
Rev. 3 Page 1
E-AB412-PT6T-2

Module Page
Number Title Number
5. Elbow check valve - description .............................................................................................................2

6. Elbow check valve - removal ..................................................................................................................2
7. Elbow check valve - installation .............................................................................................................3
8. Elbow check valve - inspection ...............................................................................................................3
9. Inline check valve - description ..............................................................................................................3
10. Inline check valve - removal ...................................................................................................................7
11. Inline check valve - installation ..............................................................................................................7
12. Inline check valve - inspection ................................................................................................................7
13. Three-way, two-position, pressure-operated valve - description ............................................................7
14. Three-way, two-position, pressure-operated valve - removal .................................................................9
15. Three-way, two-position, pressure-operated valve - installation ............................................................9
16. Three-way, two-position, pressure-operated valve - inspection ..............................................................9
29-11-06 HYDRAULIC SYSTEM COMPONENTS - PRESSURE SWITCH
1. Pressure switch - description ...................................................................................................................1

2. Pressure switch - removal .......................................................................................................................1
3. Pressure switch - installation ...................................................................................................................1
29-11-07 HYDRAULIC SYSTEM COMPONENTS - HYDRAULIC ACCUMULATOR
1. Hydraulic accumulator - description .......................................................................................................1

2. Hydraulic accumulator - removal ............................................................................................................1
3. Hydraulic accumulator - installation .......................................................................................................1
4. Hydraulic accumulator - inspection ........................................................................................................1
29-11-08 HYDRAULIC SYSTEM COMPONENTS - HYDRAULIC CHECK VALVE
1. Hydraulic check valve - description ........................................................................................................1

2. Hydraulic check valve - removal ............................................................................................................1
3. Hydraulic check valve - installation ........................................................................................................1
4. Hydraulic check valve - inspection ..........................................................................................................2
5. Hydraulic check valve - repair ................................................................................................................2
29-11-09 HYDRAULIC SYSTEM COMPONENTS - PRESSURE TRANSMITTER
1. Pressure transmitter - description ............................................................................................................1

2. Pressure transmitter - removal .................................................................................................................1
3. Pressure transmitter - installation ............................................................................................................1
4. Pressure transmitter - inspection ..............................................................................................................2
Figure 1. Pressure transmitter.........................................................................................................................................3
29-11-10 HYDRAULIC SYSTEM COMPONENTS - PULSATION DAMPER (HYDRAULIC SYSTEM

NO. 2)
1. Pulsation damper (hydraulic system No. 2) - description .......................................................................1

2. Pulsation damper (hydraulic system No. 2) - removal ............................................................................1
3. Pulsation damper (hydraulic system No. 2) - installation .......................................................................1
29-11-11 HYDRAULIC SYSTEM COMPONENTS - HYDRAULIC SYSTEM RESERVOIR NO. 2 AND

NO. 3 [B] [C]
1. Hydraulic system reservoir no. 2 and no. 3 [B] [C] - description ...........................................................1
29-Index
Page 2 Rev. 3
E-AB412-PT6T-2

Module Page
Number Title Number
2. Hydraulic system reservoir no. 2 and no. 3 [B] [C] - removal ............................................................... 1
3. Hydraulic system reservoir no. 2 and no. 3 [B] [C] - installation ........................................................... 3
4. Hydraulic system reservoir no. 2 and no. 3 [B] [C] - inspection ............................................................ 3
5. Hydraulic system reservoir no. 2 and no. 3 [B] [C] - repair .................................................................... 4
29-11-12 HYDRAULIC SYSTEM COMPONENTS - HYDRAULIC FILTER ASSEMBLIES
1. Hydraulic filter assemblies - description ................................................................................................ 1

2. Hydraulic filter assemblies (P/N 212-076-006-7) - removal .................................................................. 1
3. Hydraulic filter assemblies (P/N 212-076-006-105) - removal .............................................................. 1
4. Hydraulic filter assemblies (P/N 212-076-006-7) - installation .............................................................. 3
5. Hydraulic filter assemblies (P/N 212-076-006-105) - installation .......................................................... 4
6. Hydraulic filter assemblies - cleaning .................................................................................................... 4
7. Hydraulic filter assemblies (P/N 212-076-006-7) - inspection ............................................................... 6
8. Hydraulic filter assemblies (P/N 212-076-006-105) - inspection ........................................................... 6
29-Index
Rev. 3 Page 3
E-AB412-PT6T-2
FIGURES
Figure Page
Number Title Number
29-00-00 HYDRAULIC POWER
Figure 1. Hydraulic system No. 1...................................................................................................................................3

Figure 2. Hydraulic system No. 2...................................................................................................................................4
Figure 3. Hydraulic system schematic (sheet 1 of 2) .....................................................................................................3
Figure 1. Hydraulic pump (hydraulic system No. 1)......................................................................................................3
Figure 1. Hydraulic pump (hydraulic system No. 2)......................................................................................................3
29-11-04 HYDRAULIC SYSTEM COMPONENTS - HYDRAULIC RESERVOIR
Figure 1. Hydraulic reservoir arrangement.....................................................................................................................4

Figure 2. Hydraulic reservoir assembly..........................................................................................................................5
29-11-05 HYDRAULIC SYSTEM COMPONENTS - VALVES
Figure 1. Integrated valve and filter assembly arrangement ..........................................................................................4

Figure 2. Integrated valve and filter assembly ...............................................................................................................5
Figure 3. Elbow check valve ..........................................................................................................................................6
Figure 4. Inline check valve ...........................................................................................................................................8
Figure 5. Three-way, two-position, pressure operated valve .......................................................................................10
29-11-06 HYDRAULIC SYSTEM COMPONENTS - PRESSURE SWITCH
Figure 1. Pressure switch................................................................................................................................................2
29-11-07 HYDRAULIC SYSTEM COMPONENTS - HYDRAULIC ACCUMULATOR
Figure 1. Hydraulic accumulator ....................................................................................................................................2
29-11-08 HYDRAULIC SYSTEM COMPONENTS - HYDRAULIC CHECK VALVE
Figure 1. Hydraulic check valve.....................................................................................................................................3
29-11-09 HYDRAULIC SYSTEM COMPONENTS - PRESSURE TRANSMITTER
Figure 1. Pressure transmitter.........................................................................................................................................3
29-11-10 HYDRAULIC SYSTEM COMPONENTS - PULSATION DAMPER (HYDRAULIC SYSTEM

NO. 2)
Figure 1. Pulsation damper (hydraulic system No. 2) ....................................................................................................2
29-11-11 HYDRAULIC SYSTEM COMPONENTS - HYDRAULIC SYSTEM RESERVOIR NO. 2 AND

NO. 3 [B] [C]
Figure 1. Hydraulic system reservoir No. 2 and No. 3 arrangement [B] [C] .................................................................2
29-Index
Page 4 Rev. 3
E-AB412-PT6T-2
FIGURES (CONT.D)
Figure Page
Number Title Number
Figure 2. Hydraulic system reservoir No. 2 and No. 3 assembly [B] [C]...................................................................... 5
29-11-12 HYDRAULIC SYSTEM COMPONENTS - HYDRAULIC FILTER ASSEMBLIES
Figure 1. Hydraulic filter assemblies ............................................................................................................................. 2
29-Index
Rev. 3 Page 5
E-AB412-PT6T-2
TABLES
Table Page
Number Title Number
Table 1. Troubleshooting - hydraulic system................................................................................................................1

Table 2. Permitted leakage for in-service hydraulic components .................................................................................7
29-Index
Page 6 Rev. 3
E-AB412-PT6T-2
29-0 -0 HYDRAULIC POWER
29-00-00
HYDRAULIC POWER
1. HYDRAULIC SYSTEMS - GENERAL
The hydraulic system is subdivided into the following systems:

— Two independent systems (helicopters codes [A] [D]).
— Three independent systems (helicopters codes [B] [C]).
The hydraulic system is comprised of two independent systems identified as hydraulic system No. 1 and hydraulic system
No. 2. The hydraulic system No. 1 (figure 1) is located in the center of the compartment below the transmission, the
hydraulic system No. 2 (figure 2) is located on the left side of the compartment.
Each system has a non-pressurized reservoir, a variable-flow pump driven by the transmission, an integrated valve and filter
assembly, an accumulator, and check valves. Each pump is powered by a separate drive quill driven by the transmission.
The valve and filter assembly contains filters, solenoid valves, and relief valves. Fluid under pressure operates the
servo-actuators.
The two systems differ from each other because the primary system (No. 1) supplies the cyclic and collective control
actuators and the tail rotor servo-actuator while the secondary system (No. 2) supplies the cyclic and collective controls
actuators only. The two hydraulic systems are provided with external fittings for connection to the test stand for maintenance
and testing
The three dual hydraulic servo actuators in cyclic and collective flight control systems are operated by both hydraulic
systems. Two isolated sets of passages and piston chambers inside the servo actuators maintain integrity of each system. In
event of failure in one system, the remaining system will continue to operate the servo actuators.
The directional control (anti-torque) system servoactuator is operated by hydraulic system No. 1 only; therefore, hydraulic
system No. 1 has a larger rated volume pump than hydraulic system No. 2.
Hydraulic system No. 2 has a pulsation damper between pump and integrated valve and filter assembly. Hydraulic system
No. 1 does not have a pulsation damper.
Both hydraulic systems have a temperature bulb located at reservoir inlet and a pressure transmitter at module outlet. These
sensors are connected to a hydraulic pressure/temperature gauge on the instrument panel. In addition, a temperature switch
at reservoir inlet causes the appropriate NO.1 HYDRAULIC or NO. 2 HYDRAULIC caution segment on the caution/
warning panel to illuminate if hydraulic fluid temperature reaches 190F (88C). A pressure switch at module outlet
energizes the same segment if pressure drops below 650 psi (4481.6 kPa).
Each valve and filter assembly has two red indicator buttons for the two filters, and is also electrically connected to a remote
warning indicator located in the cabin nose (visible through the right nose window) forward and below pedestal of the pilot
station. If any of the four filters becomes clogged enough to cause a differential pressure of 70 ± 10 psi (483 ± 69 kPa) across
the element, this differential pressure will cause the adjacent red button to extend and the remote indicator to change from
green to red or, cause the “cats-eye” indicator to turn from black to white, as applicable. The remote indicator will remain
red, and the red button will remain extended until the clogged filter element is cleaned or changed and both indicators are
reset. The remote indicator is intended to provide an impending bypass indication. If the remote indicator keeps going back
to red after being reset and the indicators on the filter and valve assemblies are not extended, the remote indicator is very
likely defective. It will be acceptable to return helicopter to service with noted condition, provided the indicators on the filter
and valve assemblies are not extended and until such time the remote indicator may be repaired.
29-00-00
Rev. 3 Page 1
E-AB412-PT6T-2
In normal operation of each system, hydraulic fluid is supplied from non-pressurized reservoirs by gravity feed and suction
to a transmission driven pump. The pumps are variable delivery types with internal pressure compensation, preset to provide
1000 ± 25 psi (6895 ± 172 kPa) output pressure at operating RPM, according to system demands. Pump output is delivered
to the module and passes through the pressure filter. A relief valve in the module guards the system against excessive
pressure, being set to open at 1100 psi (7584 kPa). The system solenoid valve is normally de-energized and open to the SYS
PRESS outlet of the module but can be electrically energized to OFF position by means of the HYDR SYS NO. 1 and HYDR
SYS NO. 2 switches. The figure 3 provides a hydraulic system schematic.
29-00-00
Page 2 Rev. 3
E-AB412-PT6T-2
1. Reservoir 10. Three-way, two-position, pressure-operated valve

2. Hydraulic pump 11. Pressure transmitter
3. Directional flight control cylinder 12. Integrated valve and filter assembly
4. Collective flight control cylinder 13. Cyclic flight control cylinder
5. Inline check valve 14. Pressure-operated check valve
6. Ground test fittings 15. Hydraulic check valve
7. Cyclic flight control cylinder 16. Temperature bulb
8. Pressure-operated check valve 17. Temperature switch
9. Accumulator
G6AB0190B
Figure 1. Hydraulic system No. 1
29-00-00
Rev. 3 Page 3
E-AB412-PT6T-2
1. Hydraulic pump
2. Reservoir
3. Pressure transmitter
4. Accumulator
5. Integrated valve and filter assembly
6. Collective flight control cylinder
7. Pressure-operated check valve
8. Cyclic flight control cylinder
9. Pressure-operated check valve
10. Inline check valve
11. Ground test fittings
13. Three-way, two-position
pressure-operated valve
14. Hydraulic check valve
15. Pulsation damper
G6AB0191B
Figure 2. Hydraulic system No. 2
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Page 4 Rev. 3
E-AB412-PT6T-2
29-0 -0
HYDRAULIC SYSTEM NO. 1
G6AB0186B
Figure 3. Hydraulic system schematic (sheet 1 of 2)
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Rev. 3 Page 5
E-AB412-PT6T-2
HYDRAULIC SYSTEM NO. 2
G6AB0187B
Figure 3. Hydraulic system schematic (sheet 2 of 2)
29-00-00
Page 6 Rev. 3
E-AB412-PT6T-2
29-01-01
GENERAL MAINTENANCE PRACTICES
1. GENERAL MAINTENANCE PRACTICES - GENERAL
The following paragraphs provide troubleshooting, leakage limits, and operational checks using a test stand and using
helicopter power.
2. GENERAL MAINTENANCE PRACTICES - TROUBLESHOOTING
The following list of probable causes, isolation procedures, and remedies is intended to aid in hydraulic system
troubleshooting. The guide should be used with other sources of information such as: Hydraulic schematic illustration,
electrical diagrams, and operational check and other detailed procedures in this chapter.
NOTE
Perform operational check of hydraulic system following any corrective action or
component replacement.
Table 1. Troubleshooting - hydraulic system
PROBABLE CAUSE ISOLATION PROCEDURE CORRECTIVE ACTION
INDICATION OF TROUBLE — ONE SYSTEM LACKS POWER AND PRESSURE IS LOW
Leaks in system. Visually check for leaks due to loose Repair connections; replace faulty lines,
connections, line rupture, component hoses, seals, or components. Service
rupture, or failed seals. system and perform operational check.
Hydraulic pump malfunction. Check system can be powered by Replace hydraulic pump.
hydraulic test unit.
System check valve stuck closed If operation on hydraulic test unit is Replace check valve.
in pump pressure line. normal, but operation with a known
serviceable pump remains faulty,
check valve may be defective.
Reservoir vent obstructed. If system pressure is intermittently low Clear reservoir vent screen or replace
when operating on pump, though nor- reservoir. Operationally check for possi-
mal with test unit, check reservoir for ble pump damage.
obstructed vent causing pump cavita-
tion.
System solenoid valve remaining Electrically check solenoid is not ener- Repair electrical circuit, or replace valve
in Off position. gized. If not circuit fault, valve may be and filter assembly.
mechanically stuck.
29-01-01
Rev. 3 Page 1
E-AB412-PT6T-2
(Cont.d)
Pressure operated shutoff valve in If system normal on test unit but con- Replace valve.
reservoir return line locked in trols not powered by pump operation,
energized (test coupling) position. valve may be defective.
Reservoir return port screen Visually check reservoir return screen. Clean screen or replace reservoir.
clogged.
Pressure operated shutoff valve or Disconnect reservoir return line. With Replace integrated valve and filter
internal check valve in integrated system on, move controls and check assembly.
valve and filter assembly mal- for steady flow. If not, valve is faulty.
functioning.
INDICATION OF TROUBLE — PRESSURE FLUCTUATION WITH CONTROLS MOTIONLESS
Airlock in line between pressure Operating on ground test unit, briefly If pressure is steady after bleeding line,
transmitter and restrictor. loosen line connection on elbow at P no further action. If fluctuation contin-
port of pressure transmitter. Tighten ues, check transmitter and gauge, replac-
connector after bleeding, and recheck ing faulty units.
pressure indication.
Reservoir return screen ruptured, Check for foaming in reservoir after Clear obstructed vent, or replace reser-
or vent screen partially rapid control movements, as indication voir.
obstructed. of return screen damage. Inspect reser-
voir screens.
INDICATION OF TROUBLE — FILTER INDICATORS TRIPPED
Filters clogged. If indicator in cabin nose is red, check Clean filter elements as required. Reset
both system filter assemblies for module indicators and remote indicator.
tripped indicators. Manually reset
indicators and operate system. Move
controls rapidly. If indicators again
trip, filters are clogged.
Indicators defective. Indicators trip with known serviceable Replace defective integrated valve and
filter elements. filter assembly.
Remote indicator defective. Indicator in cabin nose is red and nei- Replace or repair defective remote indi-
ther system filter assembly indicators cator.
are extended.
INDICATION OF TROUBLE — EITHER HYDRAULIC SYSTEM OVERHEATS
NOTE
System 2 operates at slightly higher temperature than system 1, due to difference in pump RPM.
29-01-01
Page 2 Rev. 3
E-AB412-PT6T-2
(Cont.d)
Hydraulic pump defective, allows Use a test gauge to check system pres- Replace hydraulic pump.
increasing pressure. sure, 1050 psi (7239,5 kPa) maximum.
System relief valve held fully Check for loss of control response, and Replace integrated valve and filter
open. for flow through relief valve. assembly.
INDICATION OF TROUBLE — HYDRAULICS AND MASTER CAUTION LIGHTS ON
Hydraulic systems No. 1 or No. 2 Check temperature gauge for tempera- Refer to troubleshooting data for Either
overheating. ture higher than 190F (88C) Hydraulic System Overheats.
Hydraulic systems No. 1 or No. 2 Check pressure gauge for low pressure Refer to troubleshooting data for One
has low pressure. below 650 psi (4481.6 kPa). System Lacks Power and Pressure is
Low.
Temperature switch malfunction- Temperature gauge indicates normal. Replace switch of each hydraulic system
ing. independently and recheck system.
Pressure switch malfunctioning. Pressure gauge indicates normal. Replace switch of each hydraulic system
independently and recheck system.
INDICATION OF TROUBLE — CONTROLS DO NOT OPERATE SMOOTHLY
Servo or bypass valve sticking. With hydraulic pressure off, discon- 1. Check lever pivot for binding. Clean
nect control tube from servo input or replace bolt.
lever of dual actuator. Manually check
force required to displace lever 0.070
in (1.78 mm), not to exceed 32 oz.
(142 N).
2. Flush system thoroughly. Recheck

operation.
3. Replace seals on servo or bypass

valves, or replace actuator.
Control tube bearing rotational With hydraulic pressure off, discon- Replace control tube.
force excessive. nect control tubes from cyclic and col-
lective control cylinder servo input
levers. Manually check force required
to rotate inner race (ball) of the bear-
ing, not to exceed 4 in oz. (0.028 Nm)
(Chapter 67).
29-01-01
Rev. 3 Page 3
E-AB412-PT6T-2
(Cont.d)
Binding in flight control linkage. Check linkage components for free- Replace defective parts.
dom of motion. Check for loose
clamps and dislocated boots on control
linkage under aft center floor panel of
cabin.
INDICATION OF TROUBLE — INADEQUATE CONTROL RESPONSE
Internal leakage past piston in Check actuator is only partially pow- Replace servo actuator.
actuator. ered.
Check valve stuck closed in pres- Substitute valve with one known to be Replace check valve.
sure port of actuator or in return serviceable. Operationally check sys-
port of integrated valve and filter tem.
assembly.
INDICATION OF TROUBLE — RESERVOIR OVERFLOWS WHEN USING GROUND TEST UNIT
Test unit pressure too low. Check test unit setting. Increase test unit pressure above 550 psi
(3790 kPa).
Pressure operated shutoff valve Check for increased overflow when Replace valve.
(212-076-008) malfunction. flight controls are moved.
System check valve in pump pres- Check for overflow with no control Replace valve.
sure line open. motion. Rotor may rotate slowly when
on ground cart.
INDICATION OF TROUBLE — HIGH FREQUENCY VIBRATIONS DUE TO TAIL ROTOR CONTROLS
Stiffness or binding in action of 1. Cylinder input lever binding on 1. Polish spacer OD until free in lever
tail rotor control hydraulic cylin- spacer at bellcrank. (Move lever later- bearing.
der. ally to check.)
2. Cylinder trunnions binding in 2. Polish trunnion plate bushings ID for

mounting plates. (Move cylinder later- free fit.
ally 0.003 to 0.050 in (0.076 to 1.270
mm).
3. Cylinder input lever binding at Repair cylinder assembly per overhaul

pivot. instructions.
Cylinder input lever bearing rota- Disconnect anti-torque control cylin- Repair lever bearing or replace cylinder
tional force excessive. der input lever from bellcrank. Check (Chapter 67).
cylinder lever bearing rotational force
not to exceed 8 in oz. (0.055 Nm)
(Chapter 67).
29-01-01
Page 4 Rev. 3
E-AB412-PT6T-2
(Cont.d)
Binding in tail rotor controls. 1. Check pitch control tube for binding 1. Remove pitch change tube. Clean ID
in bearing in left side of tail rotor gear- of bearing and OD of tube. Reinstall and
box. recheck.
2. Check lever on left side of tail rotor 2. Replace unserviceable lever.

gearbox for stiffness of lower end
bearing in alignment motion. If stiff-
ness occurs, twist attached link to turn
nut end of bolt upward. Pull nut down-
ward with a spring scale. If force to
move bearing exceeds 10 lbs (4.536
kg), lever is unserviceable.
INDICATION OF TROUBLE — MOTORING SERVO ACTUATOR IN TAIL ROTOR CONTROLS
Servo or bypass valves sticking. Disconnect anti-torque control cylin- Replace cylinder (Chapter 67).
der input lever from bellcrank. Manu-
ally check force to operate lever at
bearing, not to exceed 24 in oz. (0.165
Nm) (Chapter 67).
INDICATION OF TROUBLE — COLLECTIVE STICK LIGHT OR HEAVY IN DOWNSTROKE
Collective minimum friction Check friction preload on collective Adjust minimum friction (Chapter 67).
incorrect. stick.
Balance spring on collective cyl- Check condition of balance spring on Replace defective spring.
inder defective. input lever of collective hydraulic cyl-
inder.
INDICATION OF TROUBLE — INABILITY TO MAKE NORMAL RIGHT AND LEFT TURNS IN FLIGHT
Tail rotor controls rigging incor- Check tail rotor rigging. Rig tail rotor controls.
rect.
INDICATION OF TROUBLE — BINDING IN TAIL ROTOR MOVEMENT
Pitch change tube binding in bear- Manually check tube for free move- Clean surfaces of tube and bearing.
ing at left side of tail rotor gear- ment through full range of travel.
box.
Binding bearing in lower end of Manually check bearing. Replace lever.

lever on left side of tail rotor gear-
box.
29-01-01
Rev. 3 Page 5
E-AB412-PT6T-2
3. GENERAL MAINTENANCE PRACTICES - LEAKAGE LIMITS
The following provides guide lines for allowable external leakage of in-service hydraulic system components, and suggested
methods of measuring such leakage.
1. Scope — Limits described are only for components in service in helicopter hydraulic systems. Intent is to minimize
replacement of hydraulic components which are still serviceable.
a. These limits may differ from those contained in various specifications for components, which are intended to
control quality, assembly, and proper functioning. Components in service sometimes develop leakage rates in
excess of specification limits, without necessarily becoming detrimental to the system or failing to provide
reliable operation.
b. These limits are not to be used as basis for acceptance or rejection of components of any bench functional test
or systems on new helicopters.
c. These limits are not applicable to self-contained closed-compartment hydraulic units such as viscous dampers,
liquid springs, or oleo struts.
2. Causes of Leakage — Some seepage is normally present, since static or dynamic seals are not functionally perfect, due
to such causes as follows:
a. A film of hydraulic fluid being retained by metal surfaces, such as piston rods, and thus carried past seals. This
film is necessary for seal lubrication.
b. Pressure and temperature variations affecting seals.
c. Seals tending to take a permanent set after a period of time.
3. Classification of Leakage — External leakages of hydraulic fluid can be broadly classified as excessive or allowable.
a. Excessive Leakage: Fluid leakage such that hydraulic reservoir level may be dangerously lowered or depleted
during normal operation, or fire hazard created, or airworthiness of helicopter otherwise comprised.
b. Allowable Leakage: Fluid leakage such that quantity lost is insignificant, no detrimental effect on helicopter
operation, and correction does not warrant maintenance time involved.
c. General: Leakage usually shows as a seepage, stain, or wet area. It is possible for allowable leakage or seepage
to collect in a cavity or depression in adjacent structure over a period of time and falsely indicate excessive
leakage. Accumulation on a flat area or a white-painted surface often appears to be excessive, though actually
being allowable. It is also possible to have enough components with allowable leakages that the combined
leakage is excessive.
4. Leakage Checks — Measurement of leakage rates, for classification according to table 2, can be performed as follows:
a. When hydraulic systems have remained in a static, unpressurized condition for an appreciable period of time,
leakage checks should not be performed immediately after starting. Activate systems and cycle components
several times. Wipe off any accumulated hydraulic fluid before making leakage checks.
b. Where location of a component does not permit direct observation, measure leakage on a flat surface, either part
of structure below the component or a panel temporarily positioned for that purpose. Wipe surface clean and
place a drop of fluid on area, allow to stabilize, then outline area with soft lead pencil before wiping off fluid.
Pressurize system and cycle component to observe leakage rate, comparing wetted surface to marked one-drop
area.
c. Where fluid leaking from a component can be directly observed, pressurize and cycle the component until a drop
falls free. Continue operating, observing time until next drop to determine leakage rate.
d. For tests requiring long periods of time and where fluid can drop, wipe surface clean and dry without using a
solvent. Use a clean blotter or white cloth after system has operated or has been idle the required period of time.
29-01-01
Page 6 Rev. 3
E-AB412-PT6T-2
Table 2. Permitted leakage for in-service hydraulic components
COMPONENT FUNCTION LEAK TYPE LEAKAGE RATE (Max.)

1
FLIGHT Rod seal D 1 drop/20 full stroke cycles
CONTROLS S-D 1 drop/15 min.
ACTUATORS End cap S 2 drops/day
Valve input D 1 drop/5 cycles
S-D 1 drop/5 min.
Pressure switch S-D 1 drop/5 min.
Valve body (weep holes) S-D 1 drop/5 min.
PUMPS Output shaft D 8 drops/min.
S-D 1 drop/min.
Housing (mating surfaces) S 2 drops/day
VALVES Body (weep hole) S 2 drops/day
Manual stem D 1 drop/5 cycles
S-D 1 drop/15 min.
Dump valve S 2 drops/day
FITTINGS Flared or flareless S None
Compression seals S 1 drop/30 min. (less if readily

accessible)
CHECK Pressure operated D 2 drops/25 cycles
VALVE S None at static pressures of 5 to

1000 psi (34,5 to 6894,75 kPa)
NOTES:
1 Leak Types: D = Dynamic

S = Static
S-D = Static leakages through dynamic seal
1. Approximately 20 drops = 1 cubic centimeter.
2. Components a in static condition, such as a parked helicopter, are permitted maximum leakage of two drops per seal
or packing per day.
29-01-01
Rev. 3 Page 7
E-AB412-PT6T-2
4. GENERAL MAINTENANCE PRACTICES - FLUSHING
MATERIALS REQUIRED
NUMBER NOMENCLATURE
C-304 SOLVENT
WARNING
CLEANING OF HYDRAULIC COMPONENTS SHALL BE ACCOMPLISHED

WITH SOLVENT (C-304) ONLY. DO NOT USE ALCOHOL.
1. Flush hydraulic system No. 1 and/or hydraulic system No. 2 when evidence of contamination is present in system.
2. Remove, clean, and install reservoir filler strainer and return port.
3. Remove hydraulic system pump, attach a tag stating reason for removal, and forward hydraulic pump to overhaul
facility.
4. Remove hydraulic pump supply hose and hydraulic pump pressure hose and flush with solvent (C-304). Install hoses.
5. Remove and clean filter bowls. Replace filter elements and install filter bowls.
6. Remove flight control cylinders. Tag cylinders with a statement giving reason for removal and forward cylinders to
overhaul facility. Connect pressure and return hoses with reducers (MS21916D6-4).
7. If hydraulic system No. 1 is contaminated, remove directional control cylinder. Attach a tag stating reason for removal,
and forward cylinder to overhaul facility. Connect pressure and return hose with reducers (MS21916D6-4).
8. Connect hydraulic test stand to appropriate ground test connections under left rear door of helicopter.
CAUTION
THROUGHOUT THE OPERATIONAL CHECKS, DO NOT OPERATE BELOW

550 PSI. HOWEVER, IF IT BECOMES NECESSARY TO REDUCE SYSTEM
PRESSURE TO ZERO, DE-ENERGIZE TEST UNIT FLOW TO HELICOPTER,
AND THEN REDUCE SYSTEM PRESSURE. FAILURE TO FOLLOW THE
ABOVE INSTRUCTIONS WILL RESULT IN OVERFILLING OF SYSTEM
RESERVOIR. TESTS REQUIRING DEACTIVATION OF A SYSTEM SHALL BE
ACCOMPLISHED BY DISCONNECTING TEST UNIT FROM THAT SYSTEM.
9. Set test unit pressure relief valve for a cracking pressure of 2100 psi (14479 kPa) and set test unit to pressure sufficient
to maintain a 6.0 gallons (22.7 liters) per minute minimum flow through system.
NOTE
Test unit reservoir shall be used in this flushing procedure.
10. Maintain pressure setting for at least five minutes while observing all portions of system for external leakage. Take
appropriate action to correct any leakage.
11. Stop fluid flow and decrease pressure. Disconnect hydraulic test stand.
29-01-01
Page 8 Rev. 3
E-AB412-PT6T-2
12. Install replacement directional control cylinder and cyclic and collective control cylinders.
13. Install replacement hydraulic pump.
14. Install new hydraulic filter elements.
15. Service reservoir (Chapter 12).
16. Ground run helicopter and operationally check all components (Chapter 96). Check for leaks and indications of tripped
clogged filter indicators.
17. Remove, clean, and install reservoir return port strainer.
5. GENERAL MAINTENANCE PRACTICES - OPERATIONAL CHECKS
5-1. OPERATIONAL CHECK (USING TEST STAND)
MATERIAL REQUIRED
NUMBER NOMENCLATURE
C-405 LOCKWIRE
1. Provide a portable hydraulic test unit conforming to the following requirements:
a. Thoroughly clean and service with same type hydraulic fluid used in system.
b. Equipped with a 10 micron absolute maximum particle size metal filter through which all fluid passes before
leaving unit and a 10 micron filter on return line to test unit before fluid returns to test unit.
c. Capable of producing pressure to 1400 psi (9652.66 kPa) and a minimum flow rate of 6.0 gallons (22.7 liters)
per minute.
d. Equipped with a calibrated pressure gauge with minimum 1500 psi (10342.14 kPa) capacity.
2. Visually inspect entire hydraulic system of helicopter to ensure all lines and components are secure and appear capable
of operation. Obtain access by opening transmission cowling, doors on front and sides of pylon structure in cabin, and
door to fuselage compartment in which tail rotor control actuator is located.
3. Prepare portable test unit for operation: Relief valve set for 1300 psi (8693.18 kPa) pressure; pump set for at least 6
gallons (22.7 liters) per minute flow.
4. Remove test coupling access doors below left cargo door opening, at approximately station 150 for hydraulic system
No. 1 and station 134 for hydraulic system No. 2.
CAUTION
THROUGHOUT OPERATIONAL CHECKS, DO NOT OPERATE BELOW 550

PSI. IF NECESSARY TO REDUCE SYSTEM PRESSURE TO ZERO,
DE-ENERGIZE TEST UNIT FLOW TO HELICOPTER BEFORE REDUCING
SYSTEM PRESSURE. FAILURE TO DO THIS MAY RESULT IN
OVERFILLING SYSTEM RESERVOIR. TESTS REQUIRING DEACTIVATION
OF A SYSTEM SHALL BE ACCOMPLISHED BY DISCONNECTING TEST
UNIT FROM THAT SYSTEM.
29-01-01
Rev. 3 Page 9
E-AB412-PT6T-2
5. Connect test unit to both systems. If test unit does not have dual hoses, perform test on each system in turn. Apply 1000
psi (6894.76 kPa) pressure for at least 15 minutes, meanwhile performing the following:
a. Observe all parts of system for evidence of leakage, taking corrective action as necessary.
b. Slowly cycle all controls through full motions. Verify all moving parts have clearance to preclude fouling or
binding. Give particular attention to flexible connections to ensure hoses are not pinched or twisted and vibration
does not tend to loosen fittings.
c. Work any air from system by actuating each of flight controls through at least ten full strokes, cyclic and
collective on both systems, and tail rotor pedals in hydraulic system No. 1.
6. Check system pressure gages as follows:
a. Close HYD NO. 1 SYS and HYD NO. 2 SYS circuit breakers. Place BATTERY BUS 1 and BATTERY BUS 2
switches ON. Energize inverters with INV 1 and INV 2 switches.
b. Slowly decrease test unit pressure to 550 psi (3792.12 kPa) observing both hydraulic system pressure gauges
operate smoothly throughout range and NO. 1 HYDRAULIC and NO. 2 HYDRAULIC caution lights illuminate
when pressure drops below 650 psi (4481.59 kPa) .
c. Slowly increase test unit pressure to 1000 psi (6894.76 kPa) observing both hydraulic system pressure gauges
operate smoothly throughout the range and caution lights extinguish when pressure rises above 750 psi
(5171.07 kPa) .
7. Check single system operation, if not already accomplished in performing step 5., as follows:
a. With test unit connected to hydraulic system 2 only, apply 1000 psi (6894.76 kPa) pressure from test unit. Verify
HYDR SYS 2 pressure gauge indicates 1000 psi (6894.76 kPa) while HYDR SYS 1 gauge indicates 0. Move
flight controls. Verify cyclic and collective controls are smooth, positive, and fully powered and directional (tail
rotor) controls are not powered.
b. With test unit connected to hydraulic system No. 1 only, apply 1000 psi (6894.76 kPa) test unit pressure. Verify
HYDR SYS 1 pressure gauge indicates 1000 psi (6894.76 kPa) while HYDR SYS 2 gauge indicates 0. Move
flight controls. Verify cyclic, collective, and directional controls are smooth, positive, and fully powered.
c. Shut off test unit flow and reduce pressure to 0.
NOTE
If operational checkout is satisfactory, proceed to step 9. When further checks for
proper operation of pressure operated shutoff valves and system relief valves are
required, perform step 8.
8. With hydraulic test unit connected to one system only, monitor pressure gage of test unit while performing following
checks:
a. Apply 550 psi (3792.12 kPa) test unit pressure. Station a person to check action of flight controls and slowly
increase test unit pressure. Controls should become fully powered (directional controls will not be powered if
hydraulic system No. 2 is being checked) before pressure exceeds 900 psi (6205.28 kPa), indicating pressure
operated shutoff valve in system integrated valve and filter assembly has opened.
CAUTION
DO NOT INCREASE PRESSURE ABOVE 1400 PSI (9652.66 kPa) WHILE

PERFORMING THE FOLLOWING STEP.
29-01-01
Page 10 Rev. 3
E-AB412-PT6T-2
b. Stop all movement of flight controls. Continue increasing pressure. Listen to, or feel, integrated valve and filter
assembly, for evidence of system relief valve opening between 1100 psi (7584.23 kPa) and 1300 psi
8963.18 kPa), and being fully open by 1400 psi (9652.66 kPa).
c. Slowly reduce pressure. Observe for evidence of system relief valve closing at not less than 1065 psi
(7342.92 kPa).
d. Continue reducing pressure while checking action of flight controls. Controls should lose hydraulic power
between 600 psi (4136.85 kPa) and 750 psi (5171.07 kPa) indicating pressure-operated shutoff valve has closed.
The appropriate NO. 1 HYDRAULIC or NO. 2 HYDRAULIC caution light will illuminate.
e. Shut off test unit flow and reduce pressure to zero. Remove filter bowls and drain all fluid. Clean filter elements
and filter bowls. Install elements and tighten filter bowls 100 to 140 in-lbs (11.30 to 15.82 Nm) and secure to
housing with lockwire (C-405).
f. Apply 1000 psi (6894.76 kPa) test unit pressure and bleed air from system by cycling all controls through full
travel a minimum of ten cycles.
CAUTION
IF HYDRAULIC TEST STAND REMAINS CONNECTED AFTER IT IS SHUT

OFF, GRAVITY WILL CAUSE HYDRAULIC RESERVOIRS TO DRAIN INTO
TEST STAND.
g. Shut off test unit flow and reduce pressure to zero. Note NO. 1 HYDRAULIC/NO. 2 HYDRAULIC light
illuminates when pressure drops below 650 psi (4481.59 kPa). If required, connect hydraulic test stand to other
system and repeat checks. Disconnect hydraulic test stand.
9. When checks are completed, place BATTERY BUS 1 and BATTERY BUS 2 and INV 1 and INV 2 switches OFF.
Open circuit breakers.
NOTE
For complete electrical functional check of hydraulic systems, refer to Chapter 96.
11. Verify hydraulic fluid level and replenish fluid as required (Chapter 12).
5-2. OPERATIONAL CHECK (USING HELICOPTER POWER)
1. Start either power section (E-AB412-PT6T-1). After ten main rotor revolutions, shut down power section.
2. Replenish hydraulic fluid as required.
3. Start power sections and operate at idle speed.
CAUTION
WHILE GROUND RUNNING HELICOPTER, EXERCISE CAUTION TO AVOID

MOVING FLIGHT CONTROLS TO EXTREME POSITIONS.
29-01-01
Rev. 3 Page 11
E-AB412-PT6T-2
4. Cycle collective, cyclic, and anti-torque controls as follows:
a. Slowly cycle collective cylinder a minimum of 25 times by moving collective control up and down through
approximately 2.0 in (50.8 mm) of travel.
b. With rotor RPM set at 100%, cycle cyclic cylinder by slowly displacing cyclic stick in any direction to a
maximum of 2.5 in (63.5 mm) from stick center and then back to center. Repeat a minimum of 25 times.
c. Slowly cycle anti-torque cylinder a minimum of 15 times by moving pedals left and right through approximately
2.0 in (50.8 mm) of travel.
5. The collective, cyclic, and anti-torque controls should feel smooth and positive after cycling. If control feedback of
erratic cylinder operation is present, air may still remain in system. Repeat cylinder cycling as required.
6. Shut down engine.
7. Check for leaks and replenish fluid as required (Chapter 12).
29-01-01
Page 12 Rev. 3
E-AB412-PT6T-2
29-1 -01 HYDRAULIC SYSTEM COMPONENTS
29-11-01
HYDRAULIC SYSTEM COMPONENTS
1. HYDRAULIC SYSTEM COMPONENTS - DESCRIPTION
MATERIALS REQUIRED
NUMBER NOMENCLATURE
C-304 SOLVENT
The following modules provide maintenance information on the various hydraulic system components.
CAUTION
CAP OR PLUG ALL LINES, HOSES, AND PORTS AS COMPONENTS ARE

REMOVED.
WARNING
CLEANING OF HYDRAULIC COMPONENTS SHALL BE ACCOMPLISHED

29-11-01
Page 1
E-AB412-PT6T-2
29-11-01
Page 2
E-AB412-PT6T-2
29-1 -02 HYDRAULIC SYSTEM COMPONENTS - HYDRAULIC PUMP (HYDRAULIC SYSTEM NO. 1)
29-11-02
HYDRAULIC SYSTEM COMPONENTS - HYDRAULIC PUMP (HYDRAULIC
SYSTEM NO. 1)
1. HYDRAULIC PUMP (HYDRAULIC SYSTEM NO. 1) - DESCRIPTION
Hydraulic system No.1 hydraulic pump is installed on transmission sump case. The hydraulic pump is an axial piston type
rated at 6.3 gallons (23.9 liters) per minute at 1000 ± 25 psi (6894.76 ± 172 kPa) at operating speed.
2. HYDRAULIC PUMP (HYDRAULIC SYSTEM NO. 1) - REMOVAL
1. Remove forward pylon fairing and access panel on right side of pylon support structure inside cabin.
2. Loosen connections of hoses (3, 4, 10, and 11, figure 1) on hydraulic pump (2) to break torque but not to point of
leaking.
3. Remove nuts (5), aluminum washers (6), and hydraulic pump (2) from transmission studs. Place pump, with hoses (3,
4, 10 and 11) attached, in container large enough to hold fluid contents of reservoir and hoses.
4. Disconnect hoses (3, 4, 10 and 11) from hydraulic pump (2), draining fluid from reservoir (1) and hoses. Cap or plug
hoses, as applicable.
5. If replacing hydraulic pump (2), remove incline check valve (7) and fittings from pump for reuse on new hydraulic
pump. Discard gasket (8).
6. Plug ports in hydraulic pump to prevent contamination.
3. HYDRAULIC PUMP (HYDRAULIC SYSTEM NO. 1) - INSTALLATION
MATERIALS REQUIRED
NUMBER NOMENCLATURE
C-002 or C-072 1 HYDRAULIC FLUID
NOTE:
1 Refer to Chapter 12 for information on usage and

mixing of hydraulic fluid (C-002) and hydraulic fluid
(C-072).
29-11-02
Rev. 3 Page 1
E-AB412-PT6T-2
CAUTION
DO NOT LUBRICATE SPLINES FOR PUMPS P/N 731634 (PV3-044-8A), P/N

66003-01 (AP2V-77-01), OR P/N 212-076-010-101 WITH NON-METALLIC
COUPLING INSTALLED.
1. Apply a thin coat of bearing grease (C-007) to splines of hydraulic pump (2).
CAUTION
ENSURE HYDRAULIC PUMP CASE IS FULL PRIOR TO INSTALLATION.
2. Fill hydraulic pump (2) with hydraulic fluid (C-002) or hydraulic fluid (C-072) through case drain port.
3. Install fittings and incline check valve (7) into hydraulic pump (2) if not previously accomplished.
4. Position new gaskets (8) and hydraulic pump (2) on studs in hydraulic drive quill (9). Install aluminum washers (6)
and nuts (5). Tighten nuts (5) evenly.
NOTE
If the 212-076-010-001 hydraulic pump is being installed as an alternate to the
PV3-044-8 hydraulic pump, install a MS21916D8-6 reducer and MS28778-8
packing in pressure port of hydraulic pump.
6. Service reservoir (1) (Chapter 12). Install forward pylon fairing.
7. Perform operational check (module 29-01-01 paragraph "5. General maintenance practices - operational checks").
8. Install access panel on pylon support inside cabin.
4. HYDRAULIC PUMP (HYDRAULIC SYSTEM NO. 1) - INSPECTION
1. Inspect hydraulic pump (2) for damage and leakage.
2. Inspect fittings for damaged threads.
3. Inspect incline check valve (7) for damage and proper operation.
4. Inspect splines and mounting studs for damage.
5. HYDRAULIC PUMP (HYDRAULIC SYSTEM NO. 1) - REPAIR
1. Replace damaged studs and fittings as necessary.
2. Replace incline check valve (7) if check valve shows evidence of malfunction.
3. Replace damaged hydraulic pump (2).
29-11-02
Page 2 Rev. 3
E-AB412-PT6T-2
1. Reservoir
2. Hydraulic pump
3. Pressure hose
4. Case drain line
5. Nut
6. Aluminum washers
8. Gasket
9. Hydraulic drive quill
10. Seal drain hose
11. Pump suction hose
G6AB0188B
Figure 1. Hydraulic pump (hydraulic system No. 1)
29-11-02
Rev. 3 Page 3
E-AB412-PT6T-2
29-11-02
Page 4 Rev. 3
E-AB412-PT6T-2
29-1 -03 HYDRAULIC SYSTEM COMPONENTS - HYDRAULIC PUMP (HYDRAULIC SYSTEM NO. 2)
29-11-03
HYDRAULIC SYSTEM COMPONENTS - HYDRAULIC PUMP (HYDRAULIC
SYSTEM NO. 2)
1. HYDRAULIC PUMP (HYDRAULIC SYSTEM NO. 2) - DESCRIPTION
Hydraulic system No.2 hydraulic pump is installed on front of transmission main case. The pump is an axial piston type
rated at 5.6 gallons (21,2 liters) per minute at 1000 ± 25 psi (6894.76 ± 176 kPa) at operating speed.
2. HYDRAULIC PUMP (HYDRAULIC SYSTEM NO. 2) - REMOVAL
NUMBER NOMENCLATURE
COMMERCIAL HYDRAULIC SUCTION GUN
1. Remove forward pylon fairing.
2. Remove hydraulic fluid from hydraulic system II reservoir (2, figure 1) using a suction gun.
3. Disconnect hoses (6, 10, 12, and 14).
4. Remove nuts (7), aluminum washers (8), and hydraulic pump (1).
5. Plug open hoses (6, 10, 12 and 14) to prevent contamination.
3. HYDRAULIC PUMP (HYDRAULIC SYSTEM NO. 2) - INSTALLATION
MATERIALS REQUIRED
NUMBER NOMENCLATURE
NOTE:

(C-072).
29-11-03
Rev. 3 Page 1
E-AB412-PT6T-2
CAUTION
DO NOT LUBRICATE PUMP SPLINE FOR P/N 212-076-011-101 WITH

NON-METALLIC DRIVE SPLINES.
1. Apply a thin coat of bearing grease (C-007) to splines of hydraulic pump (1).
CAUTION
ENSURE HYDRAULIC PUMP CASE IS FULL PRIOR TO INSTALLATION.
2. Fill hydraulic pump (1) with hydraulic fluid (C-002) or hydraulic fluid (C-072) through case drain port.
3. Remove caps and connect hoses (6, 10, 12, and 14).
4. Place new gasket (9) and hydraulic pump (1) over studs on transmission case (11) and secure with aluminum washers
(8) and nuts (7).
5. Service reservoir (2) (Chapter 12).
6. Perform operational check (module 29-01-01 paragraph "5. General maintenance practices - operational checks").
7. Install forward pylon fairing.
4. HYDRAULIC PUMP (HYDRAULIC SYSTEM NO. 2) - INSPECTION
1. Inspect hydraulic pump (1) for damage and signs of leakage.
3. Inspect inline check valve (13) for damage and proper operation.
4. Inspect splines and studs for damage.
5. HYDRAULIC PUMP (HYDRAULIC SYSTEM NO. 2) - REPAIR
1. Replace damaged studs, fittings, and inline check valve (13).
2. Replace damaged hydraulic pump (1).
29-11-03
Page 2 Rev. 3
E-AB412-PT6T-2
1. Hydraulic pump
2. Reservoir
4. Accumulator
6. Pump suction hose
7. Nut
8. Aluminum washer
9. Gasket
10. Hose
11. Transmission
12. Hose
14. Pump pressure hose
G6AB0189B
Figure 1. Hydraulic pump (hydraulic system No. 2)
29-11-03
Rev. 3 Page 3
E-AB412-PT6T-2
29-11-03
Page 4 Rev. 3
E-AB412-PT6T-2
29-1 -04 HYDRAULIC SYSTEM COMPONENTS - HYDRAULIC RESERVOIR
29-11-04
HYDRAULIC SYSTEM COMPONENTS - HYDRAULIC RESERVOIR
1. HYDRAULIC RESERVOIR - DESCRIPTION
The hydraulic system reservoir No. 1 consists of a non-pressurized, magnesium alloy unit located on the R.H. side of the
cabin roof.
The reservoir has a capacity of 0.55 gal (2,5 liters) at overflow and of 1.3 liters (0.29 gal) at refill level. It is fitted with a
sight-gauge, a filler cap and screen, a screened vent, a scupper with overboard drain line and two connections for supply (to
pump) and return (from-system) lines.
The reservoir has a sight glass for visual indication of fluid level. Decals on the reservoirs give reservoir capacity, filling
instructions and type hydraulic fluid required. Each hydraulic system have temperature bulbs reservoir capacity, filling
instructions and type fluid required. Each hydraulic system have a temperature bulbs and temperature switch installed in the
system return fitting of the reservoir. Temperature sensed by the temperature bulbs is transmitted to instruments on the pilot
instrument panel.
The purpose of the switches is to cause the following lights to illuminate in the event that hydraulic fluid temperature
exceeds 88°C (190°F):
— MASTER CAUTION light on instrument panel.
— HYDRAULIC CAUTION segment in caution panel.
In the event the HYDRAULIC CAUTION segment illuminates, the pilot can verify whether fault is high temperature or low
pressure in system No. 1 or system No.2 from separate instrument readings.
2. HYDRAULIC RESERVOIR - REMOVAL
1. Remove forward pylon fairing on cabin roof.
3. Remove majority of fluid from reservoir (1) by removing temperature bulb (4). Catch fluid in suitable container.
4. Disconnect tubes (11 and 16) and hose (14), and catch remaining fluid.
5. If replacing reservoir (1), or removing for cleaning because of contamination, remove fittings and filter screen (10,
figure 2).
6. Remove bolts (8 and 9, figure 1). Remove reservoir (1).
7. Plug open tubes (11 and 16) and hose (14) to prevent contamination.
3. HYDRAULIC RESERVOIR - INSTALLATION
1. Position reservoir (1, figure 1) on cabin roof.
2. Install bolts (8) and washers (7). Install bolts (9), washers (10 and 12), and nuts (13).
3. Install filter screen (10, figure 2) and fittings.
29-11-04
Rev. 3 Page 1
E-AB412-PT6T-2
4. Remove caps and connect tubes (11 and 16, figure 1) and hose (14).
5. Connect electrical connectors (3 and 6) to temperature bulb (4) and temperature switch (5).
7. Perform ground run and verify system functions normally and no leaks are present.
4. HYDRAULIC RESERVOIR - INSPECTION
1. Inspect reservoir (1, figure 2) for mechanical and corrosion damage and evidence of leakage.
2. Inspect cap (5), filler adapter (4), and strainer screen (3) for mechanical and corrosion damage.
3. Inspect fluid level sight plug (7) for cracks, crazing, staining, or other defects that would affect visibility.
4. Inspect vent screen (2) for distortion, corrosion, cracks, and tears. Damage to vent screen (2) resulting in enlarged holes
is not acceptable.
5. Remove screen (10), and inspect for distortion, corrosion, cracks, and tears. Damage to screen (10) resulting in
enlarged holes is not acceptable.
6. Inspect bosses for damaged seal contact surfaces and thread damage.
7. Inspect temperature bulb (11) and temperature switch (12) for damage.
5. HYDRAULIC RESERVOIR - REPAIR
MATERIALS REQUIRED
NUMBER NOMENCLATURE
C-201 PRIMER
C-405 LOCKWIRE
NOTE:

(C-072).
1. Replace unserviceable filler cap strainer screen (3, figure 2) as follows:
a. Unscrew filler adapter (4) from filler opening, and lift out strainer screen (3).
b. Clean threads of filler adapter (4) and opening.
c. Place strainer screen (3) into reservoir (1).
d. Coat filler adapter (4) threads with zinc chromate primer (C-201) and screw filler adapter into reservoir (1).
29-11-04
Page 2 Rev. 3
E-AB412-PT6T-2
2. Replace unserviceable vent screen (2) as follows:
CAUTION
EXERCISE CARE TO PREVENT FOREIGN DEBRIS FROM ENTERING

RESERVOIR (1) WHILE VENT SCREEN (2) IS REMOVED.
a. Carefully drill out area where vent screen (2) is staked in place.
b. Position new vent screen (2) in reservoir (1) and stake in three places to secure vent screen in reservoir.
3. Replace unserviceable sight plug (7) as follows:
a. Remove old sight plug (7).
b. Lubricate new preformed packing (6) with hydraulic fluid (C-002) or hydraulic fluid (C-072) and position
packing on serviceable sight plug (7).
c. Install sight plug (7) and lockwire (C-405) to fitting in adjacent boss.
4. Replace damaged screen (10), damaged or defective temperature bulb (11), and temperature switch (12).
29-11-04
Rev. 3 Page 3
E-AB412-PT6T-2
1. Reservoir
2. Hydraulic pump
4. Temperature bulb
5. Temperature switch
7. Washer
8. Bolt
9. Bolt
10. Washer
11. Tube
12. Aluminum washer
13. Nut
14. Hose
15. Fitting
16. Tube
17. Cabin roof structure
G6AB0192B
Figure 1. Hydraulic reservoir arrangement
29-11-04
Page 4 Rev. 3
E-AB412-PT6T-2
1. Reservoir
2. Vent screen
3. Strainer screen
4. Filler adapter
5. Cap
6. Preformed packing
7. Sight plug
9. Plug
10. Filter screen
11. Temperature bulb
G6AB0193B
Figure 2. Hydraulic reservoir assembly
29-11-04
Rev. 3 Page 5
E-AB412-PT6T-2
29-11-04
Page 6 Rev. 3
E-AB412-PT6T-2
29-1 -05 HYDRAULIC SYSTEM COMPONENTS - VALVES
29-11-05
HYDRAULIC SYSTEM COMPONENTS - VALVES
1. INTEGRATED VALVE AND FILTER ASSEMBLY - DESCRIPTION
Hydraulic system No.1 and hydraulic system No.2 have separate integrated valve and filter assemblies. Each assembly is
comprised of a valve body with the following components installed: pressure filter, return filter, pressure relief valve,
thermal relief valve, return shutoff valve, clogged filter indicators, clogged filter switch, and a solenoid-operated valve
which allows fluid to flow in either direction in event of system failure. The pressure and return filters are completely
separate. Each filter is provided with an indicator button which extends at 70 psi (483 kPa) differential pressure across the
filter. This indicator gives a visual indication of filter clogging. The indicator button described above trips an electrical
switch on the integrated valve and filter assembly which causes an indicator located in helicopter nose compartment to
change from green to red. The indicator is visible through the right nose window.
The system pressure relief valve opens at 1100 psi (7584.23 kPa) to allow fluid to return to reservoir.
The return shutoff valve is pressure operated. When system pressure decreases, the shutoff valve closes to maintain pressure
in cyclic, collective, and directional servo actuators.
The thermal relief valve prevents damage to hydraulic system components due to excessive pressure buildup by trapped
hydraulic fluid when helicopter is not operating.
The solenoid operated system bypass valve is normally de-energized. In the event of failure of hydraulic system No.1, the
pilot can position HYDR SYS NO. 1 switch to OFF. This will cause bypass valve to directly connect pressure port to return
port to prevent hydraulic lock within hydraulic system No.1.
Operation of the corresponding valve in hydraulic system No.2 is the same except the pilot positions HYDR SYS NO. 2
switch to OFF.
NOTE
Except as noted, the following procedures are the same for hydraulic systems No.1
and 2.
2. INTEGRATED VALVE AND FILTER ASSEMBLY - REMOVAL
1. Remove access panel on forward side of pylon support inside cabin, for hydraulic system No.1.
NOTE
Disconnecting tube (4, figure 1) will drain fluid from reservoir. Provide a suitable
container to catch fluid.
3. Disconnect tubes and hoses (2, 3, 6, 10, 16, 17, 18, 19, and 20). Remove clamps and loosen opposite ends of tubes as
needed.
4. Disconnect electrical connectors (9, 11, and 12).
5. Remove bolts (7 and 15). Remove integrated valve and filter assembly (1).
29-11-05
Rev. 3 Page 1
E-AB412-PT6T-2
6. Plug open lines to prevent contamination.
3. INTEGRATED VALVE AND FILTER ASSEMBLY - INSTALLATION
1. Position integrated valve and filter assembly (1, figure 1). Install four bolts (7 and 15) and thin aluminum washers (8
and 14).
2. Connect electrical connectors (9, 11, and 12).
3. Connect tubes and hoses (2, 3, 6, 10, 16, 17, 18, 19, and 20). Install clamps. Tighten fittings at opposite ends of all
tubes.
7. Install access panels.
4. INTEGRATED VALVE AND FILTER ASSEMBLY - INSPECTION
1. Inspect integrated valve and filter assembly (1, figure 2) for damage and signs of leakage. Inspect clogged filter
indicators for tripped condition.
2. Inspect inline check valves (2, 7, and 8) and elbow check valve (11) for damage.
3. Inspect pressure switch (5) for damage.
5. ELBOW CHECK VALVE - DESCRIPTION
Hydraulic system No.1 and hydraulic system No.2 each have elbow check valves installed at the outlet port of integrated
valve and filter assembly. The check valves prevent loss of hydraulic fluid when filter is removed for inspection.
NOTE
The following procedures are the same for hydraulic systems No.1 and 2.
6. ELBOW CHECK VALVE - REMOVAL
1. Remove access panel on forward side of pylon support structure.
NOTE
Disconnecting tube (6, figure 3) will drain fluid from reservoir. Provide a suitable
container to catch fluid.
3. Loosen nut (4). Remove elbow check valve (5). Remove and discard preformed packings (2).
29-11-05
Page 2 Rev. 3
E-AB412-PT6T-2
4. Plug open tube (6) to prevent contamination.
7. ELBOW CHECK VALVE - INSTALLATION
1. Install nut (4, figure 3) all the way into elbow check valve (5).
2. Install retainer (3) into elbow check valve (5).
3. Lubricate new preformed packing (2) with same type hydraulic fluid used in system (Chapter 12). Position packing on
unthreaded area of elbow check valve (5).
4. Install elbow check valve (5) into integrated valve and filter assembly (1) until preformed packing (2) contacts
integrated valve and filter assembly.
6. Tighten nut (4).
7. Install access panel.
8. ELBOW CHECK VALVE - INSPECTION
NUMBER NOMENCLATURE
COMMERCIAL HYDRAULIC HAND PUMP
1. Inspect elbow check valve (5, figure 3) for damage.
2. Attach elbow check valve (5) to a hand pump. Verify fluid passes in direction of arrow, and is blocked in opposite
direction.
9. INLINE CHECK VALVE - DESCRIPTION
Hydraulic system No.1 contains seven inline check valves as follows: three in return ports on integrated valve and filter
assembly, one between ground test connections, one between ground test pressure connection and pump pressure line, one
at directional control actuator inlet, and one in hydraulic pump case drain outlet.
Hydraulic system No.2 contains six inline check valves as follows: three in return ports on integrated valve and filter
assembly, one between ground test connections, one between ground test pressure connection and pump pressure line, and
one in hydraulic pump case drain outlet.
NOTE
29-11-05
Rev. 3 Page 3
E-AB412-PT6T-2

2. Tube
3. Tube
4. Tube
5. Support
6. Tube
7. Bolt
10. Tube
13. Bracket
15. Bolt
16. Hose
17. Hose
18. Hose
19. Hose
20. Tube
G6AB0194B
Figure 1. Integrated valve and filter assembly arrangement
29-11-05
Page 4 Rev. 3
E-AB412-PT6T-2

5. Pressure switch
11. Elbow check valve
12. Nut
13. Retainer
G6AB0195B
Figure 2. Integrated valve and filter assembly
29-11-05
Rev. 3 Page 5
E-AB412-PT6T-2

3. Retainer
4. Nut
5. Elbow check valve
6. Tube
G6AB0196B
Figure 3. Elbow check valve
29-11-05
Page 6 Rev. 3
E-AB412-PT6T-2
10. INLINE CHECK VALVE - REMOVAL
1. Remove access panels as necessary to reach inline check valve (3, figure 4).
2. Disconnect hose (4) from inline check valve (3).
3. Remove inline check valve (3). Remove and discard preformed packing (2).
11. INLINE CHECK VALVE - INSTALLATION
1. Lubricate new preformed packing (2, figure 4) with hydraulic fluid (Chapter 12) and install on inline check valve (3).
2. Install inline check valve (3) into integrated valve and filter assembly (1), carefully observing arrow and direction of
fluid flow.
3. Connect hose (4) to inline check valve (3).
12. INLINE CHECK VALVE - INSPECTION
NUMBER NOMENCLATURE
1. Inspect inline check valve (3, figure 4) for damage.
2. Use a hand pump to verify inline check valve (3) will pass fluid in direction of arrow and blocks fluid in opposite
direction.
13. THREE-WAY, TWO-POSITION, PRESSURE-OPERATED VALVE - DESCRIPTION
Hydraulic system No.1 and hydraulic system No.2 have separate three-way, two-position, pressure-operated valves. The
valves port system return fluid to ground test run fitting when 90 to 360 psi (621 to 2482 kPa) pressure is applied to ground
test pressure connection. This prevents over filling reservoir. The valves are located in the compartment below transmission.
NOTE
29-11-05
Rev. 3 Page 7
E-AB412-PT6T-2

4. Hose
G6AB0197B
Figure 4. Inline check valve
29-11-05
Page 8 Rev. 3
E-AB412-PT6T-2
14. THREE-WAY, TWO-POSITION, PRESSURE-OPERATED VALVE - REMOVAL
NUMBER NOMENCLATURE
COMMERCIAL HYDRAULIC SUCTION GUN
2. Remove hydraulic fluid from reservoir (2, figure 5) with a hydraulic suction gun.
3. Remove access panel on forward side of pylon support.
NOTE
Removal of tube (10) will drain reservoir. Provide suitable container to catch fluid.
5. Disconnect tubes (6, 7, and 8).
6. Remove bolts (9) and three-way, two-position, pressure-operated valve (5).
7. Cap or plug open tubes to prevent contamination.
15. THREE-WAY, TWO-POSITION, PRESSURE-OPERATED VALVE - INSTALLATION
1. Install fittings and reducers on three-way, two-position, pressure-operated valve (5, figure 5). Install tube (12) if
removed.
2. Place valve (5) against bracket (11) and loosely install bolts (9).
3. Connect tubes (6, 7, 8, and 10).
4. Tighten bolts (9).
6. Install pylon fairing.
16. THREE-WAY, TWO-POSITION, PRESSURE-OPERATED VALVE - INSPECTION
Inspect valve body for damaged threads.
29-11-05
Rev. 3 Page 9
E-AB412-PT6T-2
1. Hydraulic pump
2. Reservoir
4. Accumulator
5. Three-way, two-position, pressure-operated valve
6. Tube
7. Tube
8. Tube
9. Bolt
10. Tube
11. Bracket
12. Tube
G6AB0198B
Figure 5. Three-way, two-position, pressure operated valve
29-11-05
Page 10 Rev. 3
E-AB412-PT6T-2
29-1 -06 HYDRAULIC SYSTEM COMPONENTS - PRESSURE SWITCH
29-11-06
HYDRAULIC SYSTEM COMPONENTS - PRESSURE SWITCH
1. PRESSURE SWITCH - DESCRIPTION
Hydraulic system No. 1 and hydraulic system No. 2 each have a pressure operated switch installed in integrated valve and
filter assembly. The switches cause the appropriate caution segment (NO. 1 HYDRAULIC and/or NO. 2 HYDRAULIC) to
illuminate in the event pressure in affected system decreases below 650 psi (4481.6 kPa).
In the event caution segment(s) illuminates, the pilot can verify whether fault is low pressure or high temperature in
hydraulic system No. 1 or hydraulic system No. 2 from separate instrument readings.
NOTE
The following procedures are the same for hydraulic system No. 1 and hydraulic
system No. 2.
2. PRESSURE SWITCH - REMOVAL
1. Remove access panel on forward side of pylon support structure inside cabin.
3. Remove pressure switch (3). Remove and discard preformed packing (4).
4. Plug open fitting to prevent contamination.
3. PRESSURE SWITCH - INSTALLATION
1. Lubricate new preformed packing (4, figure 1) with hydraulic fluid (Chapter 12) and install on pressure switch (3).
2. Install pressure switch (3) into fitting.
29-11-06
Rev. 3 Page 1
E-AB412-PT6T-2

3. Pressure switch
G6AB0199B
Figure 1. Pressure switch
29-11-06
Page 2 Rev. 3
E-AB412-PT6T-2
29-1 -07 HYDRAULIC SYSTEM COMPONENTS - HYDRAULIC ACCUMULATOR
29-11-07
HYDRAULIC SYSTEM COMPONENTS - HYDRAULIC ACCUMULATOR
1. HYDRAULIC ACCUMULATOR - DESCRIPTION
Hydraulic No. system 1 and hydraulic system No. 2 have separate accumulators installed on the aft side of lift beam below
the transmission. The source of energy for the accumulators is a spring loaded piston which is compressed when hydraulic
pump is operating. In the event of pump failure, the spring loaded piston maintains pressure in system for a limited time.
NOTE
The following procedures are the same for Hydraulic system No. 1 and hydraulic
system No. 2.
2. HYDRAULIC ACCUMULATOR - REMOVAL
1. Disconnect tube (5, figure 1).
2. Plug tube (5) to prevent contamination.
3. Remove bolts (8 and 10). Remove accumulator (3).
4. Remove clamp (6) from accumulator (3).
3. HYDRAULIC ACCUMULATOR - INSTALLATION
1. Install clamp (6, figure 1) on accumulator (3).
2. Secure accumulator (3) to lift beam (11) with bolts (10) and aluminum washers (9).
3. Install bolt (8), aluminum washers (7 and 12), and nut (13).
4. HYDRAULIC ACCUMULATOR - INSPECTION
1. Inspect accumulator (3, figure 1) for damage and signs of leakage.
2. Inspect for fluid leaking from weep hole in spring end of accumulator (3). If fluid is leaking from weep hole, reseal
unit (E-AB412-PT6T-3).
29-11-07
Rev. 3 Page 1
E-AB412-PT6T-2
1. Reservoir
2. Hydraulic pump
3. Accumulator
5. Tube
6. Clamp
7. Aluminum washer
8. Bolt
9. Aluminum washer
10. Bolt
11. Lift beam
12. Aluminum washer
13. Nut
G6AB0200B
Figure 1. Hydraulic accumulator
29-11-07
Page 2 Rev. 3
E-AB412-PT6T-2
29-1 -08 HYDRAULIC SYSTEM COMPONENTS - HYDRAULIC CHECK VALVE
29-11-08
HYDRAULIC SYSTEM COMPONENTS - HYDRAULIC CHECK VALVE
1. HYDRAULIC CHECK VALVE - DESCRIPTION
Hydraulic system No. 1 and hydraulic system No. 2 have separate hydraulic check valves installed between the pump and
integrated valve and filter assembly in the compartment below transmission. The valves prevent pump from being
pressurized and reservoir from being overfilled when ground test connection is used.
NOTE
The following procedures are the same for hydraulic systems No. 1 and hydraulic
system No. 2.
2. HYDRAULIC CHECK VALVE - REMOVAL
1. Remove access panel on forward side of pylon.
NOTE
When disconnecting pump pressure hose (4, figure 1), provide suitable container to
catch fluid.
2. Disconnect pump pressure hose (4).
3. Disconnect tubes (10, and 11).
4. Remove nut (5) and hydraulic check valve (3).
5. Remove and discard preformed packing (8).
6. Cap or plug open tubes and hose to prevent contamination.
3. HYDRAULIC CHECK VALVE - INSTALLATION
1. Install new fittings and preformed packing (8, figure 1) and inline check valve (9) if hydraulic check valve (3) is being
replaced.
2. Place union (7) through structure (6) and loosely install nut (5).
3. Connect pump pressure hose (4) and tubes (10 and 11).
4. Tighten nut (5).
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Rev. 3 Page 1
E-AB412-PT6T-2
4. HYDRAULIC CHECK VALVE - INSPECTION
NUMBER NOMENCLATURE
1. Inspect inline check valve (9, figure 1) for proper operation and damage using hydraulic hand pump.
2. Inspect fittings for damage.
3. Inspect hydraulic check valve (3) for damage, signs of leakage, and proper operation.
5. HYDRAULIC CHECK VALVE - REPAIR
1. Replace inline check valve (9, figure 1) if defective.
2. Replace damaged fittings.
3. Replace hydraulic check valve (3) if defective.
29-11-08
Page 2 Rev. 3
E-AB412-PT6T-2
1. Reservoir
2. Hydraulic pump
5. Nut
6. Structure
7. Union
10. Tube
11. Tube
G6AB0201B
Figure 1. Hydraulic check valve
29-11-08
Rev. 3 Page 3
E-AB412-PT6T-2
29-11-08
Page 4 Rev. 3
E-AB412-PT6T-2
29-1 -09 HYDRAULIC SYSTEM COMPONENTS - PRESSURE TRANSMITTER
29-11-09
HYDRAULIC SYSTEM COMPONENTS - PRESSURE TRANSMITTER
1. PRESSURE TRANSMITTER - DESCRIPTION
Hydraulic system No.1 and hydraulic system No.2 have pressure transmitters installed in the compartment below the
transmission. Pressure sensed by the transmitters is transmitted to instruments on the pilot instrument panel.
NOTE
Except as noted, the following procedures are the same for hydraulic systems No.1
and hydraulic system No. 2.
2. PRESSURE TRANSMITTER - REMOVAL
1. Remove access panel on forward side of pylon structure for hydraulic system No.1.
3. Disconnect tube(s) (9) and (10), if installed.
4. Plug open tubes to prevent contamination.
5. Remove screws (7), thin aluminum washers (6), and transmitter (4).
6. Remove restrictor from pressure transmitter (4) (hydraulic system No.1).
3. PRESSURE TRANSMITTER - INSTALLATION
NOTE
Hydraulic system 1 restrictor is installed on pressure transmitter.
1. Place pressure transmitter (4, figure 1) into lift beam bracket (5) and secure with screws (7) and thin aluminum washers
(6).
2. Install restrictor on pressure transmitter (4) (hydraulic system 1).
3. Connect tube(s) (9) and (10), if installed.
29-11-09
Rev. 3 Page 1
E-AB412-PT6T-2
4. PRESSURE TRANSMITTER - INSPECTION
Inspect pressure transmitter (4, figure 1) for damage or signs of leakage.
29-11-09
Page 2 Rev. 3
E-AB412-PT6T-2
1. Reservoir
2. Hydraulic pump
5. Lift beam bracket
7. Screw
9. Pressure tube
10. Drain tube
NOTE:
1 Not installed on helicopters with transmitter APTE-139-1500SG.
G6AB0202B
Figure 1. Pressure transmitter
29-11-09
Rev. 3 Page 3
E-AB412-PT6T-2
29-11-09
Page 4 Rev. 3
E-AB412-PT6T-2
29-1 -10 HYDRAULIC SYSTEM COMPONENTS - PULSATION DAMPER (HYDRAULIC SYSTEM NO. 2)
29-11-10
HYDRAULIC SYSTEM COMPONENTS - PULSATION DAMPER
(HYDRAULIC SYSTEM NO. 2)
1. PULSATION DAMPER (HYDRAULIC SYSTEM NO. 2) - DESCRIPTION
Hydraulic system No. 2 has a pulsation damper installed in pump pressure line to dampen hydraulic pressure pulsations,
thereby reducing system induced noise.
2. PULSATION DAMPER (HYDRAULIC SYSTEM NO. 2) - REMOVAL
2. Disconnect pump pressure hose (4, figure 1) and tube (9).
3. Plug open tube and hose to prevent contamination.
4. Remove screws (6, 10, and 15), thin aluminum washers (7, 11, and 14) and remove pulsation damper (3).
5. Remove clamps (5, 8, and 12) from pulsation damper (3).
3. PULSATION DAMPER (HYDRAULIC SYSTEM NO. 2) - INSTALLATION
1. Place clamps (5, 8, and 12, figure 1) on pulsation damper (3).
2. Position pulsation damper (3) onto bracket (13). Install screws (6, 10, and 15) and thin aluminum washers (7, 11, and
14).
3. Connect pump pressure hose (4) and tube (9).
4. Service hydraulic reservoir (1) (Chapter 12).
29-11-10
Rev. 3 Page 1
E-AB412-PT6T-2
1. Hydraulic reservoir
2. Reservoir
3. Pulsation damper
5. Clamp
6. Screw
8. Clamp
9. Tube
10. Screw
12. Clamp
13. Bracket
15. Screw
G6AB0203B
Figure 1. Pulsation damper (hydraulic system No. 2)
29-11-10
Page 2 Rev. 3
E-AB412-PT6T-2
29-1 -1 HYDRAULIC SYSTEM COMPONENTS - HYDRAULIC SYSTEM RESERVOIR NO. 2 AND NO. 3 [B] [C]
29-11-11
HYDRAULIC SYSTEM COMPONENTS - HYDRAULIC SYSTEM RESERVOIR
NO. 2 AND NO. 3 [B] [C]
1. HYDRAULIC SYSTEM RESERVOIR NO. 2 AND NO. 3 [B] [C] - DESCRIPTION
The hydraulic system reservoir No. 2 consists of a non-pressurized, aluminum alloy unit located on the L.H side of the cabin
roof and provides support to the utility hydraulic system reservoir No. 3.
The reservoir has a capacity of 0.395 gal (1.8 lt). Capacity at minimum level is 0.30 gal (1.4 lt). It is fitted with a sight-gauge,
a filler cap and screen, a screened vent, a drain tap, a scupper with over-board drain line and two connections for supply (to
pump) and return (from system) lines.
The reservoir has a sight glass for visual indication of fluid level. Decals on the reservoirs give reservoir capacity, filling
instructions and type hydraulic fluid required. Each hydraulic System have temperature bulbs and temperature switch
installed in the System return fitting of the reservoir. Temperature sensed by the temperature bulbs is transmitted to
instruments on the pilot instrument panel.
The purpose of the switches is to cause the following lights to illuminate in the event that hydraulic fluid temperature
exceeds 88°C (190°F):
— MASTER CAUTION light on instrument panel.
— HYDRAULIC CAUTION segment in caution panel.
In the event the HYDRAULIC CAUTION segment illuminates the pilot can verify whether fault is high temperature or low
pressure in hydraulic system No. 1 or hydraulic system No. 2 from separate instrument readings.
NOTE
The maintenance procedures are the same for hydraulic system reservoir No. 2 and
No. 3.
2. HYDRAULIC SYSTEM RESERVOIR NO. 2 AND NO. 3 [B] [C] - REMOVAL
1. Remove forward pylon fairing on cabin roof.
3. Remove majority of fluid from reservoir (1) by remove drain plug (8, figure 2): catch fluid in suitable container.
4. Disconnect tubes (6 and 11, figure 1) and hose (14) and catch remaining fluid.
5. Remove reservoir (1) from roof structure by removing bolts (3 and 13), washers (4 and 12) and nuts (5).
NOTE
Pay attention that No. 3 reservoir supply line fitting is located inside No. 2 reservoir
structure.
6. Plug open tubes (6 and 11) and hose (14) to prevent contamination.
29-11-11
Rev. 3 Page 1
E-AB412-PT6T-2
SEE DETAIL A
1
1
14
3
4
4
5
13
12
11
6
10
9
7 8
DETAIL A
1. Reservoir No. 2 and No. 3

2. Hydraulic pump
3. Bolt
4. Washer
5. Nut
6. Tube
7. Temperature bulb
11. Tube
12. Washer
13. Bolt
14. Hose
G6AB0992B
Figure 1. Hydraulic system reservoir No. 2 and No. 3 arrangement [B] [C]
29-11-11
Page 2 Rev. 3
E-AB412-PT6T-2
3. HYDRAULIC SYSTEM RESERVOIR NO. 2 AND NO. 3 [B] [C] - INSTALLATION
1. Position reservoir (1, figure 1) on cabin roof and install bolts (3 and 13), washers (4 and 12) and nuts (5).
2. Install filter screen (11, figure 2) and fittings.
3. Remove caps and connect tubes (6 and 11, figure 1) and hose (14).
4. Connect electrical connectors (8 and 10) to temperature bulb (7) and temperature switch (9).
6. Perform ground run and check that system functions normally and no leaks are present.
4. HYDRAULIC SYSTEM RESERVOIR NO. 2 AND NO. 3 [B] [C] - INSPECTION
1. Inspect reservoir (1, figure 1) form mechanical and corrosion damage and evidence of leakage.
2. Inspect filler cap (2 and 3, figure 2) for mechanical and corrosion damage.
3. Inspect fluid level sight gauge (4 and 5) for cracks, crazing, staining, or other defects that would effect fluid visibility.
4. Inspect vent screen (6) for distortion, corrosion, cracks and tears. Damage to vent screen (6) resulting in enlarged holes
is not acceptable.
5. Remove screen (11), and inspect for distortion, corrosion, cracks and tears. Damage to screen (11) resulting in enlarged
holes is not acceptable.
6. Inspect plugs (10 and 8) for mechanical and corrosion damage, and filter (9) for obstruction or damage.
7. Inspect filter (7) for obstruction or damage.
8. Inspect bosses for damaged seal contact surfaces and thread damage.
9. Inspect temperature bulb (12) and temperature switch (13) for damage.
29-11-11
Rev. 3 Page 3
E-AB412-PT6T-2
5. HYDRAULIC SYSTEM RESERVOIR NO. 2 AND NO. 3 [B] [C] - REPAIR
MATERIALS REQUIRED
NUMBER NOMENCLATURE
C-405 LOCKWIRE
NOTE:
1 Refer to Chapter 12 for information on usage and mixing of hydraulic fluid

(C-002) and hydraulic fluid (C-072).
1. Remove filler cap (2 and 3, figure 2) and replace if unserviceable.
CAUTION
EXERCISE CARE TO PREVENT FOREIGN DEBRIS FROM ENTERING

RESERVOIR (1) WHILE VENT SCREEN (6) IS REMOVED.
2. Replace unserviceable vent screen (6) as follows:
a. Carefully drill out area where vent screen (6) is stacked in place.
b. Position new vent screen (6) in reservoir (1) and stake in three places to secure vent screen to reservoir.
3. Replace unserviceable sight gauge (4 and 5) as follows:
a. Remove old sight gauge (4 and 5).
b. Lubricate new preformed packings (14) with hydraulic fluid (C-002) or hydraulic fluid (C-072) and position
packing on serviceable sight gauge (4 and 5).
c. Install sight gauge and lockwire (C-405) to fitting in adjacent boss.
4. Replace filter (7) if damaged or clogged; replace respective seals if damaged or worn.
5. Replace damaged filter screen (11), damaged or defective temperature bulb (12), and temperature switch (13).
6. Replace any damaged fittings. Replace reservoir (1) if cracked or otherwise unserviceable.
29-11-11
Page 4 Rev. 3
E-AB412-PT6T-2
14
14
1. Reservoir No. 2 and No. 3 8. Drain plug

2. Filler cap 9. Filter
3. Filler cap 10. Plug
4. Sight gauge 11. Filter screen
5. Sight gauge 12. Temperature bulb
6. Vent screen 13. Temperature switch
7. Filter 14. Preformed packing
G6AB0993B
Figure 2. Hydraulic system reservoir No. 2 and No. 3 assembly [B] [C]
29-11-11
Rev. 3 Page 5
E-AB412-PT6T-2
29-11-11
Page 6 Rev. 3
E-AB412-PT6T-2
29-11-12
29-11-12
HYDRAULIC SYSTEM COMPONENTS - HYDRAULIC FILTER ASSEMBLIES
1. HYDRAULIC FILTER ASSEMBLIES - DESCRIPTION
The pressure and return filter assemblies are located on the bottom of the integrated valve and filter assembly valve body.
Each filter assembly contains: a filter bowl, a a filter element, two packings, and a retainer. The hydraulic filter element
removes the element removes the particles from the hydraulic fluid. These particles come from usual, and sometimes
unusual, wear of hydraulic components. Examine, clean, or replace filter element when the impending bypass indicator
button extends (pops), or at recommended inspection intervals (refer to E-AB412-PT6T-6).
2. HYDRAULIC FILTER ASSEMBLIES (P/N 212-076-006-7) - REMOVAL
1. Remove the forward pylon fairing (Chapter 52).
2. Remove lockwire from filter bowl (6, figure 1) and valve body (1).
3. Remove filter bowl (6).
NOTE
If filter element is to be used again, put it in a new, clean plastic bag to prevent
contamination.
4. Remove retainer (3) and filter element (5).
5. Remove and discard packings (2 and 4).
3. HYDRAULIC FILTER ASSEMBLIES (P/N 212-076-006-105) - REMOVAL
1. Remove the forward pylon fairing (Chapter 52).
2. Press on ratchet lever (10, figure 1) and remove filter bowl (11).
NOTE
If filter element is to be used again, put it in a new, clean plastic bag to prevent
contamination.
3. Remove retainer (14) and filter element (12).
29-11-12
Rev. 3 Page 1
E-AB412-PT6T-2
INTEGRATED VALVE AND FILTER ASSEMBLY INTEGRATED VALVE AND FILTER ASSEMBLY
(P/N 212-076-006-7) (P/N 212-076-006-105)
1. Valve body 9. Indicator button

2. Packing 10. Ratchet lever
3. Retainer 11. Filter bowl
4. Packing 12. Filter element
5. Filter element 13. Packing
6. Filter bowl 14. Retainer
7. Indicator button 15. Packing
8. Valve body
G6AB1024A
Figure 1. Hydraulic filter assemblies
29-11-12
Page 2 Rev. 3
E-AB412-PT6T-2
4. HYDRAULIC FILTER ASSEMBLIES (P/N 212-076-006-7) - INSTALLATION
MATERIALS REQUIRED
NUMBER NOMENCLATURE
C-405 LOCKWIRE
NOTE:

(C-072).
NOTE
Lubricate all packings, retainers, and threads with hydraulic fluid (C-002) before
installation.
CAUTION
DO NOT USE NON-CLEANABLE P/N 205-076-034-003 AND CLEANABLE

P/N 205-076-034-7 FILTER ELEMENTS IN THE SAME SYSTEM. DO NOT
MIX.
1. Lubricate packing (2, figure 1), with hydraulic fluid (C-002) or hydraulic fluid (C-072).
2. Install packing (2) in valve body (1).
3. Lubricate packing (4) with clean hydraulic fluid (C-002) or hydraulic fluid (C-072).
4. Install packing (4) in filter element (5).
5. Install filter element (5) and retainer (3) into filter bowl (6).
6. Fill filter bowl (6) half full with clean hydraulic fluid (C-002) or hydraulic fluid (C-072).
7. Lubricate threads of filter bowl (6) with clean hydraulic fluid (C-002) or hydraulic fluid (C-072).
8. Install filter bowl (6) in valve body (1).
CAUTION
DO NOT EXCESSIVELY TIGHTEN THE LOCKWIRE ON FILTER BODY AND

FILTER BOWL. DAMEGE TO THE LOCKWIRE HOLES CAN OCCUR.
9. Carefully secure filter bowl (6) to valve body (1) with lockwire (C-405).
10. Install the forward pylon fairing (Chapter 52).
29-11-12
Rev. 3 Page 3
E-AB412-PT6T-2
5. HYDRAULIC FILTER ASSEMBLIES (P/N 212-076-006-105) - INSTALLATION
MATERIALS REQUIRED
NUMBER NOMENCLATURE
NOTE:

(C-072).
CAUTION
DO NOT USE NON-CLEANABLE P/N 205-076-034-003 AND CLEANABLE P/

N 205-076-034-7 FILTER ELEMENTS IN THE SAME SYSTEM. DO NOT MIX.
1. Lubricate packing (15, figure 1) with hydraulic fluid (C-002) or hydraulic fluid (C-072).
2. Install packing (15) and retainer (14) in valve body (8).
3. Lubricate packing (13) with clean hydraulic fluid (C-002) or hydraulic fluid (C-072).
4. Install packing (13) in filter element (12).
5. Install filter element (12) into filter bowl (11).
6. Fill filter bowl (11) half full with clean hydraulic fluid (C-002) or hydraulic fluid (C-072).
7. Lubricate threads of filter bowl (11) with clean hydraulic fluid (C-002) or hydraulic fluid (C-072).
8. Install filter bowl (11) in valve body (8).
9. Make sure the ratchet lever (10) is well engaged in the ratchet teeth of filter bowl (11).
10. Install the forward pylon fairing (Chapter 52).
11. During initial run-up, check for leaks.
6. HYDRAULIC FILTER ASSEMBLIES - CLEANING
MATERIALS REQUIRED
NUMBER NOMENCLATURE
C-003 TURBINE FUEL
29-11-12
Page 4 Rev. 3
E-AB412-PT6T-2
(Cont.d)
NUMBER NOMENCLATURE
C-304 DRYCLEANING SOLVENT
C-355 DETERGENT
NOTE:

(C-072).
CAUTION
CLEAN HYDRAULIC COMPONENTS WITH DRYCLEANING SOLVENT

(C-304) ONLY. DO NOT USE ALCOHOL.
NOTE
Discard contaminated non-cleanable P/N 205-076-034-003 filter elements.
Examine filter for ‘X’s inscribed on the filter.
If there are three ‘X’s inscribed on filter element P/N 205-076-034-7, discard filter.
1. Use a suitable clean container large enough to hold cleanable filter element (5, figure 1) P/N 205-076-034-7.
2. Pour enough of one of the following fluids to cover filter element (5): hydraulic fluid (C-002) or hydraulic fluid
(C-072), drycleaning solvent (C-304), 0.5% of detergent (C-355) dissolved in clean warm water, or turbine fuel
(C-003).
3. Cap or plug both ends of the filter element (5) to prevent contamination migration into the filter element.
NOTE
Discard cleanable filter element P/N 205-076-034-7 after three cleaning events.
4. Insert cleanable filter element (5) only into container and vigorously agitate the filter in the cleaning fluid.
5. Attach an air hose with a nozzle and rubber grommet to the filter element (5) to prevent air from escaping.
CAUTION
USE NO MORE THAN 10 TO 15 PSI (68.95 TO 103.42 KPA) AIR PRESSURE

SO AS NOT TO DAMAGE THE FILTER ELEMENT.
6. Using no more than 10 to 15 psi (68.95 to 103.42 kPa) air pressure, slowly backflush the cleaning fluid through the
filter element (5) a maximum of three times until there is no indication of contamination.
NOTE
Discard cleanable filter element P/N 205-076-034-7 after three cleaning events.
7. Make an ‘X’ on bottom of filter element (5) for each cleaning event.
29-11-12
Rev. 3 Page 5
E-AB412-PT6T-2
8. Rinse the filter element (5) with clean hydraulic fluid (C-002) or hydraulic fluid (C-072) to remove traces of the
cleaning fluid.
9. Dry filter element (5) using filtered, compressed air. If element is not going to be installed immediately, put it in a new
plastic bag to prevent contamination.
10. Rinse filter bowl (5) with clean hydraulic fluid (C-002) or hydraulic fluid (C-072).
7. HYDRAULIC FILTER ASSEMBLIES (P/N 212-076-006-7) - INSPECTION
1. Examine the hydraulic fluid in filter bowl (6, figure 1) for conditions and for particles.
2. If the hydraulic fluid is dirty, discolored, or contains bubbles, flush the system (module 29-01-01 paragraph "4. General
maintenance practices - flushing").
3. Examine valve body (1), retainer (3), and filter bowl (6) for scratches, nicks, dents, thread damage, and damage to the
lockwire holes.
4. If the lockwire holes in the valve body (1) are damaged, replace the valve body.
5. Examine impending bypass indicator button (7) to make sure it is not in the extended position.
6. Examine the filter element (5) for general condition. Pay particular attention to damage to the filtering surfaces, and
bonding of the end caps to the filtering core.
7. Replace filter element (5) if any abnormality is found.
8. Inspect the filter element (5) core for metals, brass, and aluminium contamination.
9. Replace the non-cleanable filter element (5) P/N 205-076-034-003 if contamination is found and flush the hydraulic
system.
8. HYDRAULIC FILTER ASSEMBLIES (P/N 212-076-006-105) - INSPECTION
1. Examine the hydraulic fluid in filter bowl (11, figure 1) for condition and for particles.
2. If the hydraulic fluid is dirty, discolored, or contains bubbles, flush the system (module 29-01-01 paragraph "4. General
maintenance practices - flushing").
3. Examine valve body (8), retainer (14), and filter bowl (11) for scratches, nicks, dents, and thread damage.
4. Examine ratchet lever (10) for wear and security of installation.
5. Examine ratchet teeth on filter bowl (11) for wear.
6. Examine impending bypass indicator button (9) to make sure it is not in the extended position.
7. Examine the filter element (12) for general condition. Pay particular attention to damage to the filtering surfaces, and
bonding of the end caps to the filtering core.
8. Replace filter element (12) if any abnormality is found.
9. Inspect the filter element (12) for metal, brass, and aluminium contamination.
10. Replace the non-cleanable filter element (12) P/N 205-076-034-003 if contamination is found and flush the hydraulic
system.
29-11-12
Page 6 Rev. 3
E-AB412-PT6T-2
CHAPTER 30 - ICE AND RAIN PROTECTION

Module Page
Number Title Number
30-00-00 ICE AND RAIN PROTECTION
1. Ice and rain protection - general ............................................................................................................. 1
30-41-01 WINDSHIELD WIPER
1. Windshield wiper - windshield wiper assembly ..................................................................................... 1

1-1. windshield wiper assembly - operational check ............................................................................ 1
1-2. Windshield wiper assembly - troubleshooting .............................................................................. 1
1-3. Windshield wiper assembly - inspection ....................................................................................... 2
1-4. Windshield wiper assembly - adjustment ...................................................................................... 2
2. Windshield wiper blade - removal........................................................................................................... 4
3. Windshield wiper blade - installation ..................................................................................................... 4
4. Windshield wiper - removal ................................................................................................................... 4
5. Windshield wiper - installation ............................................................................................................... 4
6. Windshield wiper arm - removal ............................................................................................................ 5
7. Windshield wiper arm - installation ........................................................................................................ 5
8. Windshield wiper head guard - removal ................................................................................................. 6
9. Windshield wiper head guard - installation ............................................................................................ 6
10. Windshield wiper converter and motor - removal .................................................................................. 6
11. Windshield wiper converter and motor - installation .............................................................................. 7
30-42-01 ANTI-ICING, DE-ICING AND SNOW REMOVAL
1. Anti-icing, de-icing and snow removal - description ............................................................................. 1
30-42-02 HEATED WINDSHIELD SYSTEM (P/N 412-706-010-101)
1. Heated windshield system (P/N 412-706-010-101) - description .......................................................... 1

2. Heated windshield system (P/N 412-706-010-101) - operational check ................................................ 1
3. Heated windshield system (P/N 412-706-010-101) - troubleshooting ................................................... 3
4. Heated windshield system (P/N 412-706-010-101) - windshield heat power relay ............................... 3
4-1. Windshield heat power relay - removal ......................................................................................... 3
4-2. Windshield heat power relay - installation .................................................................................... 3
4-3. Windshield heat power relay - inspection ..................................................................................... 4
5. Heated windshield system (P/N 412-706-010-101) - controller ............................................................. 4
5-1. controller - removal ....................................................................................................................... 4
5-2. controller - installation ................................................................................................................... 4
5-3. controller - inspection .................................................................................................................... 4
30-Index
Page 1
E-AB412-PT6T-2
FIGURES
Figure Page
Number Title Number
Figure 1. Windshield wiper ............................................................................................................................................3
Figure 1. Heated windshield installation ........................................................................................................................2
TABLES
Table Page
Number Title Number
Table 1. Troubleshooting - windshield wipers..............................................................................................................1
Table 1. Heated windshield system troubleshooting.....................................................................................................3
30-Index
Page 2
E-AB412-PT6T-2
30-0 -0 ICE AND RAIN PROTECTION
30-00-00
ICE AND RAIN PROTECTION
1. ICE AND RAIN PROTECTION - GENERAL
The ice and rain protection consists of pilot and copilot windshield wipers.
Additional ice protection is provided by:
1. Heating and ventilation system (Chapter 21).
2. Winterization heater (Chapter 21).
3. Pitot static system heaters (Chapter 96).
4. Anti-icing, de-icing and snow removal (module 30-42-01 paragraph "1. Anti-icing, de-icing and snow removal -
description").
30-00-00
Page 1
E-AB412-PT6T-2
30-00-00
Page 2
E-AB412-PT6T-2
30-41-01
WINDSHIELD WIPER
1. WINDSHIELD WIPER - WINDSHIELD WIPER ASSEMBLY
Each windshield wiper assembly consists of a converter and motor (7, figure 1), arm (16), and wiper (25). The converter and
motor (7) drives arm (16) and arm (16) drives wiper (25). The WIPER SEL switch (overhead console) permits selection of
PILOT, COPILOT or BOTH wipers. Separate switches for pilot and copilot windshield wipers are located in the overhead
console. Each switch has the following positions: PARK, OFF, LOW, MEDIUM, AND HIGH. PARK is a spring loaded
position (returns to OFF) for stowing wiper to a location where vision is not obstructed.
1-1. WINDSHIELD WIPER ASSEMBLY - OPERATIONAL CHECK
CAUTION
DO NOT OPERATE WIPERS ON DRY WINDSHIELD.
1. Spray water on windshield. Rotate wiper switch to all positions. Observe operation of wipers.
2. Check opposite wiper in a similar manner.
NOTE
Refer to Chapter 98 for windshield wiper wiring diagram.
1-2. WINDSHIELD WIPER ASSEMBLY - TROUBLESHOOTING
For troubleshooting procedures, refer to table 1.
Table 1. Troubleshooting - windshield wipers
PROBABLE CAUSE ISOLATION PROCEDURE REMEDY
BLADE DOES NOT CLEAN WINDSHIELD
Damaged or deteriorated blade. Inspect blade. Replace blade (paragraph "2. Wind-
shield wiper blade - removal").
Improper blade pressure. Check blade pressure. Adjust blade pressure (paragraph "2.
Windshield wiper blade - removal").
30-41-01
Page 1
E-AB412-PT6T-2
(Cont.)
PROBABLE CAUSE ISOLATION PROCEDURE REMEDY
CONVERTER AND MOTOR INOPERATIVE
Opened circuit breaker. Reset circuit breaker. If circuit Replace circuit breaker or make
breaker will not reset, check required circuit repairs (Chapter 96).
breaker and associated wiring.
Damaged wiper switch. Inspect for obvious damage. Replace switch (Chapter 96).
Make continuity check of switch.
Broken electrical wire or loose connec- Check connections. Make conti- Replace wire if necessary. Tighten con-
tions. nuity check of circuit. nections or replace connectors or termi-
nals as required (Chapter 96).
Converter and motor inoperative. Substitute serviceable unit in Replace converter and motor (para-
place of suspected inoperative graph "10. Windshield wiper converter
unit and make operational check. and motor - removal").
1-3. WINDSHIELD WIPER ASSEMBLY - INSPECTION
1. Inspect blade (26, figure 1) for deteriorated rubber.
2. Inspect blade (26) for correct pressure on windshield (paragraph "1-4. Windshield wiper assembly - adjustment").
3. Inspect opposite blade in similar manner.
1-4. WINDSHIELD WIPER ASSEMBLY - ADJUSTMENT
NUMBER NOMENCLATURE
_ SPRING SCALE, 0 - 10 LBS. (0 - 5 KG)
T57 WRENCH
Adjustment to wiper is limited to adjusting wiper blade pressure on windshield.
1. Attach a spring scale to arm (16, paragraph "1. Ice and rain protection - general") at wiper (25) attach point.
2. Verify wiper blade (26) pressure is 2,5 to 5,5 lbs. (1,2 to 2,4 kg).
3. If necessary, increase blade pressure by turning screw (14) counterclockwise with wrench (T57), clockwise to decrease
blade pressure.
30-41-01
Page 2
E-AB412-PT6T-2
2.5 5.5
1.2 2.4
G6AB0773A
Figure 1. Windshield wiper
30-41-01
Page 3
E-AB412-PT6T-2
2. WINDSHIELD WIPER BLADE - REMOVAL
1. Raise arm (16, figure 1). Insert 0,125 in. (3,175 mm) diameter pin in hole (15).
2. Bend tabs on wiper (25). Slide blade (26) out of wiper (25).
3. Remove opposite blade in a similar manner.
3. WINDSHIELD WIPER BLADE - INSTALLATION
2. Slide blade (26) on wiper (25).
3. Bend tabs on wiper (25) to secure blade (26).
4. Remove pin from hole (15).
5. Adjust blade (26) pressure on windshield (paragraph "1-4. Windshield wiper assembly - adjustment").
6. Install opposite blade in similar manner.
4. WINDSHIELD WIPER - REMOVAL
2. Remove cotter pin (19) and nut (18). Retain attaching hardware. Remove wiper (25).
3. Remove nut (17), fitting (23), and washer (22).
4. Remove opposite wiper in a similar manner.
5. WINDSHIELD WIPER - INSTALLATION
2. If not previously accomplished, install fitting (23), washer (22), and nut (17) on arm (16).
NOTE
Wiper (25) shall be positioned per metal stamp on wiper, “MUST POINT UP
WHEN PARKED.”
3. Place threaded shaft of wiper (25) through fitting (23), washer (22), and arm (16). Install washers (21 and 20), and nut
(18). Do not tighten nut (18) at this time.
NOTE
If necessary to obtain alignment of castellations in nut (18) for installation of cotter
pin (19), use thin or standard aluminum washers (21 or 22) as required.
30-41-01
Page 4
E-AB412-PT6T-2
5. Align wiper (25) parallel to top of windshield to the park position dimension (28). Tighten nut (18). Install cotter pin
(19).
7. Install opposite wiper in a similar manner.
6. WINDSHIELD WIPER ARM - REMOVAL
2. Remove cotter pin (19) and nut (18). Retain attaching hardware. Remove wiper (25).
3. Loosen bolt (10). Remove bolt (12). Remove arm (16). Retain washers (9 and 11).
4. Remove opposite arm in a similar manner.
7. WINDSHIELD WIPER ARM - INSTALLATION
MATERIALS REQUIRED
NUMBER NOMENCLATURE
C-405 LOCKWIRE
1. Straighten arm (16, figure 1). Insert 0,125 in. (3,175 mm) diameter pin in hole (15).
2. Place washer (9) and arm (16) on converter and motor (7) serrated shaft.
NOTE
When adjusting park position dimension (28) take up converter assembly backlash
by applying light upward (towards top of windshield) pressure on windshield wiper
arm (16).
3. Adjust arm (16) as follows:
a. Operate converter (7) to Park position, as shown in figure 1.
NOTE
Removable adjustment sleeve (29) in arm (16) hub has serrations every 7.2° inside
the sleeve and on every 7.06° on the outside.
b. Adjust arm (16) wiper attach hole from top of windshield by removing and repositioning adjustment sleeve (29)
to achieve 4.0 to 4.5 inches (101.6 to 114.3 mm) dimension, as shown in figure 1.
4. Install washers (11), bolt (12), and lockwire (C-405) on converter and motor (7) serrated shaft. Tighten bolt (10).
5. Install wiper (25) (paragraph "5. Windshield wiper - installation").
30-41-01
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E-AB412-PT6T-2
CAUTION
DO NOT OPERATE WIPER ON DRY WINDSHIELD.
7. Apply power to system.
8. Check 64 sweep of arm (16) by momentarily rotating WIPER control switch to LOW.
9. Install opposite arm in a similar manner.
8. WINDSHIELD WIPER HEAD GUARD - REMOVAL
1. Remove screws (1 and 4, figure 1). Retain special washers (2 and 3).
2. Remove head guard (27).
9. WINDSHIELD WIPER HEAD GUARD - INSTALLATION
1. Position head guard (27, figure 1) on converter and motor (7).
2. Install two each washers (2 and 3) and screws (1 and 4).
10. WINDSHIELD WIPER CONVERTER AND MOTOR - REMOVAL
2. Loosen bolt (10). Remove bolt (12). Remove arm (16) and wiper (25) as a single unit. Retain washers (9 and 11).
3. Remove screws (1 and 4). Retain special washers (2 and 3). Remove head guard (27).
CAUTION
BATTERY BUS 1 AND BATTERY BUS 2 SWITCHES SHALL BE OFF.
4. Place BATTERY BUS 1 and BATTERY BUS 2 switches OFF.
5. Disconnect electrical connector from converter and motor (7). Cover connector and receptacle with caps or tape.
6. Remove bolts (5), and washers (6). Remove converter and motor (7).
7. Remove opposite converter and motor in similar manner.
30-41-01
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E-AB412-PT6T-2
11. WINDSHIELD WIPER CONVERTER AND MOTOR - INSTALLATION
MATERIALS REQUIRED
NUMBER NOMENCLATURE
C-405 LOCKWIRE
1. Position converter and motor (7, figure 1) serrated shaft in windshield structure hole. Install washers (6) and bolts (5).
CAUTION
BATTERY SWITCHES SHALL BE OFF.
2. Place BATTERY BUS 1 and BATTERY BUS 2 switches OFF.
3. Install electrical connector on converter and motor (7).
4. Position head guard (27). Install washers (2), screws (1), washers (3) and screws (4).
5. Position washer (9) and arm (16) with wiper (25) attached, on converter and motor (7) serrated shaft.
6. Hold wiper (25) in park position dimension (28). Tighten bolt (10). Install washer (11), bolt (12), and secure with
lockwire (C-405).
CAUTION
DO NOT OPERATE WIPERS ON DRY WINDSHIELD. IT CAN CAUSE

DAMAGE TO THE WINDSHIELD.
9. Apply power to system.
10. Perform windshield wiper operation check (Chapter 96).
11. Install opposite converter and motor in similar manner.
30-41-01
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E-AB412-PT6T-2
30-41-01
Page 8
E-AB412-PT6T-2
30-42-01 ANTI-ICING, DE-ICING AND SNOW REMOVAL
30-42-01
ANTI-ICING, DE-ICING AND SNOW REMOVAL
1. ANTI-ICING, DE-ICING AND SNOW REMOVAL - DESCRIPTION
MATERIALS REQUIRED
NUMBER NOMENCLATURE
C-394 DE-ICING FLUID
WARNING
DE-ICING FLUID (C-394) CAN BE HARMFUL OR FATAL IF SWALLOWED.

AVOID PROLONGED OR REPEATED BREATHING OF VAPOR. DO NOT
TAKE INTERNALLY, IF SWALLOWED, INDUCE VOMITING. CALL A
PHYSICIAN.
CAUTION
IT IS VERY DIFFICULT TO PREDICT ACCURATELY HOW LONG DE-ICING

FLUID (C-394) ONCE APPLIED, WILL PREVENT ICE BUILDUP ON
SURFACES. THE QUANTITY OF FLUID APPLIED, AMBIENT
TEMPERATURES, THE RATE OF CONTINUED PRECIPITATION, WIND
SPEED, AND OTHER FACTORS AFFECT THE LENGTH OF TIME THE FLUID
WILL PREVENT THE REACCUMULATION OF FROST AND ICE. ICE-FREE
SURFACES AND JOINTS CAN ONLY BE ASSURED THROUGH AN
EFFECTIVE ANTI-ICING/DE-ICING OPERATION AND CAREFUL VISUAL
INSPECTION OF THE HELICOPTER.
1. De-icing.
a. Remove heavy snow deposits by brushing prior to spraying.
b. Dilute de-icing fluid (C-394) concentrate with 50 percent water to produce a 50 percent solution. A 40 percent
may be used for light icing.
CAUTION
DO NOT APPLY HOT (180F) SOLUTION FOR DE-ICING DIRECTLY TO

COLD WINDSHIELDS AND WINDOWS. USE FLUID AT OR NEAR 70F.
c. Heat solution up to 180F for most efficient and effective ice removal from airframe. Allow solution to cool
before applying to windshield or windows.
d. Apply the diluted solution to helicopter by spraying, using suitable spraying equipment. Use a course stream to
loosen and remove ice.
30-42-01
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E-AB412-PT6T-2
2. Anti-icing: Spray or wipe concentrated de-icing fluid (C-394) onto helicopter surfaces to prevent ice and frost from
sticking.
NOTE
The concentrated fluid will freeze at approximately minus 25F. Some ice or slush
may form at or below minus 25F.
3. Removal: Anti-icing/de-icing solutions and residue may be removed from helicopter by washing with fresh water or
with a water/detergent solution followed by a rinse using fresh water.
30-42-01
Page 2
E-AB412-PT6T-2
30-42-02
HEATED WINDSHIELD SYSTEM (P/N 412-706-010-101)
1. HEATED WINDSHIELD SYSTEM (P/N 412-706-010-101) - DESCRIPTION
The helicopter is equipped with two heated windshields (figure 1). The electrical circuit includes the heating elements,
temperature and over-temperature sensors embedded in the windshield, control switches located on the overhead panel,
caution lights on the instrument panel, power control relays and windshields heat control units located on the cabin roof. The
circuit is powered thru the 28 V dc non essential bus is protected by WINDSHIELD HEAT CONT PWR LH and RH circuit
breakers and is energized by VSHLD HEAT LH and RH switches in the ON position. Power to the heating elements is
automatically controlled by the control unit as indicated in the following table.
Control Circuit Overtemperature Circuit
INHIBIT TEMP RESET TEMP INHIBIT TEMP RESET TEMP
43°C (110°F) 38°C (100°F) 54°C (130°F) 49°C (120°F)
The ON (green) lights on the instrument panel illuminate when the related heating element is powered.
The FAIL (yellow) lights on the instrument panel illuminate when the related heating element is operating in the overtem-
perature range or when one of the following failure condition occurs:
— control sensor open
— control sensor shorted
— O.T. sensor shorted
NOTE
Refer to Chapter 98 for heated windshield wiring diagram.
2. HEATED WINDSHIELD SYSTEM (P/N 412-706-010-101) - OPERATIONAL CHECK
1. Connect a 28 V dc power source to the external power receptacle of the helicopter. Close windshield heat circuit
breaker. Set NON ESS BUS switch to MANUAL.
2. Press to test windshield heat segment on the instrument panel. Both ”ON” lights (green) and both ”FAIL” lights
(yellow) should illuminate.
3. Set windshield heat LH switch to ON position. The LH ON segment will illuminate.
4. Set windshield heat RH switch to ON position. The RH ON segment will illuminate.
NOTE
The ON LH and RH windshield heat segments will illuminate and extinguish as the
windshield heat cycle occurs.
30-42-02
Page 1
E-AB412-PT6T-2
G6AB0990A
Figure 1. Heated windshield installation
30-42-02
Page 2
E-AB412-PT6T-2
3. HEATED WINDSHIELD SYSTEM (P/N 412-706-010-101) - TROUBLESHOOTING
Table 1. Heated windshield system troubleshooting
Heating elements do not operate. CONT circuit breaker defective. Replace circuit breaker.
PWR circuit breaker defective. Replace circuit breaker.
Control switch defective. Replace controll switch.
Power relay defective. Replace relay.
Control unit defective. Replace control unit.
Control sensor defective. Replace windshield.
Heating element defective. Replace windshield
Defective wiring. Repair wiring.
The light FAIL (yellow) illuminates. Control sensor open. Replace windshield.
Control sensor shorted. Replace windshield.
Overtemperature sensor shorted. Replace windshield.
4. HEATED WINDSHIELD SYSTEM (P/N 412-706-010-101) - WINDSHIELD HEAT

POWER RELAY
The power relays are installed on the cabin roof of the helicopter.
4-1. WINDSHIELD HEAT POWER RELAY - REMOVAL
1. Open cabin roof sound proofing.
2. Disconnect and tag wires.
3. Remove screws securing relay to structure and remove relay from helicopter.
4-2. WINDSHIELD HEAT POWER RELAY - INSTALLATION
1. Position relay on cabin roof and secure in position with provided screws.
2. Connect previously disconnected wires.
30-42-02
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E-AB412-PT6T-2
3. Close cabin roof sound proofing.
4-3. WINDSHIELD HEAT POWER RELAY - INSPECTION
Inspect relay for general condition.
5. HEATED WINDSHIELD SYSTEM (P/N 412-706-010-101) - CONTROLLER
The controllers are installed on the cabin roof of the helicopter.
5-1. CONTROLLER - REMOVAL
1. Open cabin roof sound proofing.
2. Disconnect electrical connectors.
3. Remove screws securing controller to structure and remove controller from the helicopter.
5-2. CONTROLLER - INSTALLATION
1. Position controller on cabin roof and secure in position with provided screws.
2. Connect electrical connectors.
3. Close cabin roof sound proofing.
5-3. CONTROLLER - INSPECTION
1. Inspect controller for general conditions.
2. Disconnect electrical connectors.
3. Remove screws securing controller to structure and remove controller from the helicopter.
30-42-02
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E-AB412-PT6T-2
CHAPTER 32 - LANDING GEAR

Module Page
Number Title Number
32-00-00 LANDING GEAR
1. Landing gear - general ............................................................................................................................ 1
32-11-01 LANDING GEAR ASSEMBLY
1. Landing gear assembly - description ...................................................................................................... 1

2. Landing gear assembly - removal ........................................................................................................... 3
3. Landing gear assembly - installation ...................................................................................................... 3
4. Landing gear assembly - inspection ........................................................................................................ 4
5. Landing gear assembly - repair or replacement ...................................................................................... 4
32-11-02 LANDING GEAR ASSEMBLY - SKID TUBES
1. Skid tubes - description ........................................................................................................................... 1

2. Skid tubes - removal ............................................................................................................................... 1
3. Skid tubes - installation ........................................................................................................................... 1
4. Skid tubes - inspection ............................................................................................................................ 2
5. Skid tubes - patch repair ......................................................................................................................... 2
6. Skid tubes - corrosion repair ................................................................................................................... 3
7. Skid tubes - walkway repair .................................................................................................................... 4
32-11-03 LANDING GEAR ASSEMBLY - SKID SHOES
1. Skid shoes - description .......................................................................................................................... 1

2. Skid shoes - removal ............................................................................................................................... 1
3. Skid shoes - installation .......................................................................................................................... 1
4. Skid shoes - inspection ........................................................................................................................... 3
5. Skid shoes - repair ................................................................................................................................... 3
32-11-04 LANDING GEAR ASSEMBLY - FIXED STEP
1. Fixed step - description ........................................................................................................................... 1

2. Fixed step - removal ............................................................................................................................... 1
3. Fixed step - installation ........................................................................................................................... 1
32-11-05 LANDING GEAR ASSEMBLY - EYEBOLT (GROUND HANDLING WHEELS ATTACH

POINTS)
1. Eyebolt - description ............................................................................................................................... 1

2. Eyebolt - removal .................................................................................................................................... 1
3. Eyebolt - installation ............................................................................................................................... 1
4. Eyebolt - Inspection ................................................................................................................................. 2
32-11-06 LANDING GEAR ASSEMBLY - CROSSTUBE ASSEMBLIES
1. Crosstube assemblies - removal .............................................................................................................. 1

2. Crosstube assemblies - installation ......................................................................................................... 1
3. Crosstube assemblies - inspection .......................................................................................................... 2
32-Index
Rev. 3 Page 1
E-AB412-PT6T-2

Module Page
Number Title Number
4. Crosstube assemblies - repair ..................................................................................................................3
32-11-07 LANDING GEAR ASSEMBLY - AFT CROSSTUBE SUPPORT BEAM
1. Aft crosstube support beam - description ................................................................................................1

2. Aft crosstube support beam - removal ....................................................................................................1
3. Aft cross tube support beam - installation ...............................................................................................1
4. Aft cross tube support beam - inspection and repair ...............................................................................1
32-11-08 LANDING GEAR ASSEMBLY - AFT CROSSTUBE ATTACHMENT SUPPORTS
1. Aft crosstube attachment supports - description .....................................................................................1

2. Aft crosstube attachment supports - removal ..........................................................................................1
3. Abrasion strip (Larson L101) - removal .................................................................................................2
4. Aft crosstube attachment supports - installation .....................................................................................3
5. Aft crosstube attachment supports - inspection and repair .....................................................................7
32-11-09 LANDING GEAR ASSEMBLY - FORWARD CROSSTUBE SUPPORTS
1. Forward crosstube supports - description ................................................................................................1

2. Forward crosstube supports - removal ....................................................................................................1
2-1. Two-piece support with U-clamps (crosstubes 205-050-400 and 205-050-403) ...........................1
2-2. One piece riveted support (crosstubes 412-050-040 and 412-050-046) ........................................1
3. Forward crosstube supports - installation.................................................................................................2
3-1. Two-piece support with U-clamps (crosstubes 205-050-400 and 205-050-403) ...........................2
3-2. One piece riveted support (crosstubes 412-050-040 and 412-050-046) .........................................3
4. Forward crosstube supports - inspection and repair ................................................................................5
32-11-10 LANDING GEAR ASSEMBLY - HIGH SKID GEAR (P/N 412-706-003-101/-103)
1. High skid gear (P/N 412-706-003-101/-103) - description .....................................................................1
32-21-01 TAIL SKID
1. Tail skid - description ..............................................................................................................................1

2. Tail skid - removal ..................................................................................................................................1
3. Tail skid - installation ..............................................................................................................................1
4. Tail skid - inspection and repair ..............................................................................................................1
32-31-01 PASSENGER STEP (ELECTRICALLY POWER OPERATED)
1. Passenger step - description ....................................................................................................................1

2. Passenger step - removal .........................................................................................................................1
3. Passenger step - installation ....................................................................................................................1
4. Passenger step - inspection ......................................................................................................................3
5. Passenger step - repair .............................................................................................................................3
32-41-01 GROUND HANDLING WHEELS (214-706-104-003)
1. Ground handling wheels - description ....................................................................................................1

2. Ground handling wheels - inspection ......................................................................................................1
3. Ground handling wheels - lubrication .....................................................................................................1
4. Ground handling wheels - wheel and tire assembly ................................................................................4
32-Index
Page 2 Rev. 3
E-AB412-PT6T-2

Module Page
Number Title Number
4-1. Wheel and tire assembly - removal ............................................................................................... 4

4-2. Wheel and tire assembly - installation ........................................................................................... 4
5. Ground handling wheels - tubeless tire ................................................................................................... 4
5-1. Tubeless tire - removal .................................................................................................................. 4
5-2. Tubeless tire - installation .............................................................................................................. 5
6. Ground handling wheels - tube tire ......................................................................................................... 5
6-1. Tube tire - removal ........................................................................................................................ 5
6-2. Tube tire - installation..................................................................................................................... 6
7. Ground handling wheels - pump assembly ............................................................................................. 6
7-1. Pump assembly - description ......................................................................................................... 6
7-2. Pump assembly - removal .............................................................................................................. 6
7-3. Pump assembly - installation ......................................................................................................... 6
8. Ground handling wheels - decals ............................................................................................................ 7
8-1. Decals - removal and installation .................................................................................................. 7
9. Ground handling wheels - ram assembly and trunnion .......................................................................... 7
9-1. Ram assembly and trunnion - removal .......................................................................................... 7
9-2. Ram assembly and trunnion - installation ..................................................................................... 8
10. Ground handling wheels - axles............................................................................................................... 9
10-1. Axles - removal .............................................................................................................................. 9
10-2. Axles - installation ......................................................................................................................... 9
11. Ground handling wheels - bushings....................................................................................................... 10
11-1. Bushings - removal ...................................................................................................................... 10
11-2. Bushings - installation ................................................................................................................. 10
32-Index
Rev. 3 Page 3
E-AB412-PT6T-2
FIGURES
Figure Page
Number Title Number
32-11-01 LANDING GEAR ASSEMBLY
Figure 1. Landing gear assembly (standard) - removal/installation ...............................................................................2

Figure 2. Landing gear crosstube deflection - damage limits.........................................................................................5
32-11-02 LANDING GEAR ASSEMBLY - SKID TUBES
Figure 1. Landing gear - skid tubes removal/installation (sheet 1 of 2).........................................................................5

Figure 2. Landing gear skid tubes - damage limits (sheet 1 of 2) ..................................................................................7
Figure 3. Skid tube (412-050-023) patch installation.....................................................................................................9
Figure 4. Skid tube (412-050-030/-034) patch installation ..........................................................................................10
32-11-03 LANDING GEAR ASSEMBLY - SKID SHOES
Figure 1. Landing gear - skid shoes removal/installation...............................................................................................2

Figure 2. Landing gear skid shoes - repair methods (sheet 1 of 2).................................................................................5
32-11-04 LANDING GEAR ASSEMBLY - FIXED STEP
Figure 1. Landing gear - fixed step removal/installation................................................................................................2
32-11-05 LANDING GEAR ASSEMBLY - EYEBOLT (GROUND HANDLING WHEELS ATTACH

POINTS)
Figure 1. Landing gear - eyebolt removal/installation ...................................................................................................3

Figure 2. Landing gear eyebolt - damage limits............................................................................................................4
Figure 1. Landing gear - crosstube assemblies removal/installation..............................................................................5

Figure 2. Landing gear crosstube assemblies - damage limits (sheet 1 of 5) .................................................................6
Figure 1. Landing gear - aft crosstube support beam removal/installation ....................................................................3

Figure 2. Landing gear crosstube support beam - damage and repair limits (sheet 1 of 3)............................................4
32-11-08 LANDING GEAR ASSEMBLY - AFT CROSSTUBE ATTACHMENT SUPPORTS
Figure 1. Landing gear - aft crosstube supports removal/installation (sheet 1 of 2) ......................................................8

Figure 2. Landing gear crosstube supports - damage limits .........................................................................................10
Figure 3. Crosstube support - abrasion strip removal (typical) ....................................................................................11
32-11-09 LANDING GEAR ASSEMBLY - FORWARD CROSSTUBE SUPPORTS
Figure 1. Landing gear - forward crosstube supports (205-050-400 and 205-050-403) removal/installation ...............6
Figure 2. Landing gear - forward crosstube supports (412-050-040 and 412-050-046) removal/installation ...............7
Figure 3. Landing gear crosstube supports - damage limits (sheet 1 of 2).....................................................................8
Figure 4. Cold-worked hole damage - forward crosstube (412-050-040 and 412-050-046) .......................................10
32-Index
Page 4 Rev. 3
E-AB412-PT6T-2
FIGURES (CONT.D)
Figure Page
Number Title Number
32-21-01 TAIL SKID
Figure 1. Tail skid removal/installation ......................................................................................................................... 3

Figure 2. Tail skid - damage limits (sheet 1 of 2) .......................................................................................................... 4
Figure 1. Passenger step - removal/installation ............................................................................................................. 4
32-41-01 GROUND HANDLING WHEELS (214-706-104-003)
Figure 1. Ground handling wheel assembly - removal/installation (sheet 1 of 2) ......................................................... 2

Figure 2. Ground handling wheel assembly - axles installation .................................................................................. 11
32-Index
Rev. 3 Page 5
E-AB412-PT6T-2
TABLES
Table Page
Number Title Number
Table 1. Crosstubes - damages and repair limits...........................................................................................................4
Table 1. Aft crosstube support beam configurations.....................................................................................................2
32-Index
Page 6 Rev. 3
E-AB412-PT6T-2
32-0 -0 LANDING GEAR
32-00-00
LANDING GEAR
1. LANDING GEAR - GENERAL
The landing gear consist of two longitudinal skid tubes and two arched cross tubes for attachment to fuselage and to provide
shock absorption on account of their elasticity. The skid tubes are aluminium alloy construction and are provided with
protective shoes along their whole length.
The aluminium alloy cross tubes are attached to the fuselage at four points. To allow handling, the landing gear is provided
with fittings for the ground handling wheels which are supplied with the helicopter, and with two tow rings located on the
forward section of the skid tubes.
Either a high landing gear or a standard landing gear may be installed.
An emergency flotation auxiliary equipment kit may be installed.
An auxiliary, electrically operated passenger step may be installed on standard skid gear.
32-00-00
Page 1
E-AB412-PT6T-2
32-00-00
Page 2
E-AB412-PT6T-2
32-1 -01 LANDING GEAR ASSEMBLY
32-11-01
LANDING GEAR ASSEMBLY
1. LANDING GEAR ASSEMBLY - DESCRIPTION
The landing gear is fabricated from aluminum alloy tubes. The gear consists of two skids attached on ends of two arched
crosstubes. The forward crosstube is fitted with two supports which contact mating supports in helicopter structure. The
forward crosstube is secured to helicopter structure with two cap fittings. The aft crosstube has a support beam which
contacts mating supports in helicopter structure and is secured to helicopter with two cap fittings similar to forward
crosstube. The function of the support beam on aft crosstube is to reduce possibility of ground resonance.
CAUTION
A HOIST WITH SUFFICIENT CAPACITY TO LIFT ENTIRE HELICOPTER

SHALL BE USED TO RAISE HELICOPTER CLEAR OF LANDING GEAR
WHEN REMOVING OR INSTALLING LANDING GEAR AS AN ASSEMBLY.
NOTE
The landing gear can be removed as a complete assembly or individual components
may be removed separately.
32-11-01
Rev. 3 Page 1
E-AB412-PT6T-2
1. Landing gear 18. Aluminum washer 33. Aluminum washer

2. Aluminum washer 19. Bolt 34. Bolt
3. Nut 20. Aluminum washer 35. Aluminum washer
4. Landing gear support structure 21. Aft cap fitting 36. Bolt
5. Nut 22. Aft cap fitting 37. Aluminum washer
6. Aluminum washer 23. Forward crosstube support struc- 38. Bolt
7. Aft crosstube support beam ture 39. Bolt
8. Aft crosstube 24. Aluminum washer 40. Aluminum washer
9. Aluminum washer 25. Nut 41. Bolt
10. Bolt 26. Nut 42. Aluminum washer
11. Aluminum washer 27. Aluminum washer 43. Bolt
12. Bolt 28. Forward crosstube 44. Aluminum washer
13. Aluminum washer 29. Bearing and retaining support 45. Forward cap fitting
14. Bolt 30. Bearing and retaining support 46. Bolt
15. Bolt 31. Power step electrical connector 47. Washer
16. Aluminum washer (if installed) 48. Skid tube
17. Bolt 32. Forward cap fitting
G6AB0054D
Figure 1. Landing gear assembly (standard) - removal/installation
32-11-01
Page 2 Rev. 3
E-AB412-PT6T-2
2. LANDING GEAR ASSEMBLY - REMOVAL
1. Disconnect power step electrical connector (31, figure 1) at bottom of fuselage.
NOTE
Superficial damage to cap fittings (21, 22, 32 and 45) is acceptable without repair.
Loose, missing, and/or deteriorated rubber pads on cap fittings are cause for
replacement of cap fittings.
2. Support the weight of the helicopter until it is light on the skids and remove bolts (34, 36, 38, 39, 41 and 43). Remove
forward cap fitting (32).
3. Remove forward cap fitting (45) in same manner outlined in previous step.
4. Remove bolts (10, 12, 14, 15, 17 and 19). Remove aft cap fitting (21).
5. Remove aft cap fitting (22) in same manner outlined in previous steps.
6. Raise helicopter slowly while monitoring the forward and aft crosstubes coming out of the front and airframe tunnels,
to prevent damage.
7. Raise helicopter until it is clear of skid landing gear, and remove landing gear.
8. If necessary, remove the skid tubes (2 and 9, figure 2) and the associated hardware from the crosstubes (module
32-11-02 paragraph "2. Skid tubes - removal").
9. If necessary, remove the aft crosstube support beam (6) and attaching hardware from aft crosstubes (module 32-11-07
paragraph "2. Aft crosstube support beam - removal").
3. LANDING GEAR ASSEMBLY - INSTALLATION
1. Position landing gear (1, figure 1) under helicopter.
2. Slowly lower the helicopter on each crosstubes (4 and 18, figure 2) to prevent damage.
3. Ensure forward crosstube support structure (23, figure 1) properly engages bearing and retaining support (30). Also
ensure bearing and retaining support (29) properly engages opposite support (not illustrated).
4. Ensure aft crosstube support beam (7) properly engages support in fuselage.
5. Position forward cap fitting (32) on forward crosstube support structure (23).
6. Install bolt (38) and washer (37), bolt (39) and washer (40), and bolt (41) and washer (42).
7. Install bolt (36) and washer (35), bolt (34) and washers (33 and 24), and nut (25).
8. Install bolt (43), washer (44 and 27), and nut (26).
9. Install forward cap fitting (45) in same manner outlined in preceding steps.
10. Position aft cap fitting (21) on landing gear support structure (4).
11. Install bolt (10) and aluminum washer (9).
32-11-01
Rev. 3 Page 3
E-AB412-PT6T-2
15. Install bolt (14), aluminum washers (6 and 13) and nut (5).
16. Install bolt (12), aluminum washers (2 and 20) and nut (3).
17. Install aft cap fitting (22) in same manner outlined in preceding steps.
4. LANDING GEAR ASSEMBLY - INSPECTION
NOTE
Superficial damage is mechanical damage that does not exceed 0.03 in (0.762 mm)
depth or 1.25 in (31.75 mm) length. Superficial damage is acceptable where noted.
Inspect landing gear assembly and attaching parts for superficial damage. No cracks in any landing gear parts or attaching
parts are acceptable. Inspection requirements for high landing gear are the same as for standard gear, except for crosstube
deflection limits.
1. Inspect landing gear bearing and retaining supports (29 and 30).
2. Inspect aft crosstube support beam (7) for secure installation, wear and deformation.
3. Inspect rubber bumpers on cap fittings (21, 22, 32 and 45) for voids or unbonded areas. No one void shall exceed
0.25 sq-in (161.3 mm²). The rubber bumper is not repairable.
4. If required, inspect landing gear assembly spread (figure 2).
For specific inspection related to landing gear assembly components, refer to the following modules:
— module 32-11-02 LANDING GEAR ASSEMBLY - SKID TUBES;
— module 32-11-03 LANDING GEAR ASSEMBLY - SKID SHOES;
— module 32-11-06 LANDING GEAR ASSEMBLY - CROSSTUBE ASSEMBLIES;
— module 32-11-07 LANDING GEAR ASSEMBLY - AFT CROSSTUBE SUPPORT BEAM;
— module 32-11-08 LANDING GEAR ASSEMBLY - AFT CROSSTUBE ATTACHMENT SUPPORTS;
— module 32-11-09 LANDING GEAR ASSEMBLY - FORWARD CROSSTUBE SUPPORTS.
5. LANDING GEAR ASSEMBLY - REPAIR OR REPLACEMENT
1. Repair damaged components in accordance to the applicable modules in this chapter.
2. Replace components that are damaged in excess of repairable limits. Refer to the related applicable modules in this
chapter.
32-11-01
Page 4 Rev. 3
E-AB412-PT6T-2
NOTES:
1. Deformation (distortion) of either crosstube in excess of limits is cause for replacement of crosstube(s).
2. Crosstube may be deflected on one side only. If limit is exceeded, crosstube is considered scrapped and must be replaced.
G6AB0057C
Figure 2. Landing gear crosstube deflection - damage limits
32-11-01
Rev. 3 Page 5
E-AB412-PT6T-2
32-11-01
Page 6 Rev. 3
E-AB412-PT6T-2
32-1 -02 LANDING GEAR ASSEMBLY - SKID TUBES
32-11-02
LANDING GEAR ASSEMBLY - SKID TUBES
1. SKID TUBES - DESCRIPTION
The landing gear skid tubes are mounted on ends of two arched crosstubes which are secured to fuselage structure. Each skid
tube is fitted with forward end step, tow ring, two saddles with sockets for crosstubes, rear end cap, two eyebolt fittings for
mounting ground handling wheels, and fore and aft skid shoes to absorb wear that would otherwise be inflicted to bottom
of skid tubes during take off and landings.
NOTE
Maintenance procedures for skid tubes installed on high landing gear and standard
gear are the same. Maintenance procedures for left and right tubes are the same.
2. SKID TUBES - REMOVAL
1. Remove landing gear (module 32-11-01 paragraph "2. Landing gear assembly - removal").
2. If electrically powered passenger step is installed, disconnect passenger step electrical connector (7, figure 1) from
crosstube (8).
3. Remove bolts (13) and thin aluminum washer (12).
4. Remove bolts (15) and steel washers (14).
5. Cut sealant at intersection of skid tube forward and aft saddles (2 and 6) and forward and aft crosstubes (1 and 8) with
a sharp plastic scraper.
6. Remove skid tube (3) from forward and aft crosstubes (1 and 8). Use a rubber mallet to tap skid tubes and forward and
aft saddles (2 and 6) off crosstubes, working both ends equally.
3. SKID TUBES - INSTALLATION
MATERIALS REQUIRED
NUMBER NOMENCLATURE
C-001 GREASE
C-308 ADHESIVE
1. Lubricate ends of crosstubes (1 and 8, figure 1) with grease (C-001).
2. If electrically powered passenger step (4) is installed, position passenger step electrical connector (7) in crosstube (8).
3. Position skid tube (3) on forward and aft crosstubes (1 and 8). Use rubber mallet if necessary. Push skid tube on both
crosstubes as evenly as possible and align holes for bolts (13 and 15).
32-11-02
Rev. 3 Page 1
E-AB412-PT6T-2
4. Install bolts (15) and steel washers (14).
5. Install bolts (13) and thin aluminum washer (12).
6. Apply adhesive (C-308) at intersection of crosstubes (1 and 8) and forward and aft saddles (2 and 6).
7. Install landing gear (module 32-11-01 paragraph "3. Landing gear assembly - installation").
4. SKID TUBES - INSPECTION
NOTE
Superficial mechanical damage to skid tubes (3 and 10, figure 1) is acceptable
without repair. Sharp corners and gouges should be repaired within allowable limits
(detail B). Distortion (deflection) in excess of limits shown (figure 2) is cause for
replacement. For 412-050-023 skid tubes, dents and/or holes in skid tubes up to 4.0
in (101.6 mm) in diameter in the area indicated in figure 3 are acceptable, if repaired
as described in paragraph "5. Skid tubes - patch repair". For 412-050-030/-034,
dents and/or holes in skid tubes up to 3.0 in (76.2 mm) in diameter in the area
indicated in figure 4 are acceptable, if repaired as described in paragraph "5. Skid
tubes - patch repair". No repairs (patches) are allowed under skid shoes.
1. Inspect skid tubes (3 and 10, figure 1), including skid shoes (5 and 11) and saddles (2 and 6) for dents, holes, cracks,
scratches, scuffs and corrosion (see detail A, figure 2).
NOTE
Superficial mechanical damage on tow rings (9, figure 1) is acceptable without
repair. Distorted and/or loose fitting tow rings are cause to replace tow rings and, if
attaching holes in skid tubes (3 and 10) are elongated, replace skid tube(s).
2. Inspect tow ring (9) for condition, damage and security of attachment.
3. Inspect skid tubes (3 and 10) for deformation and out-of-round condition.
4. Inspect for missing paint, primer and nonslip compound (C-223). Restore as required.
5. Apply electrical power to passenger step (4) and raise away from skid tube (3). Inspect actuator, support levers, step
and attaching hardware for condition.
5. SKID TUBES - PATCH REPAIR
MATERIALS REQUIRED
NUMBER NOMENCLATURE
C-100 CHEMICAL FILM MATERIAL
C-204 PRIMER
C-223 NONSLIP COMPOUND
C-308 ADHESIVE
32-11-02
Page 2 Rev. 3
E-AB412-PT6T-2
NOTE
Repair to skid tube is limited to patching top of skid tube in areas indicated in figure
2 and figure 3 or figure 4, and repair of skid shoes (module 32-11-03 paragraph "2.
Skid shoes - removal").
1. If dents are present in authorized repair area shown in figure 2, polish out raised areas that would interfere with
application of patch.
2. If holes are present in authorized repair area shown in figure 2, smooth rough edges of holes to remove sharp edges
and raised areas that would interfere with application of patch.
3. For skid tube 412-050-023, fabricate a patch to cover dent or hole from 2024 aluminum alloy tube, WW-T-700/2, T3
or 2024 aluminum sheet, per QQ-A-250/4, T73 with 0.095 in (2.41 mm) wall thickness and 4.0 in (101.6 mm) inside
diameter. See figure 3 for required patch size.
4. For skid tubes 412-050-030/-034, fabricate a patch to cover dent or hole from 2024 aluminum alloy tube, WW-T-700/
7, T3 or 2024 aluminum sheet, per QQ-A-250/4, T73 with 0.125 in (3.17 mm) wall thickness and 3.0 in (76.2 mm)
inside diameter. See figure 4 for required patch size.
5. Secure patch to skid tube and drill holes for M7885/6-6-3 rivets as shown on figure 3 or figure 4, as applicable. Remove
patch and deburr holes.
6. Clean patch and mating area of skid tube. Apply (brush-on) chemical film material (C-100), to bare aluminum surfaces
of skid tube and patch.
7. Apply coat of primer (C-204) to both surfaces of patch and to mating surface of skid tube.
8. Coat mating surfaces of patch and skid tube with adhesive (C-308).
9. Position patch on skid tube and install rivets.
10. Apply coat of primer (C-204) to repair area and paint to match existing finish on skid tube.
11. Apply two coats of nonslip compound (C-223) to appropriate areas.
6. SKID TUBES - CORROSION REPAIR

MATERIALS REQUIRED
NUMBER NOMENCLATURE
C-204 PRIMER
1. Repair slight damage or corrosion as follows:
a. Remove scratches, scuffs, nicks or corrosion by sanding or polishing.
b. Apply (brush on) chemical film material (C-100) to bare aluminum of skid tubes and patch.
c. Apply one coat of epoxy polyamide primer (C-204) or equivalent, to the affected skid tube area.
d. Paint the reworked area to match the rest of the tube and apply two coats of nonslip compound (C-223) to
appropriate areas.
32-11-02
Rev. 3 Page 3
E-AB412-PT6T-2
7. SKID TUBES - WALKWAY REPAIR
MATERIALS REQUIRED
NUMBER NOMENCLATURE
C-406 ABRASIVE CLOTH
C-516 CLEAN CLOTH
1. Clean the area to be repaired by lightly sanding with abrasive cloth (C-406) and wipe with a clean cloth (C-516).
2. Mask the area that will not receive nonslip compound (C-223).
3. Apply nonslip compound (C-223) to the required area. Allow a minimum of 30 minutes drying time between coats.
The first coat shall be a light coat, and the second coat shall be a heavy cross coat.
4. Remove masking paper when process is finished.
32-11-02
Page 4 Rev. 3
E-AB412-PT6T-2
SEE DETAIL A
10
11
7
8 2
9 SEE DETAIL B 3
STANDARD SKID LANDING GEAR ASSEMBLY
1. Aft crosstube
2. Aft saddle
3. Skid tube
4. Passenger step
5. Skid shoe
6. Forward saddle
7. Passenger step electrical connector
8. Forward crosstube
9. Tow ring
10. Skid tube
11. Skid shoe
13. Bolt
14. Steel washer
15. Bolt
G6AB0063C
Figure 1. Landing gear - skid tubes removal/installation (sheet 1 of 2)
32-11-02
Rev. 3 Page 5
E-AB412-PT6T-2
13
12
DETAIL A
15
14
DETAIL B
G6AB0066C
Figure 1. Landing gear - skid tubes removal/installation (sheet 2 of 2)
32-11-02
Page 6 Rev. 3
E-AB412-PT6T-2
BOW
1.5 IN (38.1 mm)
SEE DETAIL A
DETAIL A
412-050-023
DAMAGE LOCATION SYMBOLS
TYPE OF DAMAGE MAXIMUM DEPTHS AND REPAIR AREAS ALLOWED
CRACKS ALLOWED None None None

DENTS AND HOLES None 4.0 in (101.6 mm) Not critical
G6AB0064B
Figure 2. Landing gear skid tubes - damage limits (sheet 1 of 2)
32-11-02
Rev. 3 Page 7
E-AB412-PT6T-2
DETAIL A
412-050-030
412-050-034
(Does not apply to saddles)
DENTS Repair damage up to No cracks allowed. Not critical

3.0 in (76.2 mm) in Replace as needed
diameter
HOLES Repair damage up to No cracks allowed. Not critical.
3.0 in (76.2 mm) in Replace as needed Plug holes to keep out
diameter moisture
CRACKS No cracks allowed. No cracks allowed. No cracks allowed.
Replace as needed Replace as needed Replace as needed
SCRATCHES If damage is less than If damage is less than Not critical
SCUFFS 0.03 in (0.7 mm) deep 0.03 in (0.7 mm) deep
NICKS and/or 1.25 in (31.8 and/or 1.25 in (31.8
mm) length, no repair is mm) length, no repair is
needed needed
If damage is between If damage is between
0.03 to 0.05 in (0.8 to 0.03 to 0.05 in (0.8 to
1.2 mm) deep and/or 1.2 mm) deep and/or
1.25 to 1.65 in (31.8 to 1.25 to 1.65 in (31.8 to
41.9 mm) length, repair 41.9 mm) length, repair
If damage is greater If damage is greater
than established limits, than established limits,
replace as needed replace as needed
CORROSION No corrosion allowed. No corrosion allowed. No corrosion allowed.
Corrosion cleanup lim- Corrosion cleanup lim- Corrosion cleanup is
its are 0.05 in (1.3 mm) its are 0.05 in (1.3 mm) limited to 10% of mate-
depth and 1.65 in (41.9 depth and 1.65 in (41.9 rial thickness
mm) length mm) length
G6AB0065C
Figure 2. Landing gear skid tubes - damage limits (sheet 2 of 2)
32-11-02
Page 8 Rev. 3
E-AB412-PT6T-2
G6AB1050A
Figure 3. Skid tube (412-050-023) patch installation
32-11-02
Rev. 3 Page 9
E-AB412-PT6T-2
NOTES:
1 Use appropriate grip length of rivets to accommodate doubler and skid tube thickness.
2 Break all sharp edges on doubler.
G6AB0067B
Figure 4. Skid tube (412-050-030/-034) patch installation
32-11-02
Page 10 Rev. 3
E-AB412-PT6T-2
32-1 -03 LANDING GEAR ASSEMBLY - SKID SHOES
32-11-03
LANDING GEAR ASSEMBLY - SKID SHOES
1. SKID SHOES - DESCRIPTION
NOTE
Distortion damage to skid shoes is acceptable if repaired by welding on doublers,
and/or welding on new tabs as described in paragraph "5. Skid shoes - repair".
Maintenance procedures for skid shoes for both high gear and standard gear are the
same. Maintenance procedures for left and right skid shoes are the same.
2. SKID SHOES - REMOVAL
1. Support helicopter with hoist, stands, or ground handling gear.
2. Remove bolts (7, figure 1). Remove forward skid shoe (5).
3. Remove bolts (3) and remove rear skid shoe (4).
3. SKID SHOES - INSTALLATION
MATERIALS REQUIRED
NUMBER NOMENCLATURE
C-308 ADHESIVE
C-456 BARRIER TAPE
1. Support helicopter with hoist or with ground handling gear.
2. Position forward skid shoe (5, figure 1) on skid tube (1).
3. Apply barrier tape (C-456) to the entire faying surface of the forward skid shoe (5). Overlap the tape 0.25 in (6.35 mm).
Trim the tape around the periphery of the skid shoe.
4. Install bolts (7) and thin steel washers (6).
5. Apply adhesive (C-308) around bolt (7) heads.
6. Position rear skid shoe (4) on skid tube (1).
7. Install bolts (3) and thin steel washers (2).
8. Apply adhesive (C-308) around bolt (3) heads.
9. Lower helicopter.
32-11-03
Rev. 3 Page 1
E-AB412-PT6T-2
1. Skid tube
3. Bolt
4. Rear skid shoe
5. Forward skid shoe
7. Bolt
G6AB0068C
Figure 1. Landing gear - skid shoes removal/installation
32-11-03
Page 2 Rev. 3
E-AB412-PT6T-2
4. SKID SHOES - INSPECTION
1. Inspect for deformation, cracks, broken tang, and elongated holes.
2. Inspect for missing primer and cadmium plating. Restore as required.
3. Inspect for excessive corrosion.
4. Inspect beads for condition and excessive wear.
5. SKID SHOES - REPAIR
MATERIALS REQUIRED
NUMBER NOMENCLATURE
C-108 BRUSH CADMIUM PLATING SOLUTION
C-204 PRIMER
C-245 COATING
C-350 AMMONIUM NITRATE
CAUTION
PRIOR TO ANY WELDING REPAIR, REMOVE THE SKID SHOE FROM SKID
TUBE TO AVOID DAMAGE TO THE ALUMINUM SKID TUBE FROM
EXCESSIVE HEAT.
1. Heat skid shoe and reshape to remove dents that are not closer than 2 in (50.8 mm) from borium weld beads.
2. Repair skid shoe tabs with holes that are elongated in excess of 0.030 in (0.76 mm) as follows:
a. Fabricate a circular or elongated doubler as shown on figure 2, details C and D. Use 4130 steel 0.050 in
(1.27 mm) thick that has been normalized per MIL-S-18729.
NOTE
Cadmium plated stripped parts are very susceptible to corrosion and shall
immediately be repaired and primed.
b. Remove cadmium plating from repair area on skid shoes prior to welding.
(1) Mix a solution of 16 ounces (473 ml) of ammonium nitrate (C-350) per gallon of water.
(2) Maintain solution at a temperature of 120°F (49°C). Immerse section or complete skid shoes into solution
until all cadmium plating has been removed. Rinse skid shoes in clean water and allow to air dry.
c. Weld doubler to skid shoe as shown on figure 2, details C and D.
32-11-03
Rev. 3 Page 3
E-AB412-PT6T-2
3. Repair skid shoe tabs which are damaged in excess of limits noted in step 2. as follows:
a. Heat and reshape tab to original configuration if possible. After tab is reshaped, fabricate a doubler from 4130
steel 0.063 in (1.60 mm) thick that has been normalized per MIL-S-18729 and weld in place as shown in
figure 2, detail E.
b. If tab cannot be reshaped to original configuration, cut tab off parallel to skid shoe. Fabricate a new tab and weld
in place as shown on figure 2, detail F.
4. Check bottom of skid shoes for evidence of weld bead. Do not use skid shoes that have the weld beads worn off
(figure 2, detail F).
NOTE
Transverse cracks across weld beads are permissible and should not be cause for
repair or replacement of skid shoes.
5. Reform bead as follows:
a. Remove cadmium plating from skid shoes (refer to step 2.b.).
b. Weld beads 0.06 to 0.10 in (1.5 to 2.5 mm) high along skid shoe using acetylene and 0.125 in (3.18 mm) hard
facing weld tube (borium). (Material available from Stoody Manufacturing Co., Whittier, CA 90608 or DT600
HM 0.125 in (3.18 mm) hard facing weld tube from Reed Tool Co., Houston, TX 77011.)
c. Hot reform skid shoe as required to fit contour of skid tube.
6. After repair and clean up of weld deposits, apply brush cadmium plating solution (C-108) per MIL-STD-865 or two
coats of primer (C-204). When dry, apply two or three coats of lacquer (C-245) to match original finish.
32-11-03
Page 4 Rev. 3
E-AB412-PT6T-2
NOTE 1 NOTE 2
Fabricate doubler of normalized 4130 steel, MIL-S-18729, 0.063 Fabricate doubler of normalized 4130 steel, MIL-S-18720, 0.063
in (1.60 mm) thickness and of same configuration as damaged in (1.60 mm) thickness and of same configuration as removed
tab. tab. Grind weld smooth on side adjacent to skid tube.
G6AB0069B
Figure 2. Landing gear skid shoes - repair methods (sheet 1 of 2)
32-11-03
Rev. 3 Page 5
E-AB412-PT6T-2
G6AB0070A
Figure 2. Landing gear skid shoes - repair methods (sheet 2 of 2)
32-11-03
Page 6 Rev. 3
E-AB412-PT6T-2
32-1 -04 LANDING GEAR ASSEMBLY - FIXED STEP
32-11-04
LANDING GEAR ASSEMBLY - FIXED STEP
1. FIXED STEP - DESCRIPTION
NOTE
Maintenance procedures for fixed step on high gear and standard gear are the same.
Maintenance procedures for left and right steps are the same.
2. FIXED STEP - REMOVAL
1. Remove bolts (1, 4 and 7), and thin aluminum washers (2, 5 and 6) (figure 1).
2. Cut sealant at intersection of step (3) and skid tube (8) with a sharp plastic scraper.
3. Remove step (3) from skid tube (8).
3. FIXED STEP - INSTALLATION
MATERIALS REQUIRED
NUMBER NOMENCLATURE
C-308 ADHESIVE
1. Position step (3, figure 1) on skid tube (8) for installation.
2. Install bolts (1, 4 and 7), and thin aluminum washers (2, 5 and 6).
3. Apply a bead of adhesive (C-308) to intersection of step (3) and skid tube (8).
32-11-04
Rev. 3 Page 1
E-AB412-PT6T-2
1. Bolt
3. Step
4. Bolt
7. Bolt
8. Skid tube
G6AB0071B
Figure 1. Landing gear - fixed step removal/installation
32-11-04
Page 2 Rev. 3
E-AB412-PT6T-2
32-1 -05 LANDING GEAR ASSEMBLY - EYEBOLT (GROUND HANDLING WHEELS ATTACH POINTS)
32-11-05
LANDING GEAR ASSEMBLY - EYEBOLT (GROUND HANDLING WHEELS
ATTACH POINTS)
1. EYEBOLT - DESCRIPTION
NOTE
Maintenance procedures for eyebolt are the same for high gear and standard gear.
Maintenance procedures for eyebolt (3, figure 1) are given. Procedures for eyebolt
(2) are the same.
2. EYEBOLT - REMOVAL
1. Turn eyebolt (3, figure 1) counterclockwise to disengage threads.
2. Remove eyebolt (3) and thin aluminum washers (4 and 5).
3. EYEBOLT - INSTALLATION
MATERIALS REQUIRED
NUMBER NOMENCLATURE
C-251 SEALANT
C-308 SEALANT
1. Position eyebolt (3, figure 1) and thin aluminum washers (4 and 5) on skid tube (1).
2. Install eyebolt (3) by turning clockwise to engage threads in mounting hole of skid tube (1). Align axis of hole in
eyebolt parallel with longitudinal axis of skid tube (1).
3. Torque the eyebolt (3) to 40 to 58 ft-pounds (54.2 to 78.6 Nm) and check that axis of hole in eyebolt is parallel to
longitudinal axis of skid tube (1).
NOTE
A maximum of four washers (AN960JD1016L) may be used under the eyebolt for
alignment.
4. If not aligned, undo torque and with the use of washers, re-torque to 40 to 58 ft-pounds (54.2 to 78.6 Nm) and confirm
alignment described in previous step.
5. If required, reinstall setscrew in alternate eyebolt hole and add sealant.
32-11-05
Rev. 3 Page 1
E-AB412-PT6T-2
4. EYEBOLT - INSPECTION
1. Inspect eyebolts (2 and 3, figure 1) for mechanical and corrosion damage (figure 2).
32-11-05
Page 2 Rev. 3
E-AB412-PT6T-2
1. Skid tube
2. Eyebolt
3. Eyebolt
G6AB0072B
Figure 1. Landing gear - eyebolt removal/installation
32-11-05
Rev. 3 Page 3
E-AB412-PT6T-2
REF INSPECTION
CHARACTERISTIC LIMIT
LTR METHOD
A Mechanical damage Visual/measure 0.010 in (0.25 mm) maximum depth.
1 2
B Mechanical damage Visual/measure 0.005 in (0.13 mm) maximum depth and 90°
maximum length. 2 3
C Mechanical damage Visual/measure 0.005 in (0.13 mm) maximum depth and 120°
maximum length. 2 3
C Bending Visual None permitted.

D Thread damage Visual None permitted.
4
D Bending Visual None permitted.
E Mechanical damage Visual None permitted.
NOTES:
1 Maximum of four repairs per area.
2 To repair the damage, blend smooth and touchup repair the cadmium plating (Refer to Appendix I, module A1-15-01 “Chemical
film treatment”).
3 Maximum of one repair per area.
4 If required, touchup repair the cadmium plating (Refer to Appendix I, module A1-15-01 “Chemical film treatment”).
5. All dimension, wear, and damage limits provided are limits required after repair except where indicated.
G6AB1038A
Figure 2. Landing gear eyebolt - damage limits
32-11-05
Page 4 Rev. 3
E-AB412-PT6T-2
32-1 -06 LANDING GEAR ASSEMBLY - CROSSTUBE ASSEMBLIES
32-11-06
LANDING GEAR ASSEMBLY - CROSSTUBE ASSEMBLIES
1. CROSSTUBE ASSEMBLIES - REMOVAL
1. Remove the landing gear assembly from under the helicopter (module 32-11-01 paragraph "2. Landing gear assembly
- removal").
2. Remove the hardware securing the extremities of the crosstube assembly from the front or aft saddles on the left or
right skid tubes as required.
CAUTION
DO NOT DAMAGE THE SURFACE OF THE CROSSTUBES.
3. Using a plastic scraper, remove the sealant from the upper edges of the left and right skid tube saddles.
CAUTION
BE CAREFUL NOT TO DAMAGE THE ELECTRIC WIRES WHEN THE

FORWARD CROSSTUBE IS MOVED AWAY FROM THE FRONT SADDLE.
4. If applicable, tag and disconnect the electric wires from each step disconnect connector 24P2/P195 or from the LH and
RH step actuators B25/B26.
5. Apply downward force on skid tube near each saddle. Move each crosstube slightly in a fore-and-aft direction to
release the ends of the crosstubes from their mating saddles.
2. CROSSTUBE ASSEMBLIES - INSTALLATION
MATERIALS REQUIRED
NUMBER NOMENCLATURE
C-251 SEALANT
C-308 SEALANT
1. Install aft crosstube (1, figure 1) to left skid tube (2) as follows:
NOTE
Install all fasteners and grommets with sealant (C-251).
a. Insert aft crosstube into aft saddle of skid tube (2), and secure with three bolts (10), three bolts (8), and six
washers (9).
32-11-06
Rev. 3 Page 1
E-AB412-PT6T-2
b. Torque bolts 160 to 190 in-lbf (18.08 to 21.47 Nm).
2. If applicable, install the powered step cable assembly (7) as follows:
a. Route the wires for the powered step through the crosstube.
b. Install the grommet (11) on the wires and install the grommet in the crosstube or skid tubes, as applicable.
c. Remove the tags and connect the wires to the step disconnect connector 24P2/P195 or the LH and RH step
actuators B25/B26.
CAUTION
USE CARE TO AVOID CHAFING, CUTTING, OR BREAKING CABLE

ASSEMBLY WHEN PERFORMING NEXT STEP.
3. Insert forward crosstube (5) into forward saddle of left skid tube (2). Secure crosstube and saddle with six bolts (3) and
six washers (4). Torque the bolts as shown in figure 1.
4. Apply a bead of sealant (C-251) around joint of saddles and crosstubes.
5. Install crosstubes to right skid tube same as left skid tube.
6. If applicable, apply sealant (C-308) to the grommet (11) and cable assembly (7).
3. CROSSTUBE ASSEMBLIES - INSPECTION
NOTE
All crosstube damage is unacceptable and shall be repaired. Refer to figure 2 for
damage limits. Refer to paragraph "4. Crosstube assemblies - repair" for repair
criteria.
1. Inspect crosstube for condition and damage such as dents, cracks, nicks, scratches and corrosion.
2. Inspect each extremity of crosstube for fretting damage and corrosion.
3. Inspect each support or clamp assembly at BL 14,0 for damage and condition.
4. Inspect the sealant, clamps and rivets for looseness and the bondline for indication of voids.
NOTE
If support or rivets appear to be loose, remove support (fasteners for riveted supports
are installed in cold-worked holes that are not damage tolerant) and inspect surface
of crosstube for condition.
5. Inspect aft crosstube support beam for proper alignment on crosstube.
NOTE
Uneven fretting or wear on clamp assemblies at BL 14,0 may indicate that the beam
is not positioned correctly and will need realignment.
6. Remove aft crosstube support beam and inspect upper and lower supports for looseness.
32-11-06
Page 2 Rev. 3
E-AB412-PT6T-2
7. Inspect upper support bondline for voids.
8. Inspect crosstube for missing paint and primer. Restore as required.
For specific inspection related to crosstube components (support beam and upper/lower support), refer to the following
modules:
— module 32-11-07 LANDING GEAR ASSEMBLY - AFT CROSSTUBE SUPPORT BEAM;
— module 32-11-08 LANDING GEAR ASSEMBLY - AFT CROSSTUBE ATTACHMENT SUPPORTS;
— module 32-11-09 LANDING GEAR ASSEMBLY - FORWARD CROSSTUBE SUPPORTS.
4. CROSSTUBE ASSEMBLIES - REPAIR
MATERIALS REQUIRED
NUMBER NOMENCLATURE
C-204 EPOXY POLYAMIDE PRIMER
C-407 ABRASIVE PAD
1. Repair all damage (scratches, nicks, dents) and corrosion as follows (see table 1):
CAUTION
ABRASIVE BLENDING OUT STROKES MUST BE PARALLEL TO THE

CROSSTUBE, NOT CIRCUMFERENTIAL.
2. Polish the affected area in a longitudinal direction using abrasive pad (C-407). Make sure the limits presented in
table 1 and figure 2 are not exceeded
3. Clean repaired area with isopropyl alcohol (C-385), apply chemical film material (C-100) on bare aluminum areas per
MIL-DTD-81706 or equivalent, and reprime with epoxy polyamide primer (C-204) or equivalent.
4. Paint repaired area to match existing finish.
32-11-06
Rev. 3 Page 3
E-AB412-PT6T-2
Table 1. Crosstubes - damages and repair limits
MAXIMUM ALLOWABLE DAMAGE AND REPAIR LIMITS

(Damage and corrosion may be repaired per paragraph "4. Crosstube assemblies - repair")
COMPONENT
SCRATCHES, NICKS, DENTS AND CORROSION CRACKS/HOLES
Crosstube See figure 2, sheet 1 through 5 None
Forward support Refer to module 32-11-09 LANDING GEAR ASSEM- None

BLY - FORWARD CROSSTUBE SUPPORTS
Aft center support Refer to module 32-11-08 LANDING GEAR ASSEM- None
BLY - AFT CROSSTUBE ATTACHMENT SUPPORTS
Clamp assembly To a depth of 0.005 in (0.127 mm) None
NOTES:
Superficial damage on crosstubes is unacceptable. All damage on crosstubes shall be repaired. Observe limitations shown
in figure 2, section B-B. Generous radii and/or fairing shall be used in repair.
Damage limits apply to the surface areas of the crosstube as indicated by figure 2, section B-B.
Circumferential grooves or grind marks are not acceptable.
Scratches, nicks, dents or corrosion shall be polished out in the longitudinal direction within limits shown in figure 2.
All corrosion shall be cleaned up to twice the visible corrosion depth and shall not exceed the damage limits shown in
figure 2.
The orientation of scratches and corrosion damage is limited by the dimension shown in figure 2, view A-A.
The minimal longitudinal distance between repairs is 3.0 in (76.2 mm).
32-11-06
Page 4 Rev. 3
E-AB412-PT6T-2
8
9
T 2 9
10 T 2
11
9
10 T 2
8
9
T 2
2
7 SECTION A-A
VIEW B
6
A
A
B
5
2
3
4
1. Aft crosstube
1 2. Skid tube
3. Bolt
3 4. Washer
4 5. Forward crosstube
6. Power step electrical connector (if installed)
7. Cable assembly
SEALANT (C-251) 8. Bolt
1 9. Washer
10. Bolt
ADHESIVE (C-308)
2 11. Grommet
NOTE:
50 TO 70 IN-LBS
1 (5.65 TO 7.91 Nm)
1 For 1/4-28 bolts, torque per and for 3/8-24 bolts, torque per .
160 TO 190 IN-LBS
2 (18.08 TO 21.47 Nm)
G6AB1051A
Figure 1. Landing gear - crosstube assemblies removal/installation
32-11-06
Rev. 3 Page 5
E-AB412-PT6T-2
G6AB0058A
Figure 2. Landing gear crosstube assemblies - damage limits (sheet 1 of 5)
32-11-06
Page 6 Rev. 3
E-AB412-PT6T-2
STANDARD AND HIGH SKID GEAR
FOR MAXIMUM
ALLOWABLE CLEAN-UP DEPTHS
SEE TABLE 1 ON SHEET 3
G6AB0059B
32-11-06
Rev. 3 Page 7
E-AB412-PT6T-2
TABLE 1
MAXIMUM ALLOWABLE CLEANUP DEPTH STANDARD AND HIGH SKID GEAR
ZONE FWD CROSSTUBE AFT CROSSTUBE

INCHES (mm) INCHES (mm)
A1 0.005 (0.13) 0.005 (0.13)

A2 0.015 (0.38) 0.015 (0.38)
A3 0.005 (0.13) 0.005 (0.13)
A4 0.015 (0.38) 0.015 (0.38)
B1 0.015 (0.38) 0.015 (0.38)

B2 0.015 (0.38) 0.015 (0.38)
B3 0.015 (0.38) 0.015 (0.38)
B4 0.015 (0.38) 0.015 (0.38)
C1 0.010 (0.25) 0.012 (0.30)

C2 0.010 (0.25) 0.012 (0.30)
C3 0.010 (0.25) 0.012 (0.30)
C4 0.010 (0.25) 0.012 (0.30)
0.030 (0.76) 0.038 (0.96)

D 7
NOTES:
1. See sheet 2 for zone definition.

2. All dimensions are in inches (except as noted).
3. Repairs limited to one repair per “quadrant”, two at any cross section.
4. Log location and depth of all repairs for each crosstube.
5. Repair limits are lifetime accumulation at any location.
6. Repair in Zone D not to impinge on more than one fastener hole.
7 Allowable depth of repair is 0.050 in (1.27 mm) for bottom 0.50 in (12.7 mm) of area as indicated except within 0.315 in
(8.00 mm) radius of center of any fastener hole. Otherwise limits for Zone D are as shown in the table above.
8 0.50 in (12.7 mm) maximum damage allowed on first 0.50 in (12.7 mm) of crosstube except as indicated by note (9) (see
sheet 1).
9 Maximum allowable damage in shaded area is determinated in Zone D inspection limits (see sheet 1).
32-11-06
Page 8 Rev. 3
E-AB412-PT6T-2
IMPROVED STANDARD AND IMPROVED HIGH SKID GEAR
FOR MAXIMUM
ALLOWABLE CLEAN-UP DEPTHS
SEE TABLE 2 ON SHEET 5
G6AB0061B
32-11-06
Rev. 3 Page 9
E-AB412-PT6T-2
TABLE 2
MAXIMUM ALLOWABLE CLEANUP DEPTH IMPROVED STANDARD AND IMPROVED HIGH SKID GEAR
ZONE FWD CROSSTUBE AFT CROSSTUBE

INCHES (mm) INCHES (mm)
A1 0.005 (0.13) 0.005 (0.13)

A2 0.015 (0.38) 0.015 (0.38)
A3 0.005 (0.13) 0.005 (0.13)
A4 0.015 (0.38) 0.015 (0.38)
B1 0.005 (0.13) 0.005 (0.13)

B2 0.015 (0.38) 0.015 (0.38)
B3 0.005 (0.13) 0.005 (0.13)
B4 0.015 (0.38) 0.015 (0.38)
C1 0.010 (0.25) 0.012 (0.30)

C2 0.010 (0.25) 0.012 (0.30)
C3 0.005 (0.13) 0.005 (0.13)
C4 0.010 (0.25) 0.012 (0.30)
0.030 (0.76) 0.038 (0.96)

D 7
NOTES:
1. See sheet 4 for zone definition.

2. All dimensions are in inches (except as noted).
3. Repairs limited to one repair per “quadrant”, two at any cross section.
4. Log location and depth of all repairs for each crosstube.
5. Repair limits are lifetime accumulation at any location.
6. Repair in Zone D not to impinge on more than one fastener hole.
7 Allowable depth of repair is 0.050 in (1.27 mm) for bottom 0.50 in (12.7 mm) of area as indicated except within 0.315 in
(8.00 mm) radius of center of any fastener hole. Otherwise limits for Zone D are as shown in the table above.
8 0.50 in (12.7 mm) maximum damage allowed on first 0.50 in (12.7 mm) of crosstube except as indicated by note (9) (see
sheet 1).
9 Maximum allowable damage in shaded area is determinated in Zone D inspection limits (see sheet 1).
32-11-06
Page 10 Rev. 3
E-AB412-PT6T-2
32-1 -07 LANDING GEAR ASSEMBLY - AFT CROSSTUBE SUPPORT BEAM
32-11-07
LANDING GEAR ASSEMBLY - AFT CROSSTUBE SUPPORT BEAM
1. AFT CROSSTUBE SUPPORT BEAM - DESCRIPTION
The aft crosstube support beam is constructed of forged aluminum alloy incorporating an upper and lower support for
attachment of support beam to crosstube. This arrangement provides a pivot point between fuselage and aft crosstube at
centerline of helicopter to dampen vibrations caused by ground resonance.
NOTE
Maintenance procedures for aft crosstube support beam for high gear and standard
gear are the same.
2. AFT CROSSTUBE SUPPORT BEAM - REMOVAL
2. Remove nut (1, figure 1), thin steel washer (2), and bolt (4). Remove aft crosstube support beam (3).
3. AFT CROSS TUBE SUPPORT BEAM - INSTALLATION
1. Position aft crosstube support beam (3, figure 1) on aft crosstube (7).
2. Align hole in aft crosstube support beam (3) with hole in aft upper crosstube attachment support (6).
CAUTION
MAKE SURE THE WASHER (2) STAYS IN PLACE ON THE SHANK OF THE
BOLT (4) DURING INSTALLATION OF THE NUT (1). OTHERWISE, THE
WASHER COULD DROP INTO THE RADIUS BETWEEN THE SHANK AND
THREADED PORTION OF THE BOLT AND CAUSE DAMAGE TO THE
PARTS.
3. Install bolt (4), thin steel washer (2), and nut (1). Torque the nut (1) to 10 to 30 in-lbs (1.13 to 3.39 Nm) and install the
cotter pin.
4. AFT CROSS TUBE SUPPORT BEAM - INSPECTION AND REPAIR
NOTE
Superficial mechanical damage to aft crosstube support beam is acceptable without
repair. Repair is limited to replacement of two bushings.
32-11-07
Rev. 3 Page 1
E-AB412-PT6T-2
There are six configurations for the support beam and they are listed in table 1. The damage and repair limits are shown in
figure 2 for each configuration.
1. Inspect support beam for damage and repair limits per figure 2. If support beam has damage exceeding limits shown
in figure 2, discard and replace with a new one. No cracks are allowed in any circumstance.
2. In case of a lightning strike, inspect support beam and blend affected area(s) to remove damage without exceeding the
limits shown in figure 2.
Table 1. Aft crosstube support beam configurations
BEAM ASSEMBLY NEXT ASSEMBLY
412-050-002-101
412-050-003-101 412-050-002-103
412-050-011-101
412-050-011-103
412-050-003-105 412-050-002-105
412-050-011-105
412-050-011-105
412-050-003-109 412-050-041-105
412-050-045-105
412-050-003-111 412-050-041-105
412-050-045-105
412-050-002-107
412-050-003-113 412-050-041-105
412-050-045-105
32-11-07
Page 2 Rev. 3
E-AB412-PT6T-2
T 1
T 10 TO 30 IN-LBS
1 (1.13 TO 3.39 Nm)
1. Nut
3. Aft crosstube support beam
4. Bolt
5. U-bolt
6. Aft crosstube upper support
7. Aft crosstube
G6AB0073B
Figure 1. Landing gear - aft crosstube support beam removal/installation
32-11-07
Rev. 3 Page 3
E-AB412-PT6T-2
G6AB0074A
Figure 2. Landing gear crosstube support beam - damage and repair limits (sheet 1 of 3)
32-11-07
Page 4 Rev. 3
E-AB412-PT6T-2
15.93
The bushing hole can be reworked as follows:
OVERSIZE OUTER BUSHING DIAMETER BUSHING P/N
1° O/S 0.010 in 0.7595 to 0.7605 in 22X012B39-33-28

(0.25 mm) (19.292 to 19.316 mm)
2° O/S 0.020 in 0.7695 to 0.7705 in 22Y012B39-33-28

(0.50 mm) (19.546 to 19.570 mm)
3° O/S 0.031 in 0.7807 to 0.7817 in 22H012B39-33-28

(0.79 mm) (19.830 to 19.855 mm)
BUSHING HOLES OVERSIZE
G6AB0075C
32-11-07
Rev. 3 Page 5
E-AB412-PT6T-2
NOTES:
BOLT LOCATION
1 Install bushings with wet epoxy polyamide primer.
2 Ensure each bushing does not protrude from the fitting face after rework. Otherwise, install a shorter bushing so that the
bushing ends flush with fitting or 0.016 in (0.41 mm) inside.
3 Ensure 0.06 in (1.5 mm) radius is maintained, no sharp edges.
4 Spot face permissible on each outer face of fitting to remove corrosion. For support beam 412-050-003-101/-105, 0.005 in
(0.13 mm) maximum material removal per spotface and for support beam 412-050-003-109/-111/-113, 0.030 in (0.76 mm)
maximum material removal is allowed. Omit organic finish in this area.
5. Add NAS1149D10xxK, or AN960-816L, or AN960C816L washer with the minimum thickness required to ensure the nut
does not bottom out on the bolt’s thread at installation after rework. During the installation, after rework, torque nut without
clamping the lugs. Rotate the nut counterclockwise to align the cotter pin with the first hole. Protect the nut, bolt head, and
washer with anticorrosion compound.
CORROSION PROTECTION AFTER ANY REWORK
6. Blended areas shall have a surface finish of 63 RMS or better.

7. No power tools allowed.
8. All reworked areas shall be protected with touch-up alodine and touch-up polyamide epoxy primer, and then touch-up
painted.
LIMITATIONS FOR CORROSION, NICKS, SCRATCHES AND DENTS
9. One repair per cross section.

10. 2.0 in (50.8 mm) minimum between two damages in the longitudinal direction.
11. Material removed is total for inside and outside at same location.
12. Blend in the part’s longitudinal axis.
32-11-07
Page 6 Rev. 3
E-AB412-PT6T-2
32-1 -08 LANDING GEAR ASSEMBLY - AFT CROSSTUBE ATTACHMENT SUPPORTS
32-11-08
LANDING GEAR ASSEMBLY - AFT CROSSTUBE ATTACHMENT
SUPPORTS
1. AFT CROSSTUBE ATTACHMENT SUPPORTS - DESCRIPTION
MATERIALS REQUIRED
NUMBER NOMENCLATURE
C-251 SEALANT
C-252 ADHESIVE FILM
C-253 PRIMER
C-308 ADHESIVE
C-317 ADHESIVE
There are two methods for bonding the band style clamp at BL 14,0. The first method installs clamp (330C400-338S) to the
crosstube using sealant (C-251). The second method uses the same clamp with a composite material bonded to the inside
surface for enhanced corrosion protection. The clamp assembly is reidentified as 412-050-045-115. This method also
incorporates an abrasion strip that is bonded to the lower surface of the crosstube prior to the bonding of the clamp assembly
to the crosstube using (C-251).
In the center position BL 0,0, the upper support has a primer (C-253) and a ply of adhesive film (C-252) bonded to the inside
faying surface. This upper support is bonded to the crosstube surface prepared with primer (C-253). The support is finally
bonded to the prepared surface using adhesive (C-317).
The lower support is bonded to an abrasion strip (Larson L101) (raw material size 0.020 x 5.0 x 6.0 in) that is bonded to the
crosstube. This support is bonded into position on the lower surface of the crosstube using sealant (C-308).
2. AFT CROSSTUBE ATTACHMENT SUPPORTS - REMOVAL
MATERIALS REQUIRED
NUMBER NOMENCLATURE
C-326 DENATURED ALCOHOL
C-516 CLEAN CLOTH
NOTE
Maintenance procedures for aft crosstube supports on high gear and standard gear
are the same.
32-11-08
Rev. 3 Page 1
E-AB412-PT6T-2
NOTE
The upper center support on the aft crosstubes is bonded with structural adhesive
and is not designed for removal. The following removal procedure is supplied in
case bondline separation is detected during routine inspection.
1. Remove aft crosstube support beam (2, figure 1) (module 32-11-07 paragraph "2. Aft crosstube support beam -
removal").
2. Remove nuts (8 and 9), steel washers (6 and 10), and U-bolts (1 and 3).
3. Remove the aft crosstube supports (4 and 5) from the aft crosstube (7). Use of a heat gun to soften the adhesive may
facilitate removal. Do not exceed 180°F (82°C).
4. Remove the nuts from clamp assembly (12).
5. Carefully remove the clamp assembly (12) from the aft crosstube (7) and abrasion strip (13). Use of a heat gun to soften
the adhesive may facilitate removal. Do not exceed 180°F (82°C).
6. Using a plastic scraper, remove the old adhesive from aft crosstube (7) and clamp assembly (12). Clean with a clean
cloth (C-516) and denatured alcohol (C-326).
3. ABRASION STRIP (LARSON L101) - REMOVAL
NUMBER NOMENCLATURE
COMMERCIAL PLASTIC (PHENOLIC) WEDGE
COMMERCIAL PROTECTIVE GLOVES
MATERIALS REQUIRED
NUMBER NOMENCLATURE
C-137 COOLING AGENT
CAUTION
DO NOT USE ANY TYPE OF SANDPAPER OR METAL TOOLS TO REMOVE

THE ABRASION STRIP. THIS CAN DAMAGE THE SURFACE OF THE
CROSSTUBE.
DO NOT USE HEAT TO REMOVE THE ABRASION STRIP. HEATING MORE

THAN 250°F (121°C) WILL ADVERSELY AFFECT THE CONDITION OF THE
CROSSTUBE.
1. For the aft crosstube, remove the lower support (BL 0,00) (paragraph "2. Aft crosstube attachment supports -
removal").
2. Using the plastic wedge, remove any remaining sealant along the edges of the Larson L101 abrasion strip (2, figure 3).
32-11-08
Page 2 Rev. 3
E-AB412-PT6T-2
WARNING
REFER TO THE MANUFACTURERS INSTRUCTIONS FOR THE PROPER USE

OF COOLING AGENT (C-137). THE TEMPERATURES OF THE COOLING
AGENT CAN REACH -55°F (-48°C). WEAR PROTECTIVE GLOVES.
3. Apply cooling agent (C-137) to one edge of the Larson L101 abrasion strip (2). Use a brief application (or until frost
appears).
4. Initiate peeling of the Larson L101 abrasion strip (2) with the plastic wedge (3).
5. Once peeling has been initiated, grip the abrasion strip (2) with pliers.
NOTE
Keep the bondline of the adhesive frozen. This will make removal easier.
6. Apply cooling agent (C-137) to the bondline of the adhesive. Use a brief application (or until frost appears).
7. Use the plastic wedge (3) and continue to gently pull the abrasion strip (2) with pliers.
8. Repeat step 5. through step 7. until the abrasion strip (2) is completely removed.
4. AFT CROSSTUBE ATTACHMENT SUPPORTS - INSTALLATION
MATERIALS REQUIRED
NUMBER NOMENCLATURE
C-063 PRIMER
C-251 SEALANT
C-252 ADHESIVE FILM
C-253 PRIMER
C-308 ADHESIVE
C-316 ACETONE
C-317 ADHESIVE
C-364 ADHESIVE FILM
C-407 ABRASIVE PAD
32-11-08
Rev. 3 Page 3
E-AB412-PT6T-2
(Cont.d)
NUMBER NOMENCLATURE
C-474 DRY BLASTING ABRASIVE
C-478 RELEASE FABRIC
C-496 WET BLASTING ABRASIVE
C-516 LOW-LINT CLEANING CLOTH
C-571 ADHESIVE
CAUTION
A NEW CROSSTUBE HAS AN ADHESIVE COMPOSITE BOND AROUND

CENTER OF TUBE WHERE SUPPORTS ARE INSTALLED. PROTECT THIS
AREA WHILE HANDLING TUBE UNTIL TUBE IS INSTALLED ON
HELICOPTER.
WHEN CLEANING MATING SURFACES, DO NOT USE ANY TOOL OR
SUBSTANCE WHICH COULD SCRATCH TUBE OR SUPPORTS.
1. If you are installing a new support, go to step 3.
2. If you are installing the same support, proceed as follows:
a. Remove all existing adhesive and primer from the support mating surface by abrading with 400 to 600 grit
abrasive paper (C-423).
b. Wipe faying surface of upper support with clean cloth dampened with denatured alcohol (C-326) and wipe dry.
NOTE
Primed part can be kept in a controlled environment for up to 48 hours before next
step is accomplished. Controlled environment is defined as between 65 and 80°F
(18.3 and 26.6°C) with relative humidity not exceeding 60% and should be
monitored during that period of time.
c. Apply primer (C-253) to cleaned surface. Cure at a temperature between 65 and 80°F (18.3 and 26.6°C) for 2
hours.
d. Apply adhesive film (C-252) to the support primed surface. Place release fabric (C-478) over adhesive coated
surface.
NOTE
Use a release film or other release barrier between the adhesive film and caul sheet,
to prevent bonding to the adhesive film.
e. Use a caul sheet over the adhesive surface to provide a uniform and smooth surface when finished.
f. Cure adhesive film (C-252) for 30 minutes minimum at a temperature between 65 and 80°F (18.3 and 26.6°C)
plus 60 minutes between 275 and 290°F (135.0 and 143.3°C). Ramp-up and cool down rates should be between
1 and 10°F (0.6 and 5.5°C) maximum per minute. Preferred pressure to caul sheet to be 20 psi (138 kPa) or 20
to 28 in of mercury (68 to 94 kPa) (vacuum).
32-11-08
Page 4 Rev. 3
E-AB412-PT6T-2
3. Prepare the aft crosstube upper surface (BL 0,0) as follows:
a. Remove primer from the crosstube in the area 2.5 in (63.5 mm ) on either side of BL 0.0 5.0 in (127.0 mm) wide.
b. Prepare faying surface area of crosstube 0.50 in (12.7 mm) beyond the edge of support assembly with dry
blasting adhesive (C-474) using 220-grit aluminum oxide at 30 to 40 psi (206.9 to 275.8 kPa).
c. Wipe with clean cloth (C-516) dampened with denatured alcohol (C-326).
NOTE
Primed part can be kept in a controlled environment for up to 48 hours before next
step is accomplished. Controlled environment is defined as between 65 and 80°F
(18.3 and 26.6°C) with relative humidity not exceeding 60% and should be
monitored during that period of time.
d. Apply primer (C-253) to cleaned surface. Cure at a temperature 65 and 80°F (18.3 and 26.6°C) for 2 hours. Do
not cure at elevated temperatures.
4. Install aft crosstube upper support (4, figure 1) as follows:
a. Remove peel ply (C-478) from inner surface of support. Lightly sand adhesive with 180 to 200 grit abrasive
paper (C-423). Wipe with clean cloth (C-516) dampened with denatured alcohol (C-326).
b. Bond support in place on crosstube using adhesive (C-317).
c. Apply bond pressure using the aft crosstube lower support (5) with U-bolts (1 and 3), steel washers (6 and 10)
and nuts (8 and 9). Torque the nuts to 14.96 to 20 in-lbs (1.69 to 2.26 Nm). Retorque as required to maintain
noted torque as adhesive is squeezed out. Remove excess adhesive and cure at room temperature.
d. Within 30 minutes of application of the adhesive, torque nuts (8 and 9) 80 to 100 in-lbs (9.04 to 11.30 Nm).
e. Apply a bead of sealant (C-308) around periphery of supports (4 and 5).
f. Check torque on U-bolts (1 and 3) after adhesive has cured (24 hours). Retorque as required.
g. Install aft crosstube support beam (module 32-11-07 paragraph "3. Aft crosstube support beam - installation").
h. Apply epoxy polyamide primer (C-204) to the entire unprimed area of the crosstube, the edges of the adhesive
bond, and the edges of the upper support assembly. Apply fillet seal using sealant (C-251) all around support
assembly and adhesive edges.
5. Install aft crosstube lower support (5) as follows:
CAUTION
WHILE ACCOMPLISHING THE FOLLOWING STEP, DO NOT REMOVE

PRIMER FROM MATING SURFACES.
a. Size the Larson L101 abrasion strip (11) (raw material size 0.020 x 5.0 x 6.0 in (0.51 x 127 x 152.4 mm)) to
match the size of the lower support allowing 0.05 to 0.15 in (1.3 to 3.8 mm).
b. Lightly abrade the surface of the crosstube using abrasive pad (C-407). Do not remove epoxy primer from
crosstube, wipe with clean cloth dampened with denatured alcohol (C-326), then wipe dry with clean cloth.
c. Position abrasion strip (11) to be centered on the support (5). Bond the abrasion strip (11) in place on crosstube
using adhesive (C-571). Cure at room temperature for a minimum of 24 hours.
32-11-08
Rev. 3 Page 5
E-AB412-PT6T-2
d. Install the lower support (5) with sealant (C-308). Apply a uniform coat of sealant to each surface. Clamp with
U-bolts attaching lower support (5) to crosstube (7). Torque U-bolts 80 to 100 in-lbs (9.04 to 11.30 Nm) within
30 minutes of application of sealant. Fair-in the sealant around the periphery of the support. Ensure that all edges
of the abrasion strip (11) have sealant applied to them. Check torque on the U-bolts after the sealant has cured.
Retorque as required. Apply epoxy polyamide primer (C-204) to all surfaces.
6. Prepare the bare clamp assemblies (LBL 14,0 and RBL 14,0) for adhesive film as follows:
a. Degrease the clamp assembly by wiping with a clean cloth dampened with acetone (C-316).
b. Prepare the clamp assembly surface by wet blasting using abrasive (C-496). Use a slurry of 30 to 50% abrasive
(C-496) in water. Blast uniformly at 30 to 80 psi (206.84 to 551.58 kPa), adjusting the blasting pressure to
provide adequate cleaning without warping.
NOTE
Parts prepared with the wet abrasive blast method must be bonded or adhesive
primed within 96 hours after processing.
c. Spray or flush rinse to remove blasting residue. Perform a final rinse using a clean water spray or by flushing at
room temperature to 160°F (71.11°C).
NOTE
Do not allow parts to dry before rinsing.
d. Apply primer (C-063), Class 5 to the cleaned inside surface of the clamp assembly. Pre-cure for 60 minutes at
room temperature.
e. Apply one ply of adhesive film (C-364) to the inner surface, taking care to prevent air entrapment under the film.
f. Remove the protective backing from the adhesive film (C-364).
NOTE
Use a caul sheet over the adhesive surface to provide a uniform and smooth surface
for curing.
g. Cure the adhesive at 340 to 355°F (171.1 to 179.1°C) with a minimum temperature rise rate of 3°F (1.6°C) per
minute. Cure for 60 to 90 minutes at a maximum preferred bondline pressure of 50 psi (101.80 in of mercury).
7. Prepare the aft crosstube lower surfaces (LBL 14,0 and RBL 14,0) as follows:
a. Size the abrasion strip (13) (raw material size 0.02 x 3.38 x 4.74 in (0.51 x 85.85 x 120.40 mm)) as shown in
figure 1, detail B (length), and section C-C (width) to fit between the clamp assembly (12) and the crosstube.
Round the corners of the abrasion strip as shown in detail B to prevent lifting and peeling.
b. Lightly abrade the primer on the lower surface of the crosstube common to the abrasion strip (BL 16.17 to BL
11.43) using abrasive paper (C-423). Abrade the crosstube in a longitudinal direction, not circumferential. Do
not remove the primer from the crosstube. Wipe with denatured alcohol (C-326) and dry with a clean cloth
(C-516).
c. Position the abrasion strip (13) on the lower surface of the crosstube between BL 16.17 and BL 11.43, so it will
be centered under the clamp assembly (12) as shown in figure 1, section C-C.
d. Bond the abrasion strip to the crosstube as follows:
(1) Mix adhesive (C-571) (100 parts A to 30 parts B) and apply a thin coat of the adhesive to both the crosstube
and the abrasion strip. Allow adhesive to become tacky (wait 15 to 20 minutes) before assembly.
32-11-08
Page 6 Rev. 3
E-AB412-PT6T-2
(2) Place the abrasion strip (13) on the crosstube and rub in place.
NOTE
Use a release film or other release barrier between the abrasion strip and caul sheet
to prevent bonding to the adhesive film.
(3) Use a caul sheet formed with mating contour to apply a uniform pressure on abrasion strip.
(4) Remove adhesive squeeze-out with acetone (C-316).
(5) Allow to cure for 10 minutes minimum before next operation. Full cure requires 24 hours at 65°F (18.33°C).
(6) Seal edges using sealant (C-251).
8. Assemble the clamp assembly to the crosstube as follows:
a. Prepare the faying surfaces of the aft crosstube (7, figure 1) (upper surface), the abrasion strip (13) on the lower
surface, and the clamp assembly (12) by lightly abrading/cleaning with 3M Scotchbrite, Grade, fine. Do not
remove epoxy primer from the crosstube. Wipe the area clean with denatured alcohol (C-326), and dry with a
clean cloth (C-516).
b. Apply a uniform coat of sealant (C-251) to the faying surfaces of the aft crosstube (7), clamp assembly (12) and
abrasion strip (13).
c. Install the clamp assembly (12) into position on the crosstube (7). When properly placed, the top outside edge
of the clamp assembly will sit at BL 15,80 as shown in figure 1, detail B. Torque the clamp fasteners to 50 to 70
in-lbs (5.65 to 7.91 Nm).
d. Fair in the sealant squeeze-out around the periphery of the clamp assembly. Assure that the edges of the abrasion
strip (13) have sealant applied to them. Apply additional sealant as required to ensure a uniform seal.
e. Check the torque on the clamp fasteners after the sealant is cured, and retorque as required.
f. Apply epoxy polyamide primer (C-204) to all surfaces.
5. AFT CROSSTUBE ATTACHMENT SUPPORTS - INSPECTION AND REPAIR
1. Inspect aft crosstube supports (4 and 5, figure 1) for mechanical and corrosion damage. Inspect abrasion strip (11), if
installed, under aft lower crosstube support (5) for looseness or deteriorated adhesive. To repair adhesive, refer to
Appendix I.
NOTE
Scratches, dents and corrosion may be polished out to maximum depths as shown in
figure 2. No cracks are acceptable.
2. Inspect LBL 14,00 and RBL 14,00 clamp assemblies (12) for security, mechanical and corrosion damage. Inspect
abrasion strips (11) underneath the clamp assemblies for looseness or deteriorated adhesive. To repair adhesive refer
to Appendix I.
32-11-08
Rev. 3 Page 7
E-AB412-PT6T-2
1
4
5
10
9
8
6
ADHESIVE (C-308)
1. U-bolt
2. Aft crosstube support beam
3. U-bolt
4. Aft crosstube upper support
5. Aft crosstube lower support
6. Steel washer
7. Aft crosstube
8. Nut
9. Nut
10. Steel washer
11. Abrasion strip
12. Clamp assembly
13. Abrasion strip
G6AB1052A
Figure 1. Landing gear - aft crosstube supports removal/installation (sheet 1 of 2)
32-11-08
Page 8 Rev. 3
E-AB412-PT6T-2
4
7
11
12
13
12
13
G6AB1053A
Figure 1. Landing gear - aft crosstube supports removal/installation (sheet 2 of 2)
32-11-08
Rev. 3 Page 9
E-AB412-PT6T-2
AFT CROSSTUBE SUPPORTS
412-050-006
412-050-007
TYPE OF DAMAGE MAXIMUM DEPTHS AND REPAIR DEPTH
MECHANICAL 0.020 in (0.50 mm)

CORROSION DAMAGE
(AFTER CLEANUP) 0.020 in (0.50 mm)
MAXIMUM AREA PER FULL DEPTH REPAIR 1.0 sq-in (645.1 mm²)
NUMBER OF REPAIRS 2
EDGE CHAMFER 0.050 in (1.27 mm)
BORE DAMAGE 0.020 in (0.50 mm) for 1/4 circumference
G6AB1054A
Figure 2. Landing gear crosstube supports - damage limits
32-11-08
Page 10 Rev. 3
E-AB412-PT6T-2
1. Aft crosstube
2. Larson L101 abrasion strip
3. Plastic wedge
G6AB1055A
Figure 3. Crosstube support - abrasion strip removal (typical)
32-11-08
Rev. 3 Page 11
E-AB412-PT6T-2
32-11-08
Page 12 Rev. 3
E-AB412-PT6T-2
32-1 -09 LANDING GEAR ASSEMBLY - FORWARD CROSSTUBE SUPPORTS
32-11-09
LANDING GEAR ASSEMBLY - FORWARD CROSSTUBE SUPPORTS
1. FORWARD CROSSTUBE SUPPORTS - DESCRIPTION
There are two designs for the forward crosstube supports:

— the standard forward crosstube (205-050-400) and high forward crosstube (205-050-403) which are fitted with an
upper and lower support that are bonded to crosstube.
— the standard forward crosstube (412-050-040) and high forward crosstube (412-050-046) which are fitted with a single
upper support that is riveted to the crosstube. An abrasion strip (206-050-301) is bonded to the lower surface of the
crosstube at BL 14,00.
2. FORWARD CROSSTUBE SUPPORTS - REMOVAL
2-1. TWO-PIECE SUPPORT WITH U-CLAMPS (CROSSTUBES 205-050-400 AND 205-050-403)
2. Remove nuts (7 and 8, figure 1), steel washers (5 and 9), and U-bolts (1 and 2).
3. Remove forward crosstube support (3 and 4).
2-2. ONE PIECE RIVETED SUPPORT (CROSSTUBES 412-050-040 AND 412-050-046)
CAUTION
ONE PIECE CROSSTUBE/SUPPORT FASTENER HOLES ARE COLD

WORKED. REPLACEMENT OF THE SUPPORTS MUST ONLY BE
ACCOMPLISHED USING THE SAME SIZE FASTENERS. IF DAMAGE HAS
OCCURRED TO THE COLD WORKED HOLE(S); DAMAGE TO THE COLD
WORKED HOLES UP TO 0.005 IN (0.12 MM) DEEP MAY BE REPAIRED BY
REAMING THE HOLE TO 0.205 TO 0.209 IN (5,21 TO 5,30 MM) AND
INSTALLING A CR4652CW-6 FASTENER OF THE CORRECT LENGTH.
CONTACT PRODUCT SUPPORT FOR DAMAGE GREATER THAN 0.005 IN
(0.12 MM) DEEP.
2. Using caution, remove rivets (3, figure 2).
3. Remove support (2).
32-11-09
Rev. 3 Page 1
E-AB412-PT6T-2
3. FORWARD CROSSTUBE SUPPORTS - INSTALLATION
3-1. TWO-PIECE SUPPORT WITH U-CLAMPS (CROSSTUBES 205-050-400 AND 205-050-403)
MATERIALS REQUIRED
NUMBER NOMENCLATURE
C-308 ADHESIVE
C-516 CLEAN CLOTH
CAUTION
WHEN CLEANING FAYING SURFACES, DO NOT USE ANY TOOL OR

SUBSTANCE WHICH COULD SCRATCH TUBE OR SUPPORTS.
CAUTION
ABRADE CROSSTUBE SURFACE IN LONGITUDINAL DIRECTION. MAKE

SURE YOU DO NOT ABRADE THE CROSSTUBE METAL SURFACE.
1. Clean mating surfaces by lightly abrading the forward crosstube (6, figure 1) and forward crosstube supports (4 and
3) with 400 to 600 grit abrasive paper (C-423). Remove sanding residue with a clean cloth (C-516) dampened with
MEK (C-309).
2. Coat mating surfaces of forward crosstube (6) and forward crosstube supports (3 and 4) and bond using sealant
(C-308).
3. Position forward crosstube supports (3 and 4) and U-bolts (1 and 2) on forward crosstube (6) at location shown in detail
A.
4. Install two steel washers (5) and nuts (7). Install steel washers (9) and nuts (8).
5. Torque nuts (7 and 8) 80 to 100 in-lbs (9.04 to 11.30 Nm) within 30 minutes after application of adhesive.
6. Apply a bead of sealant (C-308) around periphery of forward crosstube supports (3 and 4).
7. Check torque on nuts (7 and 8) after adhesive is cured (24 hours) and apply torque as required.
32-11-09
Page 2 Rev. 3
E-AB412-PT6T-2
3-2. ONE PIECE RIVETED SUPPORT (CROSSTUBES 412-050-040 AND 412-050-046)
MATERIALS REQUIRED
NUMBER NOMENCLATURE
C-251 SEALANT
C-252 ADHESIVE FILM
C-253 ADHESIVE PRIMER
C-317 ADHESIVE
C-407 ABRASIVE PAD
C-474 DRY BLASTING ABRASIVE
C-478 PEEL PLY
C-516 CLEAN CLOTH
C-571 ADHESIVE
1. Replace support (2, figure 2) and abrasion strip (4) on forward crosstube (1) (LBL 14,00 and RBL 14,0) as follows:
a. Prepare faying surface of support (2) as follows:
(1) Remove oils and grease with dry cleaning solvent (C-304).
(2) Blast the faying surface with 80 grit dry blasting abrasive (C-474) at 50 to 80 psi (344.7 to 551.5 kPa).
(3) Flush the area with dry cleaning solvent (C-304) to remove the blasting residue.
(4) Apply primer (C-253) to cleaned area of the support (2). Cure at 65 to 80°F (18,3 to 26,6°C) for a minimum
of two hours.
(5) Apply adhesive film (C-252) to the adhesive primed surface. Place peel ply (C-478) to the inside faying
surface of the support (2).
NOTE
Provide a film or other release barrier to the caul sheet to prevent bonding to the
adhesive film.
(6) Place a caul sheet over the adhesive surface to provide a uniform and smooth surface when cured.
(7) Cure at a maximum bondline temperature of 290°F (143,3°C) with a maximum temperature rate of 1°F
(0.5°C) per minute. Cure time shall be 60 minutes minimum at a bondline pressure of 20 to 28 in of
mercury (67,8 to 94,8 kPa) (vacuum) or 20 to 125 psi (137.9 to 861.8 kPa).
32-11-09
Rev. 3 Page 3
E-AB412-PT6T-2
b. Prepare forward crosstube upper surface (LBL 14,00 and RBL 14,0) as follows:
(1) Remove primer from forward crosstube (1) in the area 2.5 in (63.5 mm) either side of BL 14,00, 5.0 in
(127.0 mm) wide.
(2) Prepare faying surface area of forward crosstube (1) 0.50 in (12.7 mm) beyond the edge of support (2) by
dry blasting abrasive (C-474) using 220 grit aluminum oxide at 30 to 40 psi (206.8 to 275.8 kPa).
CAUTION
AVOID CONTACT BETWEEN THE PAINTED SURFACE AND THE

ALCOHOL.
(3) Wipe with clean cloth dampened with denatured alcohol (C-326). Wipe dry with a clean cloth (C-516).
CAUTION
DO NOT CURE ADHESIVE PRIMER AT ELEVATED TEMPERATURES.
(4) Apply adhesive primer (C-253) to cleaned area of the forward crosstube (1). Cure at room temperature for
a minimum of two hours.
c. Install support as follows:
(1) Remove peel ply (C-478) from inner surface of support (2).
(2) Lightly sand adhesive with 180 to 200 abrasive paper (C-423). Wipe with clean cloth dampened with
alcohol (C-326). Wipe dry with a clean cloth (C-516).
CAUTION
NEW CROSSTUBE/SUPPORT FASTENER HOLES ARE COLD WORKED.

REPLACEMENT OF THE SUPPORTS MUST ONLY BE ACCOMPLISHED
USING THE SAME SIZE FASTENERS. IF DAMAGE HAS OCCURRED TO
THE COLD WORKED HOLE(S); A DAMAGE ASSESSMENT BY PRODUCT
SUPPORT IS REQUIRED BEFORE REWORK/REPAIR IS ATTEMPTED.
(3) Bond support (2) in place on forward crosstube (1) using adhesive (C-317) and wet install rivets (3) with
sealant (C-251). Remove excess adhesive and cure at room temperature.
(4) Apply epoxy polyamide primer (C-204) to the entire unprimed area of the forward crosstube (1), the edges
of the adhesive bondline, and the edges of the support (2). Apply fillet seal using sealant (C-251) all around
support (2) and adhesive edges.
d. Install abrasion strip (4) as follows:
CAUTION
WHEN PREPARING THE LOWER SURFACE OF CROSSTUBE, ENSURE

THAT THE EPOXY POLYAMIDE PRIMER (C-204) IS NOT REMOVED.
32-11-09
Page 4 Rev. 3
E-AB412-PT6T-2
CAUTION
DO NOT USE AN ALTERNATE ADHESIVE FOR THIS APPLICATION.
(1) Lightly abrade the lower surface of the forward crosstube (1) common to the abrasive strip (4) using
abrasive pad (C-407). Wipe with clean cloth dampened with denatured alcohol (C-326). Wipe dry with a
clean cloth (C-516).
(2) Bond the abrasive strip (4) in place using adhesive (C-571). Cure at room temperature for a minimum of
24 hours.
(3) Seal edges of abrasive strip (4) using sealant (C-251).
4. FORWARD CROSSTUBE SUPPORTS - INSPECTION AND REPAIR
NOTE
Superficial mechanical damage to bearing and retaining supports is acceptable
without repair. Sharp corners and gouges should be repaired within allowable limits.
Distortion and/or wear that can be detected visually is not acceptable. Refer to figure
3 for damage limits.
1. Inspect forward crosstube support (3 and 4, figure 1) for mechanical and corrosion damage. If damage has occurred to
the cold worked hole(s); a damage assessment by product support is required before rework is attempted.
2. Inspect support 412-050-038 for mechanical and corrosion damage.
3. Inspect inner adhesive film of support 412-050-038 for condition and security. No voids are permitted.
4. Scratches, dents and corrosion may be polished out to maximum depths as shown in figure 3. No cracks are acceptable.
The holes in the crosstube that accept the rivets are cold worked (figure 4). Replacement of the forward crosstube
support rivets must only be accomplished using the same size rivets.
Damage to the cold-worked holes up to 0.005 in (0.12 mm) deep may be repaired by reaming the hole to 0.205 to 0.209
in (5.21 to 5.31 mm) and installing a CR4652CW-6 fastener of the correct length.
Contact Product Support Engineering for damage greater than 0.005 in (0.12 mm) deep. Further damage assessment
by Product Support Engineering if required before rework is attempted.
32-11-09
Rev. 3 Page 5
E-AB412-PT6T-2
2
1
5
9
8 6
7
ADHESIVE (C-308)
80 TO 100 IN-LBS
(9.04 TO 11.30 Nm)
1 3 2
6
4
1. U-bolt
2. U-bolt
3. Forward crosstube upper support
4. Forward crosstube lower support
5. Steel washer
7. Nut
8. Nut
9. Steel washer
G6AB1056A
Figure 1. Landing gear - forward crosstube supports (205-050-400 and 205-050-403) removal/installation
32-11-09
Page 6 Rev. 3
E-AB412-PT6T-2
2. Support
3. Rivet
4. Abrasive strip
G6AB1057A
Figure 2. Landing gear - forward crosstube supports (412-050-040 and 412-050-046) removal/installation
32-11-09
Rev. 3 Page 7
E-AB412-PT6T-2
FORWARD CROSSTUBE SUPPORTS
205-050-132
205-050-133

CORROSION DAMAGE
AFTER CLEAN-UP 0.020 in (0.50 mm)
MAXIMUM AREA PER FULL DEPTH REPAIR 1.0 sq-in (645.1 sq-mm)
NUMBER OF REPAIRS 2
G6AB1058A
Figure 3. Landing gear crosstube supports - damage limits (sheet 1 of 2)
32-11-09
Page 8 Rev. 3
E-AB412-PT6T-2
IMPROVED FORWARD CROSSTUBE SUPPORTS
412-050-038

CORROSION DAMAGE
AFTER CLEAN-UP 0.020 in (0.50 mm)
MAXIMUM AREA PER FULL DEPTH REPAIR 1.0 sq-in (645.1 sq-mm)
NUMBER OF REPAIRS 2
G6AB1059A
Figure 3. Landing gear crosstube supports - damage limits (sheet 2 of 2)
32-11-09
Rev. 3 Page 9
E-AB412-PT6T-2
ADHESIVE (C-252)
ADHESIVE (C-571)
SEALANT (C-251)
1. Support bearing
2. Rivet
3. Rivet
4. Abrasion strip
5. Crosstube
NOTE:
1 Cold-worked hole can be reamed to 0.205 to 0.209 in (5.21 to 5.31 mm) diameter to clean maximum damage of 0.005 in
(0.12 mm) depth, before installation of oversize rivet.
G6AB1060A
Figure 4. Cold-worked hole damage - forward crosstube (412-050-040 and 412-050-046)
32-11-09
Page 10 Rev. 3
E-AB412-PT6T-2
32-1 -10 LANDING GEAR ASSEMBLY - HIGH SKID GEAR (P/N 412-706-003-101/-103)
32-11-10
LANDING GEAR ASSEMBLY - HIGH SKID GEAR (P/N 412-706-003-101/
-103)
1. HIGH SKID GEAR (P/N 412-706-003-101/-103) - DESCRIPTION
Installation of the high skid gear provide an additional 15 cm (6 in) of ground clearance. The kit contains a complete landing
gear assembly. The maintenance procedure is the same as that described for normal LANDING GEAR, for the description
refer to module 32-11-01 "LANDING GEAR ASSEMBLY".
32-11-10
Page 1
E-AB412-PT6T-2
32-11-10
Page 2
E-AB412-PT6T-2
32-21-01 TAIL SKID
32-21-01
TAIL SKID
1. TAIL SKID - DESCRIPTION
A tubular steel tail skid is attached on the lower aft section of the tailboom. The purpose of the tail skid is to warn the pilot
of a tail-low attitude when landing.
2. TAIL SKID - REMOVAL
1. Remove screws (1, figure 1) and remove navigation light cover (2) on both sides of the tailboom to gain access to tail
skid (3).
2. Remove any installed ballast (Chapter 8).
3. Remove nut (4), bolt (5), and washers (6).
4. Pull tail skid (3) aft through support block (7).
NOTE
Do not remove packing (8) if it is suitable for further service.
Do not remove support block (7) if only tail skid (3) is to be replaced.
3. TAIL SKID - INSTALLATION
1. If not previously accomplished, lubricate packing (8, figure 1) with petroleum jelly or soapy water and install packing
in support block (7).
2. Insert tail skid (3) through packing (8) and position in brackets (9 and 10) which are installed on bulkhead inside
tailboom. Align tail skid (3) with center of vertical fin and determine number of washers (6) required on each side of
tail skid. Partially withdraw tail skid and secure washers (6) on brackets (9 and 10) with masking tape. Position tail
skid in brackets (9 and 10) and install bolt (5) and nut (4).
3. Install ballast on tail skid (Chapter 8).
4. Install navigation light cover (2) on both sides of tailboom and secure with screws (1).
4. TAIL SKID - INSPECTION AND REPAIR
1. Inspect tail skid (3, figure 1) for dents. Smooth dents up to 0,050 in (1,27 mm) deep and 0,375 in (9,5 mm) in diameter
anywhere along tail skid length are acceptable without repair.
2. Inspect tail skid (3) for scratches. Longitudinal scratches up to 0,005 in. (0,12 mm) deep and 0,50 in. (12,7 mm) long
are acceptable without repair. No circumferential scratches are allowed without repair. Scratches may be polished to a
depth of 0,005 in. (0,12 mm).
32-21-01
Rev. 3 Page 1
E-AB412-PT6T-2
3. Inspect tail skid (3) for cracks. No cracks are acceptable.
4. Inspect ballast (if installed) and attaching components for security.
5. Inspect support block (7) and brackets (9 and 10) for cracks. No cracks are acceptable.
6. Refer to figure 2 for tail skid damage limits.
32-21-01
Page 2 Rev. 3
E-AB412-PT6T-2
1. Screw
2. Navigation light cover
3. Tail skid
4. Nut
5. Bolt
6. Washer
7. Support block
8. Packing
9. Bracket
10. Bracket
G6AB0051B
Figure 1. Tail skid removal/installation
32-21-01
Rev. 3 Page 3
E-AB412-PT6T-2
1.0 IN (25.4 mm)

PERMANENT DEFLECTION MAX
TYPE OF DAMAGE MAXIMUM DEPTHS AND REPAIR AREAS
MECHANICAL 0.010 in (0.25 mm) 0.020 in (0.50 mm)

CORROSION
BEFORE CLEANUP 0.005 in (0.12 mm) 0.010 in (0.25 mm)
AFTER CLEANUP 0.010 in (0.25 mm) 0.020 in (0.50 mm)
MAXIMUM AREA PER FULL DEPTH REPAIR 0.25 sq-in (1.6 cm²) 0.50 sq-in (3.2 cm²)
MAXIMUM LENGTH 1.50 in (38.1 mm) 1.50 in (38.1 mm)
NUMBER OF REPAIR AREAS 3 5
DENTS None Note 1
G6AB0052B
Figure 2. Tail skid - damage limits (sheet 1 of 2)
32-21-01
Page 4 Rev. 3
E-AB412-PT6T-2
NOTES:
1. Smooth dents up to 0.125 in (3.17 mm) deep and up to 0.60 in (15.2 mm) in diameter are acceptable without repair.
2. Scratches and corrosion shall be polished out to the depth of damage limits.
3. Radial damage across the tube, (W - view A), is limited to 1/8 of circumference.
G6AB0053B
Figure 2. Tail skid - damage limits (sheet 2 of 2)
32-21-01
Rev. 3 Page 5
E-AB412-PT6T-2
32-21-01
Page 6 Rev. 3
E-AB412-PT6T-2
32-31-01
PASSENGER STEP (ELECTRICALLY POWER OPERATED)
1. PASSENGER STEP - DESCRIPTION
The passenger step elevates for passengers to enter and exit, and retracts for flight. The installation consists of two arms,
step, actuator, and electrical system. The passenger step is mounted to skid tube on each side of helicopter. The passenger
step is actuated by a STEP switch (RAISE and STOW), located on upper left side of pedestal. The actuator retains passenger
step in raised and lowered positions.
CAUTION
DO NOT ACTUATE STEP WHEN A LOAD IS APPLIED.
NOTE
Refer to Chapter 98 for passenger step wiring diagram.
2. PASSENGER STEP - REMOVAL
1. Remove bolt (21, figure 1) attaching step assembly (1) to forward arm (14) by removing nut (33), washer (32), and
bushings (17 and 18).
2. Remove bolt (3) attaching step assembly (1) to aft arm (30) by removing nut (29), washer (28), and bushings (27 and
26). Remove step assembly (1).
3. Remove the sealant from the grommet (35) and pull the cable assembly (23) from the crosstube until the splices are
visible. Cut the wire at the splices.
4. Remove bolt (13), nut (19), and washer (20) attaching actuator (22) to forward arm (14).
5. Remove cotter pin (9), washer (8), and pin (24) attaching actuator (22) to bracket (10). Remove actuator.
6. Remove bolts (31 and 11) attaching forward and aft arms (14 and 30) to skid tube (4). Remove arms (14 and 30).
7. Remove screws (7) attaching bracket (10) to skid tube (4). Remove bracket (10).
3. PASSENGER STEP - INSTALLATION
MATERIALS REQUIRED
NUMBER NOMENCLATURE
C-308 SEALANT
C-320 SEALANT
32-31-01
Rev. 3 Page 1
E-AB412-PT6T-2
1. Position bracket (10, figure 1) on skid tube (4) and install attaching screws (7) with sealant (C-320) applied.
2. Position forward and aft arms (14 and 30) on skid tube (4) and install attaching bolts (31 and 11) with sealant (C-320).
3. Preset actuator (22) to full electrical retract dimension of 11,25 in (285.75 mm) between attachment bolt hole centers.
Adjust actuator rod end as necessary to obtain required dimension.
4. Position actuator (22) on bracket (10) and forward arm (14). Note marking THIS SIDE INBOARD. Use lower hole of
spring loaded rear anchor for mounting.
5. Install pin (24), washer (8), and cotter pin (9) to attach actuator (22) to bracket (10).
6. Install bolt (13), washer (20), and nut (19) to attach actuator (22) to forward arm (14). Torque nut 20 to 25 in-lbs
(2.26 to 2,82 Nm).
7. Position step assembly (1) on forward and aft arms (14 and 30) and install attaching washers (28 and 32), nuts (29 and
33), and bolts (3 and 21). Torque nuts 25 to 30 in-lbs (2,82 to 3,39 Nm).
NOTE
Do not cap or connect the test wires (white/red and white/black) until the step
rigging (steps 12. through 15.) is completed.
8. Install the grommet (35) on the actuator wires.
9. Connect electrical connector (23) to actuator (22). Apply a heavy coating of sealant (C-308) around wire/skid tube (4)
entrance point.
10. Fully extend actuator (22) through microswitch stop. Clearance between forward arm (14) and skid tube (4) should be
0,06 to 0,12 in (1.52 to 3.0 mm).
11. Check clearance at extreme ends (fore and aft) of step assembly (1) with assembly, in fully retracted position. Aft end
of step assembly should contact skid tube (4). Forward end of step should have a gap of approximately 0.25 in
(6.35 mm).
12. Check clearance fore and aft between skid tube (4) and step assembly (1). Adjust actuator (22) to maintain 0,09 in.
(2,3 mm) clearance.
13. With step raised, select STOW. While step is in transit, 28 VDC shall be present on the actuator white/black test wire
and shall switch to ground reference when step has reached its fully stowed position.
NOTE
Voltage between white/black or white/red test wires will be present as long as
actuator is not fully extended or fully retracted.
14. If 28 VDC remains present on test wires after extend or retract procedure is complete, actuator will require adjustment
of rod end bearing.
15. Remove bolt (13), washer (20), and nut (19) securing actuator (22) to forward arm (14) and adjust as required, until
28 VDC switches to ground reference during extend or retract procedure.
16. Once rigging is completed with satisfactory results, cap and stow test wires.
17. Carefully push the wires and splices inside the skid tube (4). Install the grommet (35) and seal with sealant (C-308).
18. Apply vinyl tape pads (2) and (34).
32-31-01
Page 2 Rev. 3
E-AB412-PT6T-2
CAUTION
DO NOT OPERATE STEP MORE THAN TWO COMPLETE CYCLES IN A

FIVE MINUTE PERIOD.
19. Perform functional check of passenger step (E-AB412-PT6T-1).
4. PASSENGER STEP - INSPECTION
1. Check actuator (22, figure 1) for proper operation (E-AB412-PT6T-1).
2. Inspect actuator boot for tears, cracks, or deterioration.
NOTE
Superficial mechanical damage is acceptable without repair. Cracked parts are not
acceptable and shall be replaced. Superficial corrosion damage shall be removed.
Parts exhibiting corrosion damage deeper than superficial shall be replaced.
3. Inspect step assembly (1), arms (14 and 30) and bracket (10) for mechanical and corrosion damage.
4. Inspect bushings (5, 6, 12, 15, 16, 17, 18, 25, 26, and 27) for secure installation and wear. Loose or worn bushing are
not acceptable and shall be replaced.
5. Inspect actuator rod and bearings for axial and radial play.
5. PASSENGER STEP - REPAIR
Passenger step and attaching parts that are damaged beyond limits in paragraph "4. Passenger step - inspection" shall be
replaced.
32-31-01
Rev. 3 Page 3
E-AB412-PT6T-2
ADHESIVE (C-308)
20 TO 25 IN-LBS
(2.26 TO 2.82 Nm)
25 TO 30 IN-LBS
(2.82 TO 3.39 Nm)
1. Step assembly 13. Bolt 25. Bushing

2. Pad 14. Forward arm 26. Bushing
3. Bolt 15. Bushing 27. Bushing
4. Skid tube 16. Bushing 28. Washer
5. Bushing 17. Bushing 29. Nut
6. Bushing 18. Bushing 30. Aft arm
7. Screw 19. Nut 31. Bolt
8. Washer 20. Washer 32. Washer
9. Cotter pin 21. Bolt 33. Nut
10. Bracket 22. Actuator 34. Pad forward
11. Bolt 23. Electrical connector 35. Grommet
12. Bushing 24. Pin
NOTE:
1 Remove sealant from grommet (35) and pull electrical connector (23). Cut wires as close as possible to splices.
G6AB0807B
Figure 1. Passenger step - removal/installation
32-31-01
Page 4 Rev. 3
E-AB412-PT6T-2
32-41-01 GROUND HANDLING WHEELS (214-706-104-0 3)
32-41-01
GROUND HANDLING WHEELS (214-706-104-003)
1. GROUND HANDLING WHEELS - DESCRIPTION
Overhaul instructions for ground handling wheels contained in this chapter are limited to inspection and replacement of
faulty parts.
2. GROUND HANDLING WHEELS - INSPECTION
1. Inspect wheel and tire assembly (1 and 5, figure 1) for tire damage and deterioration. Check both tires for inflation to
75 psi (517 kPa). Inspect wheels for corrosion, cracks, and secure installation on axles (4 and 24).
2. Inspect pump assembly (2) for adequate supply of hydraulic fluid, corrosion, obvious mechanical damage, and secure
installation on cradle assembly (11).
3. Inspect cradle assembly (11) and all detail parts shown on view B for obvious damage, and secure installation.
4. Inspect bushings (30, 47, 48 and 49) for obvious wear and for secure installation.
5. Inspect decals (19 and 20) for legibility and secure installation.
6. Inspect pin (10) and spring pin (29) to assure they are not sheared and that pin is adequately secured.
7. Inspect lubrication fittings (27, 28, and 35) and also fitting (not illustrated) that is opposite lubrication fitting (35) for
secure installation and for damage.
8. Perform operational check of ground handling wheels. Install ground handling wheel assembly on helicopter landing
gear skid and raise helicopter. Inspect for proper engagement and operation of release pin (3) and pin (10). Inspect for
hydraulic leaks. If wheel assembly will not raise helicopter, and the pump has supply of hydraulic fluid, cause is
probably internal hydraulic leak in pump assembly (2).
3. GROUND HANDLING WHEELS - LUBRICATION
MATERIALS REQUIRED
NUMBER NOMENCLATURE
C-001 GREASE
1. Use hand grease gun and lubricate with grease (C-001).
2. Lubricate fittings (27, 28, and 35, figure 1). Also lubricate the fitting that is opposite to fitting (35) (not illustrated).
32-41-01
Rev. 3 Page 1
E-AB412-PT6T-2
G6AB0084A
Figure 1. Ground handling wheel assembly - removal/installation (sheet 1 of 2)
32-41-01
Page 2 Rev. 3
E-AB412-PT6T-2
1. Wheel and tire assembly 13. Nut 25. Thin steel washer 37. Thin steel washer
2. Pump assembly 14. Thin steel washer 26. Nut 38. Clevis
3. Release pin 15. Nut 27. Lubrication fitting 39. Elbow
4. Axle 16. Hose assembly 28. Lubrication fitting 40. Ram assembly
5. Wheel and tire assembly 17. Tee 29. Spring pin 41. Trunnion
6. Bolt 18. U-bolt 30. Bushing 42. Setscrew
7. Sleeve spacer 19. Decal 31. Retainer 43. Thin steel washer
8. Nut 20. Decal 32. Thin steel washer 44. Thin steel washer
9. Cotter pin 21. U-bolt 33. Nut 45. Setscrew
10. Pin 22. Thin steel washer 34. Cotter pin 46. Bolt
11. Cradle assembly 23. Bolt 35. Lubrication fitting 47. Bushing
12. Thin steel washer 24. Axle 36. Lubrication pin 48. Bushing
49. Bushing
G6AB0085C
Figure 1. Ground handling wheel assembly - removal/installation (sheet 2 of 2)
32-41-01
Rev. 3 Page 3
E-AB412-PT6T-2
4. GROUND HANDLING WHEELS - WHEEL AND TIRE ASSEMBLY
4-1. WHEEL AND TIRE ASSEMBLY - REMOVAL
WARNING
DEFLATE TIRE IF INSTALLED ON GROUND HANDLING ASSEMBLY

PRIOR TO REMOVING NUT (8, FIGURE 1). IF BOLTS (6) ARE NOT
PROPERLY INSTALLED, AN INFLATED TIRE MAY CAUSE WHEEL
HALVES TO SEPARATE WHEN NUT (8) IS REMOVED.
NOTE
Removal procedure for wheel and tire assembly (5) is given. Removal procedure for
wheel and tire assembly (1) is the same.
1. Deflate tire, if installed.
2. Remove cotter pin (9).
3. Remove nut (8).
4. Remove sleeve spacer (7) from axle (4).
5. Remove wheel and tire assembly (5).
4-2. WHEEL AND TIRE ASSEMBLY - INSTALLATION
MATERIALS REQUIRED
NUMBER NOMENCLATURE
C-001 GREASE
NOTE
Installation procedure for wheel and tire assembly (5, figure 1) is given. Installation
procedure for wheel and tire assembly (1) is the same.
1. Apply a bead of grease (C-001) around wheel bearing and apply a film of grease to axle (4).
2. Position wheel and tire assembly on axle (4). Install sleeve spacer (7), nut (8), and cotter pin (9).
3. Inflate tires to 75 psi (517 kPa).
5. GROUND HANDLING WHEELS - TUBELESS TIRE
5-1. TUBELESS TIRE - REMOVAL
1. Remove wheel and tire assembly (paragraph "4-1. Wheel and tire assembly - removal").
32-41-01
Page 4 Rev. 3
E-AB412-PT6T-2
2. Remove valve core.
WARNING
ENSURE THAT TIRE IS DEFLATED PRIOR TO REMOVING BOLTS IN

FOLLOWING STEPS.
3. Remove bolts (6, figure 1).
4. Separate wheel halves and remove tire.
5. Remove and discard nitrile wheel seal.
6. Remove valve stem.
5-2. TUBELESS TIRE - INSTALLATION
1. Install new nitrile wheel seal on inboard machined surface of wheel half.
2. Install new valve stem.
3. Place tire on wheel half. Place opposite wheel half on tire and align holes for bolts (6, figure 1).
4. Install bolts (6) with steel washer and nut. Torque nuts 125 to 150 in-lbs (14.13 to 16.94 Nm).
5. Inflate tire to 75 psi (517 kPa).
6. Install wheel and tire assembly (paragraph "4-2. Wheel and tire assembly - installation").
6. GROUND HANDLING WHEELS - TUBE TIRE
6-1. TUBE TIRE - REMOVAL
1. Remove wheel and tire assembly (paragraph "4-1. Wheel and tire assembly - removal").
2. Remove valve core.
WARNING
ENSURE THAT TIRE IS DEFLATED PRIOR TO REMOVING BOLTS IN

FOLLOWING STEPS.
3. Remove bolts (6, figure 1).
4. Separate wheel halves and remove tire and tube.
5. If installed, remove and discard nitrile wheel seal.
32-41-01
Rev. 3 Page 5
E-AB412-PT6T-2
6-2. TUBE TIRE - INSTALLATION
1. Insert tube into tire.
2. Position tire and tube on wheel half. Position valve stem through hole in wheel.
3. Place opposite wheel half on tire and align holes for bolts (6, figure 1).
4. Install bolts (6) with steel washer and nut. Torque nuts 125 to 150 in-lbs (14.13 to 16.94 Nm).
5. Inflate tire to 75 psi (517 kPa).
6. Install wheel and tire assembly (paragraph "4-2. Wheel and tire assembly - installation").
7. GROUND HANDLING WHEELS - PUMP ASSEMBLY
7-1. PUMP ASSEMBLY - DESCRIPTION
NOTE
For repair of pump assembly (2, figure 1) (P/N BU 953 or BU 953B) and to obtain
service kit (P/N JS0953) refer to:
Porter - Ferguson, Inc.
Beverly, Massachusetts, 01915
FAX (508) 921-5560
7-2. PUMP ASSEMBLY - REMOVAL
1. Remove hose assembly (16, figure 1) from tee (17). Remove hose assembly (not illustrated) from opposite side of tee
(17).
2. Remove two nuts (13), two thin steel washers (12) and U-bolt (21).
3. Remove two nuts (15), two thin steel washers (14) and U-bolt (18).
4. Remove pump assembly (2).
7-3. PUMP ASSEMBLY - INSTALLATION
MATERIALS REQUIRED
NUMBER NOMENCLATURE
C-596 TAPE
NOTE:

(C-072).
32-41-01
Page 6 Rev. 3
E-AB412-PT6T-2
1. Apply tape (C-596) to threads of tee (17, figure 1) and install tee in pump assembly (2).
2. Position pump assembly (2) on cradle assembly (11). Install U-bolt (21), two thin steel washers (12) and nuts (13).
Install U-bolt (18), two thin steel washers (14) and two nuts (15).
3. Install hose assembly (16) on tee (17). Install hose assembly (not illustrated) on opposite side of tee (17).
4. Fill pump with hydraulic fluid (C-002) or hydraulic fluid (C-072).
5. Bleed air from hydraulic fluid in pump assembly (2) lines.
6. Perform operational check of pump assembly (2). Install ground handling wheel assembly on helicopter and raise
helicopter. Check for hydraulic leaks.
8. GROUND HANDLING WHEELS - DECALS
8-1. DECALS - REMOVAL AND INSTALLATION
MATERIALS REQUIRED
NUMBER NOMENCLATURE
1. Remove old decals (19 and 20, figure 1).
2. Clean area where decals will be installed with fine grit abrasive cloth or paper (C-423).
3. Install new decals (19 and 20) on pump cradle assembly (11).
9. GROUND HANDLING WHEELS - RAM ASSEMBLY AND TRUNNION
9-1. RAM ASSEMBLY AND TRUNNION - REMOVAL
NOTE
Removal procedure for ram assembly (40, figure 1) is given. Removal procedure for
opposite ram assembly (not illustrated) is the same.
2. Remove elbow (39).
3. Remove lubrication pin (36), lubrication fitting (35), thin steel washer (44) from clevis (38) by removing cotter pin
(34) and thin steel washer (37).
4. Remove setscrew (45).
5. Remove clevis (38) from ram assembly (40) by unscrewing.
6. Remove setscrew (42).
7. Remove ram assembly (40) by unscrewing.
32-41-01
Rev. 3 Page 7
E-AB412-PT6T-2
8. Remove opposite ram assembly (not illustrated) in the same manner.
9. Remove trunnion (41) from cradle (11) by sliding trunnion from cradle.
9-2. RAM ASSEMBLY AND TRUNNION - INSTALLATION
MATERIALS REQUIRED
NUMBER NOMENCLATURE
C-596 TAPE
NOTE:

(C-072).
NOTE
Installation procedures for ram assembly (40, figure 1) is given. Installation
procedures for opposite ram assembly (not illustrated) is the same.
1. If not previously accomplished, position trunnion (41) in cradle assembly (11).
2. Thread ram assembly (40) into trunnion (41) until it bottoms, then back out until port for elbow (39) is outboard. Install
setscrew (42).
3. Thread clevis (38) into ram assembly (40) until clevis maintains a dimension of 1.48 in (37.6 mm). Install setscrew
(45).
4. Position clevis (38) on either side of hole in flange of axle (4). Install lubrication pin (36) with lubrication fitting (35)
(facing out) through clevis (38) and flange of axle (4) with thin steel washer (37 and 44) on either side of clevis (38).
5. Install cotter pin (34).
6. Coat threads of elbow (39) with tape (C-596) and install elbow in ram assembly (40).
7. Install hose assembly (16) onto elbow (39).
8. Fill pump assembly (2) with hydraulic fluid (C-002) or hydraulic fluid (C-072).
9. Bleed hydraulic pump assembly (2).
10. Perform operational check of ram. Install ground handling wheel assembly on helicopter and raise helicopter. Check
for hydraulic fluid leaks.
32-41-01
Page 8 Rev. 3
E-AB412-PT6T-2
10. GROUND HANDLING WHEELS - AXLES
10-1. AXLES - REMOVAL
1. Remove wheel and tire assemblies (1 and 5, figure 1) (refer to paragraph "4-1. Wheel and tire assembly - removal").
2. Remove lubrication pin (36) and opposite lubrication pin (not illustrated). Refer to paragraph "9-1. Ram assembly and
trunnion - removal".
3. Remove nut (26), bolt (23), and thin steel washers (22 and 25).
4. Remove nut (33), bolt (46), and thin steel washers (32 and 43).
5. Remove axles (4) and (24).
10-2. AXLES - INSTALLATION
NOTE
If axles (4 and 24, figure 1) have not been drilled for bolts (23) and (46), accomplish
step 1. through 8. If axles have been drilled, accomplished step 1. then proceed to
step 9.
1. Operate pump assembly (2) to fully extend ram assembly (40) and opposite ram (not illustrated).
2. Position axle (24) in cradle assembly (11) from helicopters right side. Position axle (4) in cradle assembly (11) from
helicopters left side with retainer (31) positioned on axle with larger dimension from bolt hole to edge of retainer
spacer facing inboard.
3. Loosen setscrew (45) and adjust clevis (38) to hold axle (4) at 1.48 in (37.6 mm) dimension as shown in figure 2, View
B.
4. Adjust setscrew (45, figure 1) to contact axle (4) and allow lubrication pin (36) to be installed. Install lubrication pin
(36), thin steel washers (37 and 44), and cotter pin (34).
5. Adjust clevis at base of axle (24) in same manner outlined in steps 3. and 4.
6. Position axles (4 and 24) to 5.214 in (132.43 mm) dimensions as shown in figure 2, view A.
7. Line drill axles (4 and 24, figure 1) for bolts (23 and 46). Make holes 0.316 to 0.322 in (8.03 to 8.18 mm) in diameter.
8. Remove axles (4) and (24) and remove chips from drilling operation, then position axles on cradle assembly (11) in
original position.
9. Align holes in retainer (31) and axles (4 and 24). Install bolt (46), thin steel washers (32 and 43), and nut (33). Install
bolt (23), thin steel washers (22 and 25), and nut (26).
10. Install wheel and tire assemblies (1 and 5) (paragraph "4-2. Wheel and tire assembly - installation").
11. Lubricate ground handling wheels (paragraph "3. Ground handling wheels - lubrication").
12. Perform operational check of ground handling wheel assembly. Install ground handling wheel assembly on helicopter
and raise helicopter. Check for proper operation of ground handling wheel assembly.
32-41-01
Rev. 3 Page 9
E-AB412-PT6T-2
11. GROUND HANDLING WHEELS - BUSHINGS
11-1. BUSHINGS - REMOVAL
1. Remove wheels, pump assembly (2, figure 1), axles (4 and 24), and other components as necessary to gain access to
bushings (30, 47, 48 and 49). Refer to paragraph "4-1. Wheel and tire assembly - removal", paragraph "7-2. Pump
assembly - removal", and paragraph "10-1. Axles - removal". If bushing (30) must be replaced, remove spring pin (29)
and pin (10).
2. Heat cradle assembly (11) with heat lamp in area where bushings are to be removed.
3. Press or pull bushings (30, 47, 48 or 49) from cradle.
11-2. BUSHINGS - INSTALLATION
MATERIALS REQUIRED
NUMBER NOMENCLATURE
1. Clean bore in cradle assembly (11, figure 1) where bushings (30, 47, 48 or 49) will be installed.
2. Heat cradle assembly (11) with a heat lamp in area where bushings are to be installed.
3. Coat bushings with zinc chromate primer (C-201) and press into cradle assembly (11) while primer is wet. Install
bushing (47) first and ensure a recess of 0.060 in (1.52 mm) gap from surface of cradle. Outboard faces of bushings
(30 and 49) must be flush with surface of cradle. Bushing (48) must be flush with cradle surface at both ends. If
bushings protrude past cradle surface, face off bushing.
4. Line ream bushings (47, 48, and 49) 0.50 to 0.51 in (12.7 to 12.954 mm). Check release pin (3) from slip fit in bushings.
5. Ream bushing (30) 0.4995 to 0.5005 in (12.688 to 12.712 mm). Position pin (10) in bushing (30) with bevel facing
down. Install spring pin (29).
6. Install wheels, axles (4 and 24), pump assembly (2), and other components that were removed to expose bushings.
Refer to paragraph "4-2. Wheel and tire assembly - installation" , paragraph "7-3. Pump assembly - installation", and
paragraph "10-2. Axles - installation".
32-41-01
Page 10 Rev. 3
E-AB412-PT6T-2
5.214 IN
(132.43 mm)
1.48 IN
0.50 IN (37.6 mm)
(12.7 mm)
VIEW A B
1.98 IN
(50.3 mm)
VIEW B
NOTE:
Line A-B is 90 degrees to ground handling wheels attaching pins.
G6AB0086C
Figure 2. Ground handling wheel assembly - axles installation
32-41-01
Rev. 3 Page 11
E-AB412-PT6T-2
32-41-01
Page 12 Rev. 3
E-AB412-PT6T-2
CHAPTER 52 - DOORS

Module Page
Number Title Number
52-00-00 DOORS
1. Doors - general ........................................................................................................................................ 1

2. Doors - installation requirements - access doors, panels, cowling, fairings, and covers ........................ 8
3. Doors - seal installation - access doors, panels, cowling, fairings, and covers ..................................... 12
52-11-01 CREW DOORS
1. Crew doors - description ......................................................................................................................... 1

2. Crew doors - removal ............................................................................................................................. 1
3. Crew doors - installation ......................................................................................................................... 1
4. Crew doors - inspection ........................................................................................................................... 4
5. Crew doors - repair ................................................................................................................................. 4
6. Crew doors - operational check .............................................................................................................. 4
52-11-02 CREW DOORS JETTISON MECHANISM
1. Crew doors jettison mechanism - removal ............................................................................................. 1

2. Crew doors jettison mechanism - installation ......................................................................................... 1
52-11-03 CREW DOOR LATCHES
1. Crew door latches - removal ................................................................................................................... 1

2. Crew door latches - installation .............................................................................................................. 1
52-11-04 CREW DOOR HINGES
1. Crew door hinges - removal .................................................................................................................... 1

2. Crew door hinges - inspection ................................................................................................................ 1
3. Crew door hinges - installation ................................................................................................................ 2
4. Crew door hinges - repair ....................................................................................................................... 5
52-31-01 PASSENGER/CARGO AREA ACCESS DOORS
1. Passenger/cargo area access doors - description ..................................................................................... 1

2. Passenger/cargo area access doors - passenger/cargo doors ................................................................... 1
2-1. Passenger/cargo doors - removal ................................................................................................... 1
2-2. Passenger/cargo doors - installation .............................................................................................. 2
2-3. Passenger/cargo doors - inspection ................................................................................................ 2
2-4. Passenger/cargo doors - repair ....................................................................................................... 4
2-5. Passenger/cargo doors - operational check and adjustment ........................................................... 4
52-31-02 PASSENGER/CARGO AREA ACCESS DOORS - PASSENGER/CARGO DOOR LATCHES
1. Passenger/cargo door latches - removal .................................................................................................. 1

2. Passenger/cargo door latches - installation ............................................................................................. 1
52-Index
Page 1
E-AB412-PT6T-2

Module Page
Number Title Number
52-31-03 PASSENGER/CARGO AREA ACCESS DOORS - CARGO HINGED PANELS
1. Cargo hinged panels - description ...........................................................................................................1

2. Cargo hinged panels - removal ................................................................................................................1
3. Cargo hinged panels - installation ...........................................................................................................1
4. Cargo hinged panels - inspection ............................................................................................................2
5. Cargo hinged panels - repair ...................................................................................................................2
52-31-04 PASSENGER/CARGO AREA ACCESS DOORS - CARGO HINGED PANEL LATCHING

MECHANISM
1. Cargo hinged panel latching mechanism - removal ................................................................................1

2. Cargo hinged panel latching mechanism - installation ...........................................................................1
52-31-05 PASSENGER/CARGO AREA ACCESS DOORS - BAGGAGE COMPARTMENT DOOR
1. Baggage compartment door - removal ....................................................................................................1

2. Baggage compartment door - installation ...............................................................................................1
3. Baggage compartment door - inspection .................................................................................................1
4. Baggage compartment door - repair ........................................................................................................2
52-41-01 ACCESS COVERS AND DOORS - NOSE ACCESS DOORS
1. Nose access doors - description ..............................................................................................................1

2. Nose access doors - removal ...................................................................................................................1
3. Nose access doors - installation ..............................................................................................................1
4. Nose access doors - inspection.................................................................................................................2
5. Nose access doors - repair .......................................................................................................................2
52-41-02 ACCESS COVERS AND DOORS - MISCELLANEOUS ACCESS DOORS AND PANELS
1. Miscellaneous access doors and panels - description ..............................................................................1

2. Miscellaneous access doors and panels - removal ..................................................................................1
3. Miscellaneous access doors and panels - installation ..............................................................................1
4. Miscellaneous access doors and panels - inspection ...............................................................................1
5. Miscellaneous access doors and panels - repair ......................................................................................1
52-41-03 ACCESS COVERS AND DOORS - TAIL ROTOR DRIVESHAFT ACCESS COVERS
1. Tail rotor driveshaft access covers - description .....................................................................................1

2. Tail rotor driveshaft access covers - removal ..........................................................................................1
3. Tail rotor driveshaft access covers - installation .....................................................................................1
4. Tail rotor driveshaft access covers - inspection ......................................................................................1
5. Tail rotor driveshaft access covers - repair .............................................................................................1
52-Index
Page 2
E-AB412-PT6T-2
FIGURES
Figure Page
Number Title Number
52-00-00 DOORS
Figure 1. Access doors, panels, cowling, fairings, and covers (sheet 1 of 6) ................................................................ 2
52-11-01 CREW DOORS
Figure 1. Crew door ....................................................................................................................................................... 2

Figure 2. Crew door jettison mechanism ....................................................................................................................... 3
52-11-02 CREW DOORS JETTISON MECHANISM
52-11-03 CREW DOOR LATCHES
Figure 1. Crew door ....................................................................................................................................................... 3

52-11-04 CREW DOOR HINGES
Figure 1. Crew door hinges (sheet 1 of 2)...................................................................................................................... 3
Figure 1. Passenger/cargo door ...................................................................................................................................... 3

Figure 2. Passenger/cargo door latch ............................................................................................................................. 5
Figure 1. Passenger/cargo door latch ............................................................................................................................. 2
Figure 1. Cargo hinged panel ......................................................................................................................................... 3
52-31-04 PASSENGER/CARGO AREA ACCESS DOORS - CARGO HINGED PANEL LATCHING

MECHANISM
Figure 1. Cargo hinged panel ......................................................................................................................................... 3
Figure 1. Baggage compartment door............................................................................................................................ 3
Figure 1. Nose access doors ........................................................................................................................................... 3
Figure 1. Tail rotor driveshaft access covers ................................................................................................................. 2
52-Index
Page 3
E-AB412-PT6T-2
TABLES
Table Page
Number Title Number
52-00-00 DOORS
Table 1. Installation requirements for access doors, panels, cowling, fairings, and covers..........................................8
52-Index
Page 4
E-AB412-PT6T-2
52-0 -0 DOORS
52-00-00
DOORS
1. DOORS - GENERAL
This chapter provides maintenance data for access doors, panels, cowling, fairings illustrated on figure 1. The legend of
figure 1 is composed of two columns. The left column identifies individual doors, panels, etc. The right column lists major
components which are accessible when door, panel, etc. is removed.
52-00-00
Page 1
E-AB412-PT6T-2
G6AB0013A
Figure 1. Access doors, panels, cowling, fairings, and covers (sheet 1 of 6)
52-00-00
Page 2
E-AB412-PT6T-2
G6AB0014A
52-00-00
Page 3
E-AB412-PT6T-2
G6AB0015A
52-00-00
Page 4
E-AB412-PT6T-2
G6AB0843A
52-00-00
Page 5
E-AB412-PT6T-2
G6AB1021A
52-00-00
Page 6
E-AB412-PT6T-2
G6AB1020A
52-00-00
Page 7
E-AB412-PT6T-2
2. DOORS - INSTALLATION REQUIREMENTS - ACCESS DOORS, PANELS, COWLING,

FAIRINGS, AND COVERS
Refer to table 1 to identify doors, panels, cowlings, fairings, and covers which shall be installed for ground run, jacking,
towing, and flight.
Table 1. Installation requirements for access doors, panels, cowling, fairings, and covers
REQUIRED TO BE IN PLACE
FIGURE 1 GROUND FOR:
NAME
INDEX NO. RUN
JACKING TOWING FLIGHT
1 Lower nose door No No No Yes
2 Cover No No No Yes
3 Upper nose door No No No Yes
4 Crew door, copilot No No No 1
5 Cargo hinged panel No No No 1
6 Passenger cargo door No No No 1
7 Transmission fairings No No No Yes
8 Forward pylon fairing assembly No No No Yes
9 Fairing, engine inlet No No No Yes
10 Aft pylon fairing assembly No No No Yes
11 Door No No No Yes
12 Door 2
No No Yes
13 Engine oil cooler support cowling assembly No No No Yes
15 Lower cowl assembly No No No Yes
52-00-00
Page 8
E-AB412-PT6T-2
(Cont.)
NAME
INDEX NO. RUN
27 Crew door (pilot) No No No 1
35 Door 3
No No Yes
36 Door, pylon bulkhead 3

No No Yes
37 Door 3
No No Yes
38 Door 3
No No Yes
39 Door, pylon bulkhead 3

No No Yes
40 Door 3
No No Yes
41 Cover 3
No No Yes
42 Cover 3
No No Yes
43 Cover 3
No No Yes
44 Cover 3
No No Yes
45 Panel Yes No No Yes
52-00-00
Page 9
E-AB412-PT6T-2
(Cont.)
NAME
INDEX NO. RUN
46 Panel Yes No Yes Yes
49 Panel Yes Yes Yes Yes
52 Panel No No No Yes
53 Panel Yes No Yes Yes
56 Panel Yes Yes No Yes
59 Panel No No No Yes
64 Door Yes No No Yes
69 Opening, cargo hook No No No No
52-00-00
Page 10
E-AB412-PT6T-2
(Cont.)
NAME
INDEX NO. RUN
84 Lower nose access panel No No No Yes
85 Cover Yes No No Yes
86 Cover Yes No No Yes
90 Fairing No No No Yes
NOTES:
1 - Refer to the applicable E-AB412-PT6T-1.
2 - Door (12) can be removed during ground run to facilitate maintenance for a maximum of 30 minutes.
3 - Can be removed during ground run to facilitate maintenance if collective lever control is at flat pitch. Secure all
loose wiring.
52-00-00
Page 11
E-AB412-PT6T-2
3. DOORS - SEAL INSTALLATION - ACCESS DOORS, PANELS, COWLING, FAIRINGS,

AND COVERS
MATERIALS REQUIRED
NUMBER NOMENCLATURE
C-300 ADHESIVE
C-311 ADHESIVE
NOTE
Seals may be either rubber or silicone composition. Bonding procedure is different
for each type. Seals subjected to fuel or oil contamination (used in pylon
transmission and engine compartment) should be of polysulfide or neoprene (rubber)
type construction.
1. Determine type of seal to be installed as follows: Cut a small specimen from damaged seal and subject it to flame.
Silicone seals are more rapidly affected by flame and will leave a gray ash residue. Rubber type seals are much more
fire resistant and will leave a black ash residue.
2. Remove all paint and primer from metal surface where seal is to be applied.
3. Clean new seal and metal where it is to be applied with MEK (C-309) or equivalent and dry with clean cloth.
NOTE
It is necessary to thoroughly clean surfaces before sanding to preclude working any
foreign matter into pores of material.
4. Sand mating surfaces of seal and metal with 180 grit abrasive cloth or paper (C-423).
5. Clean sanded surfaces with MEK (C-309) or equivalent and dry with a clean cloth.
6. Bond rubber type (black ash) seals as follows:
a. Apply an even coat of adhesive (C-311) to mating surfaces of seal and metal.
b. Allow adhesive to air dry 10 to 15 minutes at 75F (24C) or above. Adhesive should be aggressively tacky and
adhere (but not transfer) to finger when touched.
c. Repeat preceding steps a. and b. Second coat is mandatory to obtain good adhesion.
d. Start at one end and roll on seal. Press seal down to expel all air from bond area to ensure proper contact and
adhesion.
e. Air cure for a minimum of 4 hours at 75F (24C) or above.
7. Bond silicone composition (gray ash) seals as follows:
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CAUTION
DO NOT CAP ADHESIVE AFTER MIXTURE. MIXTURE RELEASES

HYDROGEN GAS WHICH CAN CAUSE HIGH PRESSURES. POT LIFE OF
THIS ADHESIVE IS SIX HOURS.
a. Apply one even coat of adhesive (C-300) to bond surfaces of seal and metal.
b. Air dry at 75F (24C) or above for at least one hour, but not to exceed 8 hours.
c. Start at one end and roll on seal. Press seal down to expel all air from bond area to ensure proper contact and
adhesion.
d. Air cure for 7 days at 75F (24C) or for 18 hours at 110 to 115F (43 to 46C).
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52-00-00
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52-1 -01 CREW DOORS
52-11-01
CREW DOORS
1. CREW DOORS - DESCRIPTION
The two crew doors are hinged on the forward side and are equipped with a latch assembly, which may be operated from
either side of door, to secure the door in closed position. Each door incorporates three transparent acrylic plastic windows;
the forward, upper, and lower (adjustable) windows. In an emergency, doors may be jettisoned by pulling the EMERGENCY
RELEASE handle mounted inside cabin forward of each door.
2. CREW DOORS - REMOVAL
1. Pull down on latch (20, figure 1) and open crew door on helicopter.
2. Pull jettison handle (51, figure 2) to retract hinge pins (33 and 43).
3. Remove crew doors.
3. CREW DOORS - INSTALLATION
NOTE
Installation procedure for copilot door on left side is given. Installation procedure for
pilot door is the same.
1. Position crew door on helicopter.
2. Pull jettison handle (51, figure 2) to retract hinge pins (33 and 43).
3. Align hinge halves and release jettison handle.
4. Ensure hinge pins (33 and 43) engage hinge halves properly.
5. Close door slowly and observe action of latch assembly (19, figure 1).
6. Slowly move outer handle (20) to lock position. Observe engagement of two latch rod rollers (3) with upper forward
and aft strikers (2 and 13) and for clearance of 0,08 inch (2,03 mm) above each roller when fully extended.
7. Adjust rollers (3) to obtain clearance of 0,08 inch (2,03 mm) if required. Maintain minimum thread engagement of
0,30 inch (7,62 mm) as illustrated.
8. Adjust position of strikers (2, 13, and 18) if required.
9. When adjustment is satisfactory, install spring pin (14) to secure each roller (3).
52-11-01
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G6AB0019A
Figure 1. Crew door
52-11-01
Page 2
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G6AB0020A
Figure 2. Crew door jettison mechanism
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4. CREW DOORS - INSPECTION
NOTE
Inspection procedure for copilot door on left side is given. Inspection procedure for
pilot door is the same.
1. Perform operational check for both crew doors (paragraph "6. Crew doors - operational check").
2. Inspect visible portions of door latch mechanism (figure 1) for secure installation, corrosion, and damage.
3. Inspect visible portions of crew door jettison mechanism (figure 2) for secure installation, corrosion, and damage.
4. Inspect crew door structure and hinges for cracks, distortion and corrosion. Refer to E-AB412-PT6T-3, SECTION I.
In presence of an elongated hole in the lug of hinges (36, figure 1) should be possible to restore it installing a bushing.
the hole has to be enlarged to 7,925 ÷ 7,950 mm (201,3 ÷ 202 in.) after pressing in place a bushing P/N 21-005B5H5.
The bushing hole has to be line reamed at 4,775 ÷ 4,788 mm. (121,3 ÷ 121,6 in.).
5. Inspect crew door windows (module 56-11-01 paragraph "4. Cabin roof windows - inspection", module 56-11-02
paragraph "4. Upper crew door windows - inspection", and module 56-11-03 paragraph "4. Forward crew door
windows - inspection").
6. Inspect crew door seals for secure bonding and for deterioration.
5. CREW DOORS - REPAIR
NOTE
Repair of crew door latch and jettison mechanisms is restricted to replacement of
unserviceable parts.
1. Replace unserviceable parts in crew door latch mechanism (module 52-11-03 "CREW DOOR LATCHES").
2. Replace unserviceable parts in crew door jettison mechanism (module 52-11-02 "CREW DOORS JETTISON
MECHANISM").
3. Repair damaged crew door windows.
4. Install new crew door seals to replace damaged or missing seals (module 52-00-00 paragraph "3. Doors - seal
installation - access doors, panels, cowling, fairings, and covers").
6. CREW DOORS - OPERATIONAL CHECK
NOTE
The procedure for operational check/removal for copilot door on left side of
helicopter is given. The procedure for the pilot door on the right side is similar.
1. Place door to closed and locked position.
2. Verify door is securely latched. Two vertical latch rods (15 and 35, figure 1) should be extended to engage strikers (2
and 13) at top of door opening with a clearance of 0,08 inch (2,03 mm) above top of each roller (3) as illustrated. Latch
(19) should fully engage latch striker (18).
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3. Turn latch handle (20) clockwise to open position. Latch (19) should disengage from latch striker (18) and rollers (3)
should disengage from strikers (2 and 13) to allow door to open.
4. Close door and turn handle (20) to horizontal position. Handle (20) should operate smoothly and door should be held
firmly against fuselage.
5. Check jettison mechanism as follows:
a. Close and lock door with latch handle (20).
b. Station one man outside helicopter to support door. Pull emergency release handle (51, figure 2). Hinge pins (33
and 43) should retract smoothly and release hinges. Striker (1) should pivot upward to release rear door latch. If
necessary, push outward on door to separate door from fuselage.
c. Install door (paragraph "3. Crew doors - installation").
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52-11-01
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52-1 -02 CREW DOORS JETTISON MECHANISM
52-11-02
CREW DOORS JETTISON MECHANISM
1. CREW DOORS JETTISON MECHANISM - REMOVAL
NOTE
The removal procedure for copilot crew door jettison mechanism is given. The
removal procedure for the pilot crew door ejection mechanism is the same.
1. Remove crew door (module 52-11-01 paragraph "2. Crew doors - removal").
2. Remove pin (39, figure 1) and detach cable (42) from plate (45). When required, detach two clamps (50) securing
handle tube (49) to support angle and pull handle assembly up through grommet (48).
3. Remove swivel (19) from plate (45). Pull swivel from end of ejection-cable (20). Keep nut and washer with swivel.
4. Remove two bolts (36), washers (35) and remove support (32). Pull hinge pins (33 and 43) free of hinge bushings.
Remove assembled jettison mechanism from inboard side of nose structure.
5. Disassemble jettison mechanism as follows:
a. Remove cotter pins (27) to release pins (28). Remove pins (28) to detach upper and lower hinge pins (33 and 43)
from plate (45) and link (26).
b. Remove bolt (47), nut (31), washers (29, 30, and 46), and spacer (44) to separate plate (45) and link (26) from
support (32).
6. Remove cable (20) as follows:
a. Disconnect aft end fork of cable (20) from latch striker (1) by removing cotter pin (3) and pin (4).
b. Pull cable aft out of flex tube (17) leaving tube in place.
2. CREW DOORS JETTISON MECHANISM - INSTALLATION
NOTE
The installation procedure for the copilot crew door jettison mechanism is given.
The installation procedure for the pilot crew door jettison mechanism is the same.
1. Check ends of flex tube (17, figure 1) for proper installation as follows:
a. Aft end of flex tube (17) should be positioned vertically at F.S. 68,96 in door post, secured between clamp (6)
and spacer (7) and attached to bracket (8) on structure with two screws (5), washers (9), and nuts (10). End of
tube should extend 0,10 inch (2,54 mm) above clamp (6).
b. Forward end of flex tube should pass up through grommet (25) in nose structure forward of door opening and
be secured between clamp (21) and spacer (22) attached to structure with two screws (18), washers (24), and
nuts (23). End of tube should extend 0,10 inch (2,54 mm) above horizontal angle at W.L. 30.
2. Thread plain end of cable (20) through flex tube (17) from aft end.
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NOTE
Forward end of cable will be attached during installation of jettison mechanism
(refer to step 4. below).
3. Attach cable fork terminal on aft end of latch striker (1) with pin (4) secured by cotter pin (3). Verify spring (2) is
attached between striker and bracket in door post.
4. Install jettison mechanism as follows:
a. Insert spacer (44) through pivot holes of plate (45) and link (26).
b. Place standard steel washer (46) on bolt (47), and insert bolt from plate side through spacer (44).
c. Place thin aluminum washer (29) on bolt next to spacer (44), and insert bolt (47) through support (32).
d. Install nut (31) and aluminum washer (30) outboard end of bolt and torque 50 to 70 inch-pounds (5,65 to 7,91
Nm).
e. Position slotted ends of hinge pins (33 and 43) between plate (45) and link (26). Align holes and install pins (28)
secured by cotter pins (27).
f. Position assembly in nose structure, with hinge pins inserted in hinge bushings and support (32) resting on
horizontal structural member at W.L. 30.
g. Align support (32) to holes with plate nuts, and install two bolts (36) with aluminum washers (35). Torque bolts
20 to 25 inch-pounds (2,26 to 2,82 Nm).
h. Position ejection handle (51) with cable tube (49) inserted through grommet (48) at W.L. 35,56.
i. Align tube clamps (50) to mounting holes in angle and attach with two screws, washers, and nuts.
j. Connect fork terminal of cable (42) to forward end of plate (45) with pin (39), washer (40), and cotter pin (41).
5. Connect cable (20) with swivel (19) to hole with bushing in middle of plate (45).
6. Adjust cable length to remove slack with hinge pins extended and latch striker (1) held down in latching position.
Tighten nut on swivel (19) to hold end of cable securely.
7. Perform operational check (module 52-11-01 paragraph "6. Crew doors - operational check").
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G6AB0020A
52-11-02
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52-11-02
Page 4
E-AB412-PT6T-2
52-1 -03 CREW DOOR LATCHES
52-11-03
CREW DOOR LATCHES
1. CREW DOOR LATCHES - REMOVAL
NOTE
Remove latch parts only to the extent required for replacement or other maintenance.
1. Remove cotter pin (23, figure 1). Remove pin (22) and separate rod (15) from latch arm. Remove spring pin (14) and
unscrew latch rod (15) from roller (3).
2. Remove inner access door (39) and plug button from inner face of door.
3. Remove pin (32), and separate rod (31) from bellcrank (28).
4. Remove screws (24). Hold latch shaft (21) and slide latch assembly (19) off shaft.
5. Remove screws securing outer handle (20) to door and remove handle and shaft (21).
6. Remove spring (33) and pin (34). Separate rod (35) from bellcrank (28).
7. Remove bolt (26), washers (27 and 29), and nut (30). Remove bellcrank (28).
8. Remove spring pin (14) and unscrew latch rod (35) from roller (3).
9. Remove screws (1) and striker (2).
10. Remove screws (6 and 7), striker (13), and backing plates (11 and 12). Index backing plates for reinstallation in same
position.
11. Remove cotter pin (3, figure 2). Remove pin (4) and separate cable from latch striker (1).
12. Remove spring (2) by unhooking from latch striker (1).
13. Remove bolt and remove latch striker (1).
2. CREW DOOR LATCHES - INSTALLATION
1. Position latch striker (1, figure 2) on door post and install bolt.
2. Install spring (2).
3. Position cable (20) on latch striker (1), install pin (4). Install cotter pin (3) to secure pin (4).
4. Position backing plates (11 and 12, figure 1) on door frame in position indexed at time of removal. Position striker (13)
on backing plate, install screws (6 and 7), washers (9 and 10) and nut (8).
5. Position striker (2) on door frame and install screws (1).
6. Position latch assembly (19), and inboard handle in door. Install nine screws (24).
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E-AB412-PT6T-2
7. Position shaft (21) and outer handle (20) on door and install two screws to secure handle to door.
8. Position rod (31) in door and thread into rod end in latch assembly (19).
9. Position bellcrank (28) in door and install bolt (26), washers (27 and 29), and nut (30).
10. Position rod (31) clevis on bellcrank (28) and install pin (32). Secure pin (32) with cotter pin.
11. Position rod (15) in door and thread into roller (3). Do not install spring pin (14) at this time.
12. Position rod (15) on latch assembly (19) and install pin (22). Secure pin (22) with cotter pin (23).
13. Position rod (35) in door and thread into roller (3) as described in step (11). Do not install spring pin at this time.
14. Position rod (35) on bellcrank (28) and install pin (34). Install cotter pin to secure pin (34).
15. Install spring (33) on latch rod (35) with pin (34).
16. Close door and check position of strikers (2 and 13) and rollers (3). Adjust rods (15 and 35) in rollers (3) to obtain 0,08
inch (2,03 mm) clearance as illustrated. Also adjust strikers (2 and 13) to hold door firmly in closed position. Ensure
rods (15 and 35) have 0,30 inch (7,62 mm) thread engagement as illustrated. Install spring pin (14) in rods (15 and 35)
to secure rollers (3).
17. Install access door (39) and plug button on door.
18. Perform crew door latch operational check (module 52-11-01 paragraph "6. Crew doors - operational check").
52-11-03
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G6AB0019A
Figure 1. Crew door
52-11-03
Page 3
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G6AB0020A
52-11-03
Page 4
E-AB412-PT6T-2
52-1 -04 CREW DOOR HINGES
52-11-04
CREW DOOR HINGES
1. CREW DOOR HINGES - REMOVAL
MATERIALS REQUIRED.
NUMBER NOMENCLATURE
1. Remove the crew door (module 52-11-01 paragraph "2. Crew doors - removal").
NOTE
This procedure is applicable to the upper and lower hinge half assemblies. Procedure
for the upper hinge half assembly is given; differences for the lower hinge half
assembly are identified.
2. Carefully remove the sealant from around the upper fixed hinge half assembly (1, figure 1) and the upper movable
hinge half assembly (2).
3. Remove screw (5), nuts (7), and washers (6).
4. Remove upper fixed hinge half assembly (1), upper movable hinge half assembly (2), and shim (17) from the crew
door.
5. Carefully remove the remaining sealant with aliphatic naphtha (C-305).
2. CREW DOOR HINGES - INSPECTION
1. Inspect the applicable fixed hinge half assembly (1 or 3, figure 1) for cracks, wear, and holes with signs of deformation.
2. Inspect the applicable movable hinge half assembly (2 or 4) for cracks, wear, and holes with signs of deformation.
3. Inspect the bushings (15 and 16) for excessive wear or play.
4. Inspect the bushings (14) for excessive wear.
5. Inspect the spring assemblies (11 and 13) for excessive wear to the striker blocks.
6. Replace the spring assemblies (11 or 13) if the rivets of the striker blocks are visible.
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E-AB412-PT6T-2
3. CREW DOOR HINGES - INSTALLATION
MATERIALS REQUIRED
NUMBER NOMENCLATURE
C-308 SEALANT
NOTE
This procedure is applicable to the upper and lower hinge half assemblies. Procedure
for the upper hinge half assembly is given; differences for the lower hinge half
assembly are identified.
New hinge half assemblies can be supplied without the three mountings holes.
1. Install upper fixed hinge half assembly (1, figure 1) and upper movable hinge half assembly (2) with shims (17), screws
(5), nuts (7), and washers (6).
2. Temporarily install the crew door (module 52-11-01 paragraph "3. Crew doors - installation") to make sure the fit is
correct.
3. Remove the crew door (module 52-11-01paragraph "2. Crew doors - removal")
52-11-04
Page 2
E-AB412-PT6T-2
G6AB0817A
Figure 1. Crew door hinges (sheet 1 of 2)
52-11-04
Page 3
E-AB412-PT6T-2
G6AB0818A
Figure 1. Crew door hinges (sheet 2 of 2)
52-11-04
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E-AB412-PT6T-2
4. If necessary, adjust the thickness of the shims (17) to get the correct fit.
5. Apply sealant (C-308) around the edge of the upper fixed hinge half assembly (1) and the upper moveable hinge half
assembly (2).
6. Clean the excess sealant (C-308) with aliphatic naphtha (C-305).
7. Install the crew door (module 52-11-01 paragraph "3. Crew doors - installation").
4. CREW DOOR HINGES - REPAIR
MATERIALS REQUIRED
NUMBER NOMENCLATURE
C-317 ADHESIVE
1. Replace the bushings (14 and 15, figure 1) as follows:
a. Hold the legs that contains the bushings (14 or 15) and push them out.
b. Make sure that the holes are free of damage.
c. Measure the holes and make sure that the diameters are from 0,312 to 0,313 inch (7,925 to 7,950 mm).
NOTE
Make sure that the flanges of the bushings are in the hinge assembly slot.
d. Apply epoxy polyamide primer (C-204) to the holes.
e. Hold the legs of the fixed hinge half assemblies (1 and 3) and push the new bushings (15) into position.
NOTE
Install the bushings to be flush with the inner face of the fixed hinge half assemblies.
f. Apply epoxy polyamide primer (C-204) to the holes.
g. Hold the legs of the fixed hinge half assemblies (1 and 3) and push the new bushings (14) into position.
h. Ream bushings (14) to have a diameter from 0,1880 to 0,1885 inch (4,775 to 4,788 mm).
2. Replace bushings (16) as follows:
a. Hold the legs that contains the bushings (16) and push them out.
b. Make sure that the holes are free of damage.
c. Measure the holes and make sure that the diameters are from 0,312 to 0,313 inch (7,925 to 7,950 mm).
NOTE
Make sure that the ends of the bushings are flush or below the surface of the
moveable hinge half assembly.
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E-AB412-PT6T-2
d. Apply epoxy polyamide primer (C-204) to the holes.
e. Ream bushings (16) to have a diameter from 0,1880 to 0,1885 inch (4,775 to 4,788 mm).
f. If removed, install a new bumper (18) with adhesive (C-317).
52-11-04
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E-AB412-PT6T-2
52-31-01
PASSENGER/CARGO AREA ACCESS DOORS
1. PASSENGER/CARGO AREA ACCESS DOORS - DESCRIPTION
The passenger/cargo area access doors consist of the sliding passenger/cargo door and the hinged panel door located on
either side of the helicopter aft of the crew doors.
2. PASSENGER/CARGO AREA ACCESS DOORS - PASSENGER/CARGO DOORS
The passenger/cargo doors operate on rollers and tracks. These doors give access to passenger/cargo area. Each door has
two emergency exit push-out windows (betalight panel LH/RM).
CAUTION
BE AWARE THESE EXIT LIGHTS ARE FILLED WITH A RADIOACTIVE

ISOTOPE OF THE HYDROGEN ATOM, CALLED “TRITIUM”. HANDLE
WITH CARE, WHEN BROKEN OR DAMAGED, THESE BETALIGHTS
SHOULD BE TREATED AS FOLLOWS:
-IMMEDIATELY EVACUATE PERSONNEL FROM AREA. VENTILATE
AREA WELL FOR 20 MINUTES.
- WEAR RUBBER GLOVES DURING CLEAN UP AFTER BREAKAGE. RINSE
AREA UNDER BROKEN TUBES WITH LIBERAL AMOUNTS OF WATER.
-PLACE ALL MATERIAL INCLUDING GLOVES IN SEALED BAG AND
RETURN TO SUPPLIER IN A STURDY CONTAINER.
-ANY OPEN FOOD OR DRINK IN AREA WHERE SIGN IS BROKEN SHOULD
BE DISCARDED.
2-1. PASSENGER/CARGO DOORS - REMOVAL
NOTE
The removal procedure for left passenger/cargo door is given, the removal procedure
for right passenger/cargo door is the same.
1. Unlatch cargo door (38, figure 1).
2. Retract open position stop spring (22).
3. Remove screw (19) and stop (18) from aft end of lower door track.
4. Slide cargo door (38) aft out of tracks.
NOTE
Step 5. below is applicable only if new door is to be installed.
52-31-01
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E-AB412-PT6T-2
5. Remove all attaching hardware from door. Mark position of serrated plates (4, 11, and 13) before removal of forward
roller support (2), upper roller support (10), and aft upper roller support (15). This will provide a starting point during
adjustment procedure.
2-2. PASSENGER/CARGO DOORS - INSTALLATION
NOTE
The installation for left passenger/cargo door is given. The installation procedure for
right passenger cargo door is the same.
1. If new door is being installed, install all attaching hardware.
NOTE
To aid in adjustment procedures, note marked position of serrated plates (4, 11 and
13) on installation of forward roller support (2), upper roller support (10), and aft
roller support (15).
2. Position passenger/cargo door (38, figure 1) on helicopter with forward edge in line with aft end of door tracks.
3. Start rollers and slider through cut outs at aft ends of tracks.
4. Push passenger/cargo door (38) forward.
5. Position stop (18) at end of lower track on structure and install with screw (19).
6. Perform operational check (paragraph "2-5. Passenger/cargo doors - operational check and adjustment").
2-3. PASSENGER/CARGO DOORS - INSPECTION
1. Perform operational check for both passenger/cargo doors (paragraph "2-5. Passenger/cargo doors - operational check
and adjustment").
2. Inspect door latch for binding, wear, damage, and secure mounting.
3. Inspect door structure and hinges for cracks and/or distortion.
4. Inspect door windows (module 56-21-02 paragraph "4. Passenger door windows - inspection").
5. Inspect door seals for secure bonding and deterioration.
6. Inspect door lock caution switch (Chapter 96).
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E-AB412-PT6T-2
Figure 1. Passenger/cargo door
52-31-01
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2-4. PASSENGER/CARGO DOORS - REPAIR
1. Replace unserviceable parts in passenger/cargo door latch mechanism (module 52-31-02 "PASSENGER/CARGO
AREA ACCESS DOORS - PASSENGER/CARGO DOOR LATCHES").
2. Repair passenger/cargo door structural damage.
3. Repair damaged passenger door windows (module 56-21-02 "WINDOWS AND WINDSHIELDS - PASSENGER
DOOR WINDOWS").
4. Repair damaged passenger/cargo door seals (module 52-00-00 paragraph "3. Doors - seal installation - access doors,
panels, cowling, fairings, and covers").
2-5. PASSENGER/CARGO DOORS - OPERATIONAL CHECK AND ADJUSTMENT
MATERIALS REQUIRED
NUMBER NOMENCLATURE
C-405 LOCKWIRE
1. Ensure hinged panel (40, figure 1) is closed and latched. Place door to fully closed and latched position. Verify upper
edge of door is parallel to top of cabin door frames and upper track (16).
2. If door is out of alignment, loosen screws attaching roller support (15) and slider support (33) on rear edge of door.
Adjust slider support. Tighten slider support screws.
3. Adjust roller support (15) so that roller is fully engaged in track. Tighten attaching screws.
4. Operate door through full travel while verifying all rollers on upper edge are fully engaged in upper track (16) at all
positions. Adjust roller supports (10) as required.
5. With door fully closed and latched, ensure lower door track (37) is engaged not less than 0,25 inch (6,35 mm) in cabin
door channel without restricting door travel through full range from fully closed to fully open. Verify door track
attaching screws are tightened after adjustment.
6. Operate door through full travel while checking for dragging or binding.
7. Roller supports (2, 15 and 33) are installed with peel shims (3, 12 and 32). To adjust, peel new shims to required
thickness. Pay particular attention to slider (44) when checking for binding. Minimum friction on slider will improve
operation of door.
8. Cut lockwire on adjustment screws (8, figure 2) and adjust so upper and lower cams (9) will bottom simultaneously.
After adjustment has been obtained, secure screws (8) with lockwire (C-405).
9. Move door to full open position and check for fit of hold-open spring (22, figure 2) on striker bushing near upper edge
of door.
10. Adjust lock caution light switch (Chapter 96).
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E-AB412-PT6T-2
G6AB0023A
Figure 2. Passenger/cargo door latch
52-31-01
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E-AB412-PT6T-2
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E-AB412-PT6T-2
52-31-02
PASSENGER/CARGO AREA ACCESS DOORS - PASSENGER/CARGO
DOOR LATCHES
1. PASSENGER/CARGO DOOR LATCHES - REMOVAL
NOTE
The following instructions are for removing the upper door latch. Procedure for
removing lower door latch is the same.
1. Unhook tension springs (6, figure 1) from latches (1) and hangers (2) on door structure.
2. Remove cotter pin, washer and guide pin from actuating arm (4) and door latch.
3. Remove cotter pin, washer and guide pin from door latch and door latch support (7).
4. Remove door latch.
2. PASSENGER/CARGO DOOR LATCHES - INSTALLATION
NOTE
The following instructions are for installing upper door latch. Procedure for
installing the lower door latch is the same.
1. Insert door latch (1, figure 1) in door latch support (7).
2. Align door latch (1) to door latch support (7) and insert guide pin. Secure guide pin with washer and cotter pin.
3. Align actuating arm (4) to door latch (1) and insert guide pin. Secure guide pin with washer and cotter pin.
4. Connect tension springs (6) to door latch (1) and hangers (2) on door structure.
52-31-02
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E-AB412-PT6T-2
G6AB0023A
Figure 1. Passenger/cargo door latch
52-31-02
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52-31-03
PASSENGER/CARGO AREA ACCESS DOORS - CARGO HINGED PANELS
1. CARGO HINGED PANELS - DESCRIPTION
The cargo hinged panels (figure 1), located forward of passenger/cargo doors, provide a wider opening for cargo loading.
2. CARGO HINGED PANELS - REMOVAL
NOTE
The removal procedure of the left cargo hinged panel is given. The removal
procedure for the right cargo hinged panel is the same.
1. Open passenger/cargo door.
2. Operate latch handle (18, figure 1) of panel door to release pins (8) and (20) from upper and lower channels of door
opening.
3. Open cargo hinged panel (31).
4. Remove positioning spring (2) from stud at top of opening.
5. Remove two quick-release pins (1) from hinges (5).
6. Remove cargo hinged panel (31).
3. CARGO HINGED PANELS - INSTALLATION
NOTE
The installation procedure for left cargo hinged panel is given. The installation for
right cargo hinged panel is the same.
1. Align cargo hinged panel (31, figure 1) on hinge and install two pins (1).
2. Swing panel partly closed and engage positioning spring (2) on stud at top of door opening.
3. Close door and operate handle (18) to extend latch pins (8) and (20) into holes in upper and lower structural channels
of frame. Ensure pins properly engage channels.
4. Adjust hinge panel as follows:
a. Verify pin on lower inside of panel is engaged in door post.
b. Remove screws (7) to remove cover (6) and screws (29) to remove cover (28).
c. Operate handle (18) to open hinged panel.
d. Verify upper and lower pins (8) and (20) retract to clear top and bottom of door opening.
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E-AB412-PT6T-2
e. If necessary to adjust either pin (8) or (20), loosen nut (9) and adjust pin to obtain secure engagement and proper
release.
f. Tighten nut (9) against pin (8).
g. Install covers (6) and (28).
h. Check action of positioning spring (2) on pivot (4) as panel is opened. Detent in spring slot should catch and
hold panel at approximately 90 to fuselage. Hook of spring should catch when panel is forced beyond detent.
i. Close and latch hinged panel.
j. Slowly close passenger/cargo door.
k. Check proper engagement of latches on passenger/cargo door with striker (25).
l. When adjustment is necessary, remove cover (28) over striker (25). Adjust striker positioning by means of
slotted mounting holes, or adjust thickness of laminated shim (23). Tighten screws (21), washers (26), and nuts
(27).
m. Install cover (28) on striker (25).
4. CARGO HINGED PANELS - INSPECTION
NOTE
The inspection procedure of left cargo hinged panel is given. The inspection
procedure for right cargo hinged panel is the same.
1. Inspect visible portions of both hinge panel latching mechanism for binding, wear, damage, and secure mounting
(figure 1).
2. Inspect panel structure and hinge for cracks and/or distortion.
3. Inspect panel windows for damage.
4. Inspect panel seals for secure bonding and deterioration.
5. CARGO HINGED PANELS - REPAIR
NOTE
The repair procedure for left cargo hinged panel is given. The repair procedure for
right cargo hinged panel is the same.
1. Replace unserviceable parts in hinged panel latch mechanism (module 52-31-04 "PASSENGER/CARGO AREA
ACCESS DOORS - CARGO HINGED PANEL LATCHING MECHANISM").
2. Repair cargo hinged panel structural damage.
3. Repair cargo hinged panel windows (module 56-21-01 "WINDOWS AND WINDSHIELDS - CARGO HINGED
PANEL DOOR WINDOWS").
4. Repair damaged cargo hinged panel door seals (module 52-00-00 paragraph "3. Doors - seal installation - access doors,
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E-AB412-PT6T-2
G6AB0024A
Figure 1. Cargo hinged panel
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52-31-04 PASSENGER/CARGO AREA ACCESS DOORS - CARGO HINGED PANEL LATCHING MECHANISM
52-31-04
PASSENGER/CARGO AREA ACCESS DOORS - CARGO HINGED PANEL
LATCHING MECHANISM
1. CARGO HINGED PANEL LATCHING MECHANISM - REMOVAL
NOTE
The maintenance procedures for the left cargo hinged panel latching mechanism are
given. The procedures for the right cargo hinged panel latching mechanism are the
same.
1. Remove screws (7, figure 1) and remove cover (6).
2. Remove screws (29) and remove cover (28).
3. Remove screws, washers (12) and nuts (11) to detach escutcheon (13).
4. Remove escutcheon (13) and handle (18) as an assembly.
5. Remove cotter pins (15 and 16) and pins (17) to detach tubes (10 and 19) from spindle assembly (14).
6. Pull tube (10) until pin (8) is free of guide in top of panel.
7. Pull tube (19) until pin (20) is free of guide in bottom of panel.
8. Remove striker mechanism from top or bottom of panel as follows:
a. Remove screw (21), washer (26), and nut (27).
b. Remove striker guide (22), shim (23), plate (24), and striker (25).
2. CARGO HINGED PANEL LATCHING MECHANISM - INSTALLATION
1. Position striker guide (22, figure 1) on outside surface of panel and position shim (23), plate (24), and striker (25) on
inside surface of panel.
2. Install screws (21) with washers (26) and nuts (27).
3. Insert tube (10) through access opening at top of panel.
4. Install nut (9) and pin (8) on tube (10).
5. Insert pin (8) through guide at top of panel.
6. Connect tube (10) to spindle assembly (14) with pin (17) and cotter pin (15).
7. Insert tube (19) through access opening at bottom of panel.
8. Install pin (20) on tube (19).
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E-AB412-PT6T-2
9. Insert pin (20) through guide at bottom of panel.
10. Connect tube (19) to spindle assembly (14) with pin (17) and cotter pin (16).
11. Install escutcheon (13) and handle (18) as an assembly. Secure with screws, washers (12) and nuts (11).
12. Install cover (6) with screws (7).
13. Install cover (28) with screws (29).
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E-AB412-PT6T-2
G6AB0024A
Figure 1. Cargo hinged panel
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52-31-04
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52-31-05
PASSENGER/CARGO AREA ACCESS DOORS - BAGGAGE
COMPARTMENT DOOR
BAGGAGE COMPARTMENT DOOR - DESCRIPTION
The baggage compartment door is located on forward right side of tailboom. The door is hinged on forward end and has a
latch and lock on aft end. The inside of the door is honeycomb panel construction sandwiched between inner and outer panels
of aluminum alloy. The baggage door latch includes a roller to actuate a switch when door is closed. The switch illuminates
a caution panel worded segment DOOR LOCK when the door is open and activates an overhead light in the baggage
compartment.
1. BAGGAGE COMPARTMENT DOOR - REMOVAL
1. Open baggage compartment door (1, figure 1).
2. Remove screws (2) and washers (3) to disconnect chain (4) from baggage compartment.
3. Remove nuts (5) and bolts (6) from hinges (7 and 8). Remove baggage compartment door.
2. BAGGAGE COMPARTMENT DOOR - INSTALLATION
1. Position baggage door (1) over hinges on tailboom.
2. Install bolts (6) and nuts (5).
3. Connect chain (4) to door using screws (2) and washers (3).
4. Check operation of door lock caution switch (Chapter 96).
3. BAGGAGE COMPARTMENT DOOR - INSPECTION
1. Inspect chain (4) for security of installation.
2. Inspect hinge (7 and 8) for cracks and distortion.
3. Inspect latch (9) for proper operation and security of installation.
4. Inspect lock (not shown) for proper operation.
5. Inspect switch for operation of baggage compartment light and caution panel segment DOOR LOCK when baggage
compartment door is opened (Chapter 96).
6. Inspect door for cracks and distortion.
7. Inspect door seals (10) for secure bonding and for deterioration.
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E-AB412-PT6T-2
4. BAGGAGE COMPARTMENT DOOR - REPAIR
1. Replace unserviceable parts in baggage compartment door latch mechanism.
2. Repair baggage compartment door structural damage.
3. Replace damaged baggage compartment door seals (module 52-00-00 paragraph "3. Doors - seal installation - access
doors, panels, cowling, fairings, and covers").
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E-AB412-PT6T-2
G6AB0027A
Figure 1. Baggage compartment door
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52-41-01
ACCESS COVERS AND DOORS - NOSE ACCESS DOORS
1. NOSE ACCESS DOORS - DESCRIPTION
Two doors give access to the nose compartment. Lower nose door (1, figure 1) is of aluminum alloy construction and swings
down on hinges after release of attaching studs. Upper nose door (2) is of fiberglass faced honeycomb construction and
swings up after release of either six latches or six fasteners.
2. NOSE ACCESS DOORS - REMOVAL
NOTE
To remove lower nose door (1, figure 1), upper nose door (2) must be open.
1. Release latches (helicopters codes [A] [B] ) or attaching studs from upper nose door (2).
2. Open upper nose door (2).
3. To remove upper nose door (2), disconnect hinge assemblies from brackets on door by removing screws, washers, and
nuts.
4. To remove lower nose door (1):
a. Release attaching studs from lower nose door (1) by turning them counterclockwise.
b. Open lower nose door (1).
c. Disconnect hinge assemblies from fitting on structure supporting lower nose door (1) by removing screws, nuts,
and washers.
d. Remove lower nose door (1).
3. NOSE ACCESS DOORS - INSTALLATION
NOTE
To install or close lower nose door (1, figure 1), upper nose door (2) must be open.
1. To install lower nose door (1):
a. Support lower nose door (1) and connect assemblies to fittings on structure with screws, nuts, and washers.
b. Close lower nose door (1).
c. Secure lower nose door (1) with attaching studs by turning them clockwise.
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E-AB412-PT6T-2
4. NOSE ACCESS DOORS - INSPECTION
1. Inspect hinges for cracks and distortion.
2. Inspect latches for operation and security of installation.
3. Inspect doors for structural damage.
4. Inspect door seals for secure bonding and for deterioration.
5. NOSE ACCESS DOORS - REPAIR
1. Replace unserviceable parts in nose access doors.
2. Repair nose access door structural damage.
3. Replace damaged nose access door seals (module 52-00-00 paragraph "3. Doors - seal installation - access doors,
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E-AB412-PT6T-2
1. Lower nose door

2. Upper nose door
G6AB0842A
Figure 1. Nose access doors
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52-41-01
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52-41-02 ACCESS COVERS AND DOORS - MISCELLANEOUS ACCESS DOORS AND PANELS
52-41-02
ACCESS COVERS AND DOORS - MISCELLANEOUS ACCESS DOORS AND
PANELS
1. MISCELLANEOUS ACCESS DOORS AND PANELS - DESCRIPTION
Doors and panels are provided at various locations on the fuselage for access to interior areas. Three types of construction
are used: Honeycomb with sheet metal and fiberglass faces, honeycomb with both faces of fiberglass, and contoured flat
sheet metal. Screws or twist type fasteners retain doors in place.
2. MISCELLANEOUS ACCESS DOORS AND PANELS - REMOVAL
Remove screws or disengage fasteners as applicable and remove door, panel or fairing.
3. MISCELLANEOUS ACCESS DOORS AND PANELS - INSTALLATION
Position door, panel, or fairing on helicopter and fasten twist-type fastener or install screws as applicable.
4. MISCELLANEOUS ACCESS DOORS AND PANELS - INSPECTION
1. Inspect doors, panels, and fairings for damaged and/or missing twist-type fasteners if applicable.
2. Inspect doors, panels, and fairings for mechanical and corrosion damage.
5. MISCELLANEOUS ACCESS DOORS AND PANELS - REPAIR
1. Replace unserviceable and/or missing twist-type fasteners.
2. Repair structural and corrosion damage.
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52-41-03
ACCESS COVERS AND DOORS - TAIL ROTOR DRIVESHAFT ACCESS
COVERS
1. TAIL ROTOR DRIVESHAFT ACCESS COVERS - DESCRIPTION
The tail rotor driveshaft access cover installation consists of three formed aluminum alloy parts. Each cover is hinged on
right side and is secured on left side by twist-type studs through support angles between B.S. 18 and 200.
2. TAIL ROTOR DRIVESHAFT ACCESS COVERS - REMOVAL
1. Loosen stud (1, figure 1) in two places and hinge open cover (4).
2. Loosen studs (10) and open hinge access covers (6 and 9).
3. Remove cotter pin (3) and hinge pin (2). Remove access covers (4 and 6).
4. Remove cotter pin (7), hinge pin (8), and aft access cover (9).
3. TAIL ROTOR DRIVESHAFT ACCESS COVERS - INSTALLATION
1. Install aft cover (9, figure 1) with hinge pin (8) and secure with cotter pin (7).
2. Align forward access cover (6) with hinge half (5). Align access cover (4) with hinge half (5).
3. Install hinge pin (2) forward to aft through access cover (4) then through forward access cover (6) and secure with
cotter pin (3).
4. Close access cover (4) and fasten two studs (1). Close access covers (6 and 9) and latch studs (10).
4. TAIL ROTOR DRIVESHAFT ACCESS COVERS - INSPECTION
1. Inspect access covers (4, 6 and 9, figure 1) for missing, damaged, or loose studs with ejecting blades (10).
2. Inspect support angles on left side for missing, damaged, or loose grommets.
3. Inspect support angles and hinge on right side for corrosion and mechanical damage.
4. Inspect access covers (4, 6 and 9) for corrosion and mechanical damage.
5. TAIL ROTOR DRIVESHAFT ACCESS COVERS - REPAIR
Repair structural and corrosion damage.
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G6AB0028A
Figure 1. Tail rotor driveshaft access covers
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CHAPTER 53 - FUSELAGE

Module Page
Number Title Number
53-00-00 FUSELAGE
1. Fuselage - general ................................................................................................................................... 1
53-10-01 FORWARD FUSELAGE
1. Forward fuselage - description ............................................................................................................... 1

2. Fuselage - generic sheet metal part replacement procedure ................................................................... 1
53-10-02 TENSION ROD ASSEMBLY
1. Tension rod assembly - removal ............................................................................................................. 1

2. Tension rod assembly - installation ........................................................................................................ 1
3. Tension rod assembly - inspection .......................................................................................................... 1
53-20-01 TAILBOOM
1. Tailboom - description and maintenance ................................................................................................ 1

2. Tailboom - removal ................................................................................................................................ 1
3. Tailboom - installation ............................................................................................................................ 1
4. Tailboom - inspection ............................................................................................................................. 2
5. Tailboom - repair .................................................................................................................................... 7
6. Upper tail fairing...................................................................................................................................... 8
7. Upper tail fairing - removal .................................................................................................................... 8
8. Upper tail fairing - cleaning .................................................................................................................... 8
9. Upper tail fairing - inspection ................................................................................................................. 9
10. Upper tail fairing - repair ........................................................................................................................ 9
11. Upper tail fairing - installation ................................................................................................................ 9
12. Lower tail fairing ................................................................................................................................... 11
13. Lower tail fairing - removal .................................................................................................................. 11
14. Lower tail fairing - cleaning ................................................................................................................. 11
15. Lower tail fairing - inspection .............................................................................................................. 12
16. Lower tail fairing - repair ...................................................................................................................... 12
17. Lower tail fairing - installation ............................................................................................................. 12
18. Strakes ................................................................................................................................................... 13
19. Strakes - inspection ............................................................................................................................... 13
20. Strakes - repair ...................................................................................................................................... 13
21. Strakes - replacement ............................................................................................................................ 14
53-31-01 FIXED STEP (P/N 212-706-057-1 AND -2)
1. Fixed step (P/N 212-706-057-1 and -2) - description ............................................................................. 1

2. Fixed step (P/N 212-706-057-1 and -2) - removal ................................................................................. 1
3. Fixed step (P/N 212-706-057-1 and -2) - installation ............................................................................. 1
4. Fixed step (P/N 212-706-057-1 and -2) - inspection ............................................................................... 2
53-Index
Rev. 2 Page 1
E-AB412-PT6T-2
FIGURES
Figure Page
Number Title Number
53-00-00 FUSELAGE
Figure 1. Fuselage assembly...........................................................................................................................................1
Figure 1. Forward fuselage.............................................................................................................................................3
Figure 1. Tension rod assembly - removal and installation............................................................................................2

Figure 2. Tension rod assembly - damage limits............................................................................................................3
53-20-01 TAILBOOM
Figure 1. Tailboom .........................................................................................................................................................4

Figure 2. Disconnect points for tailboom .......................................................................................................................5
Figure 3. Tailboom attaching bolts.................................................................................................................................6
Figure 4. Upper tail fairing - removal and installation ................................................................................................10
Figure 5. Lower tail fairing - removal and installation.................................................................................................15
53-31-01 FIXED STEP (P/N 212-706-057-1 AND -2)
Figure 1. Fixed step installation .....................................................................................................................................3

Figure 2. Strut dimension diagram .................................................................................................................................4
53-Index
Page 2 Rev. 2
E-AB412-PT6T-2
53-0 -0 FUSELAGE
53-00-00
FUSELAGE
1. FUSELAGE - GENERAL
The fuselage (figure 1) can be divided into 2 sections: the forward section or cabin and the aft section or tail boom.
The cabin which is divided into cockpit and cargo/passenger compartment by a panel, provides pilot and passenger
accommodation and consists of 2 longitudinal beams, transverse bulkheads, stringers and panels in aluminium alloy. The
cabin supports the engines and main transmission on the top and has attachments for the skid landing gear on the bottom.
The tail boom, connected to the cabin by 4 bolts, is a semicoque structure of skins and light alloy stringers. The tail boom
supports the tail rotor, the tail rotor drive shaft and synchronized elevator.
G6AB0819A
Figure 1. Fuselage assembly
53-00-00
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53-00-00
Page 2
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53-10-01
FORWARD FUSELAGE
1. FORWARD FUSELAGE - DESCRIPTION
The forward fuselage (figure 1) is built up on two main longitudinal beams and is of combined semi-monocoque and
reinforced-shell construction with transverse bulkheads and metal covering. The longitudinal beams act as primary
supporting structure for the cabin section, landing gear, fuel cells, power plant, transmission, tailboom, and useful load.
Work and engine decks, some main beam panels, as well as cabin floor, cabin roof panels, are of aluminum alloy honeycomb
construction. Avionics and electrical equipment is contained, primarily, in the nose compartment. Lower and upper hinged
nose compartment doors (8 and 9) provide access to the nose compartment. A windshield wiper (6) is located on each of the
two windshields (10). Crew seats (11) are located in the forward cabin area. Crew doors (5), passenger-cargo doors (2), and
hinged panel doors on both sides of the helicopter permit entrance and exit. Acrylic windows in the lower nose compartment,
roof (12), and doors permit a wide range of visibility. Transmission fairing (13) and engine cowling may be opened or
removed for access. The cargo-passenger area is equipped with tiedown rings and studs.
2. FUSELAGE - GENERIC SHEET METAL PART REPLACEMENT PROCEDURE
MATERIALS REQUIRED
NUMBER NOMENCLATURE
C-251 SEALANT
C-308 SEALANT
C-328 SEALANT
NOTE
As no procedure can cover all sheet metal part replacements, the following
guidelines can be used for most applications, but must be adapted as required. Refer
to E-AB412-PT6T-3 Manual for specific application.
1. Once the part to be replaced has been determined, provide bracing and support as required. Refer to E-AB412-PT6T-3
Manual.
2. Identify the type, size and location of fasteners by looking at the manufactured head of the fasteners and referring to
information contained in E-AB412-PT6T-3 Manual.
3. Remove part while making a note which portion of the part was installed with sealant (if applicable).
4. Inspect supporting structure for cracks and damaged fastener holes. Repair or replace as required.
5. Trim and drill new part to fit in place. Maintain edge distance of 2D for all regular holes and 2,5D for all countersunk
holes. Deburr.
6. Apply sealant on faying surfaces, as determined previously (if applicable). Unless otherwise stated, use sealant C-251
or C-308 for general applications or C-328 for screwed-on access panels (low adhesion).
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7. Install fasteners as identified previously. Apply a small bead of sealant (C-251 or C-308) around the part (if required).
8. Refinish as required.
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E-AB412-PT6T-2
1. Engine cowling
2. Passenger-cargo door
3. Passenger step
4. Landing gear
5. Crew door
6. Windshield wiper
7. Nose compartment window
8. Upper hinged nose door
9. Lower hinged nose door
10. Windshield
11. Crew seat
12. Roof window
13. Transmission cowling
G6AB0012B
Figure 1. Forward fuselage
53-10-01
Rev. 2 Page 3
E-AB412-PT6T-2
53-10-01
Page 4 Rev. 2
E-AB412-PT6T-2
53-10-02
TENSION ROD ASSEMBLY
1. TENSION ROD ASSEMBLY - REMOVAL
1. Remove the nut (1, figure 1), bolt (3) and washer (2) from the aft end of the tension rod assembly (4).
2. Remove the nut (1), bolt (3), washer (2) and tension rod assembly (4) from the bulkhead attachment point.
2. TENSION ROD ASSEMBLY - INSTALLATION
1. Install the tension rod assembly (4, figure 1) on the bulkhead attachment point with the bolt (3), washers (2) and nut (1).
2. Install the aft end of the tension rod assembly (4) with the bolt (3), washers (2) and nut (1). Tighten the nuts.
3. TENSION ROD ASSEMBLY - INSPECTION
1. Examine the tension rod assembly (4, figure 1) for cracks, wear, mechanical damage and corrosion damage (figure 2).
Repair or replace as applicable.
53-10-02
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E-AB412-PT6T-2
G6AB0820A
Figure 1. Tension rod assembly - removal and installation
53-10-02
Page 2
E-AB412-PT6T-2
G6AB0821A
Figure 2. Tension rod assembly - damage limits
53-10-02
Page 3
E-AB412-PT6T-2
53-10-02
Page 4
E-AB412-PT6T-2
53-20-01 TAILBOOM
53-20-01
TAILBOOM
1. TAILBOOM - DESCRIPTION AND MAINTENANCE
The tailboom (figure 1) is of semi-monocoque construction. External components consist of formed aluminum alloy skins
and driveshaft covers (4), a fiberglass fairing, and one aluminium alloy honeycomb cover. Internal components of the
tailboom and aerodynamically actuated elevator are of aluminum alloy. The tailboom support the tail rotor driveshafts,
gearboxes, and driveshaft hangers. The baggage compartment is located in the forward end with the door (5) on the right side.
On helicopters equipped with the BLR FastFinTM system kit 412-705-040-101 (or subsequent), an upper and lower tail
fairing (10 and 9) provide the vertical fin with a new shape to increase thrust from the tail rotor. As part of this kit, the
tailboom includes two aerodynamic strakes (11) to control the down-wash from the main rotor around the tailboom.
2. TAILBOOM - REMOVAL
1. Open combining gearbox side panels.
2. Remove clamps from no. 2 driveshaft (Chapter 65). Remove driveshaft section.
3. Open access door on right aft side of forward fuselage. Disconnect electrical harnesses and antenna cables.
4. Disconnect tail rotor control tube (figure 2).
5. Remove plug bottoms from four tailboom attaching points.
6. Support tailboom. Remove bolts attaching tailboom to fuselage.
7. Remove tailboom. Place in a suitable cradle.
3. TAILBOOM - INSTALLATION
MATERIALS REQUIRED
NUMBER NOMENCLATURE
NOTE
If a replacement tailboom is installed or misalignment is suspected, carry out tail
rotor driveshaft alignment procedure (Chapter 65).
1. Position tailboom adjacent to forward fuselage. Line up bolt holes (figure 3)
2. Apply a coating of corrosion preventive compound (C-104) to all bolt shanks prior to installation. Do not apply
corrosion preventive compound to bolt threads.
53-20-01
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E-AB412-PT6T-2
3. Place countersunk washer on each bolt with countersunk side of washer toward bolt head. Install bolts, using plain
washers as required, between countersunk washer and fitting so not less than one thread or more than two threads are
showing. Torque bolts as follows:
a. Upper left - 1300 to 1600 in-lbs (147 to 181 Nm).
b. Upper right - 1000 to 1200 in-lbs (113 to 136 Nm).
c. Both bottom bolts - 400 to 430 in-lbs (45.2 to 48.6 Nm).
4. Install plug buttons in four tailboom attaching points.
5. Connect tail rotor control tube (figure 2).
6. Connect electrical harnesses and antenna cables.
7. Install no. 2 tail rotor driveshaft section (Chapter 65).
8. Install matched clamp sets on couplings, with bolt heads in direction of rotation and clamp joints indexed 90° to those
of adjacent clamps. Tighten clamp bolts evenly, torque 30 to 35 in-lbs (3.39 to 3.95 Nm) above nut friction.
9. Close combining gearbox side panels.
4. TAILBOOM - INSPECTION
MATERIALS REQUIRED
NUMBER NOMENCLATURE
C-308 SEALANT
1. Inspect doors, covers, and access panels for misalignment, damage, and security of mounting.
2. Inspect tailboom skid for dents corrosion, scratches, or other damage.
3. Inspect structure for cracks, distortion, corrosion, or loose rivets.
4. Inspect forward side of vertical fin spar caps and web from upper tailboom skin to approximately 4.0 in (101.6 mm)
below upper tailboom skin as follows:
a. Remove aft tailboom flight control inspection door (Chapter 52).
NOTE
If necessary, clean area to be inspected with cloth dampened with MEK (C-309).
b. From inside of tailboom, face aft, use bright light and small mirror, inspect area for cracks. Pay particular
attention to areas near rivet holes, especially cold worked holes.
5. Inspect tailboom upper longerons as follows:
a. Remove plug button at BS 99,0.
53-20-01
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E-AB412-PT6T-2
NOTE
Paint fissures are common in the splice area, cracks will be evident by black powder
emanating from cracked area, and corrosion will leave evidence of white powder.
b. Using a borescope or suitable means, inspect inside of longeron, paying particular attention to cracked and/or
corrosion in area of splice.
c. Report any cracks to Product Support Engineering.
d. Install plug button with sealant (C-308).
6. Inspect tailboom bonded panels for dents, scratches, delamination and corrosion.
7. Inspect diameter of tailboom to fuselage attaching holes. The allowable limits are as follows:
LOCATION MAXIMUM DIAMETER
Upper right 0.516 in (13.1 mm)
Upper left 0.578 in (14.7 mm)
Lower left 0.391 in (9.9 mm)
Lower right 0.391 in (9.9 mm)
8. Inspect corresponding four tailboom-to-fuselage attaching bolt holes in fuselage fitting for elongation.
53-20-01
Rev. 2 Page 3
E-AB412-PT6T-2
1. Vertical fin door

2. Intermediate gearbox cover
3. Aerodynamically actuated elevator
4. Tail rotor driveshaft cover
5. Baggage compartment door
6. Tailboom
7. Lower fin fairing
8. Tail skid
9. Lower tail fairing
10. Upper tail fairing
11. Strakes
NOTE:
1 For helicopters equipped with the BLR FastFin™ system kit 412-705-040-101 or subsequent.
G6AB0046B
Figure 1. Tailboom
53-20-01
Page 4 Rev. 2
E-AB412-PT6T-2
G6AB0047A
Figure 2. Disconnect points for tailboom
53-20-01
Rev. 2 Page 5
E-AB412-PT6T-2
G6AB0048A
Figure 3. Tailboom attaching bolts
53-20-01
Page 6 Rev. 2
E-AB412-PT6T-2
5. TAILBOOM - REPAIR
MATERIALS REQUIRED
NUMBER NOMENCLATURE
C-222 PRIMER
C-233 ENAMEL
C-509 TAPE
1. Replace damaged or unserviceable doors, covers, and access panels.
2. Touch-up paint on mating surfaces of tail rotor driveshaft covers as follows:
a. Clean area with MEK (C-309). Allow to air-dry.
b. Apply one coat of primer (C-222). Allow to dry one hour. Apply one coat of enamel (C-233).
3. Replace damaged or unserviceable fasteners and hinges on tail rotor driveshaft covers. In order to eliminate chafing
between the tail rotor drive shaft covers and the tail boom upper skin, install anti-chafing tape, (C-509), on vertical lug
of angle on rotor drive shaft tunnel.
In order to restore the tail boom upper skin structure, is it referred to E-AB412-PT6T-3, Section 8, Paragraph 8-1-2-1-4.
4. Replace tailboom if attaching holes in tailboom fittings exceed maximum allowable diameter.
NOTE
If a new tailboom is installed, confirmation of tail rotor driveshaft alignment is
recommended (Chapter 65).
5. When replacing tailboom, remove the following and install on replacement tailboom:
a. Tail rotor controls (Chapter 65).
b. Electrical and avionics (Chapters 96 and 97).
c. Aerodynamically actuated elevator (Chapter 67).
d. Tail rotor driveshaft and hanger and bearings (Chapter 65).
e. Intermediate gearbox (Chapter 65).
f. Tail rotor gearbox (Chapter 65).
g. Tail rotor driveshaft covers and vertical fin cover.
h. Access doors and inspection panels.
53-20-01
Rev. 2 Page 7
E-AB412-PT6T-2
6. UPPER TAIL FAIRING
NOTE
Instructions for the upper tail fairing (10, figure 1) apply to helicopters equipped
with the BLR FastFin™ system kit 412-705-040-101 (or subsequent). For
helicopters equipped with the Dual Tailboom Strakes and FastFin™ system
Supplemental Type Certificate (STC), refer to the applicable BLR Aerospace
documents.
The upper tail fairing (10) is made of graphite and installed on the vertical fin with screws. The fairing replaces the aluminum
trailing edge of the vertical fin on helicopters equipped with the BLR FastFin™ system kit 412-705-040-101 (or
subsequent).
7. UPPER TAIL FAIRING - REMOVAL
1. Remove sealant from the edges of the upper tail fairing (1, figure 4) with a plastic scraper.
2. Remove the screws (4 and 6) and the washers (5 and 7) from the overlap of the upper tail fairing (1) and the lower tail
fairing.
3. Remove the screws (3) and the washers (2) from the upper tail fairing (1).
4. Remove the upper tail fairing (1) from the vertical fin.
8. UPPER TAIL FAIRING - CLEANING
MATERIALS REQUIRED
NUMBER NOMENCLATURE
C-330 CLEANER
C-355 DETERGENT
CAUTION
DO NOT USE COMPOUNDS CONTAINING ABRASIVES OR CHLORINATED

HYDROCARBONS. AVOID EXCESSIVE SCRUBBING OR POLISHING OF
PLASTIC PANELS. HEAT BUILDUP MAY DAMAGE PLASTIC PANELS.
REMOVE RINGS, WATCHES, AND HARD OBJECTS FROM HANDS AND

WRISTS BEFORE WASHING TRANSPARENT PANELS.
1. Clean the upper tail fairing (1, figure 4) with large quantities of clean water and a solution of detergent (C-355).
2. Gently free all insects or dirt with soft pads or fingers. Do not use sponges or coarse cloths. Rinse the area continuously
while removing insects or dirt.
3. Flush entire area throughly with clean water.
4. Allow surfaces to air dry.
53-20-01
Page 8 Rev. 2
E-AB412-PT6T-2
5. Minor scratches may be reduced or removed by using cleaner (C-330).
6. Apply cleaner (C-330) with a clean soft cloth or tissue in a circular motion until clean. Polish with another clean, soft,
cotton cloth.
9. UPPER TAIL FAIRING - INSPECTION
NUMBER NOMENCLATURE
COMMERCIAL TAP HAMMER
1. Examine the upper tail faring (1, figure 4) for cracks, damage, delamination, and voids. As required, repair damage
(paragraph "10. Upper tail fairing - repair") or replace the part.
2. Visually examine the attaching hardware for condition. Replace as required.
10. UPPER TAIL FAIRING - REPAIR
MATERIALS REQUIRED
NUMBER NOMENCLATURE
C-323 FAIRING COMPOUND
1. For information on damage repair on the upper tail faring (1, figure 4) other than those specified in step 2., contact
Product Support Engineering.
2. Fill and fair scratches, nicks, or any equivalent superficial damage on the upper tail faring (1) with fairing compound
(C-323). Do a finishing of the area after repair.
11. UPPER TAIL FAIRING - INSTALLATION
MATERIALS REQUIRED
NUMBER NOMENCLATURE
C-308 SEALANT
1. Put the upper tail fairing (1, figure 4) in position on the vertical fin.
2. Wet install the screws (3) and the washers (2) on the upper tail fairing (1) with sealant (C-308). Tighten the screws.
3. Wet install the screws (4 and 6) and the washers (5 and 7) on the overlap of the upper tail fairing (1) and lower tail
fairing with sealant (C-308). Tighten the screws.
4. Seal the edges of the upper tail fairing (1) with sealant (C-308).
53-20-01
Rev. 2 Page 9
E-AB412-PT6T-2

2. Washer
3. Screw
4. Screw
5. Washer
6. Screw
7. Washer
NOTE:
1 Seal edges of upper tail fairing after installation.
G6AB1027A
Figure 4. Upper tail fairing - removal and installation
53-20-01
Page 10 Rev. 2
E-AB412-PT6T-2
12. LOWER TAIL FAIRING
NOTE
Instructions for the lower tail fairing (9, figure 1) apply to helicopters equipped with
the BLR FastFin™ system kit 412-705-040-101 (or subsequent). For helicopters
equipped with the Dual Tailboom Strakes and FastFin™ system Supplemental Type
Certificate (STC), refer to the applicable BLR Aerospace documents.
The upper tail fairing (10) is made of graphite and installed on the vertical fin with screws. The fairing replaces the aluminum
trailing edge of the vertical fin on helicopters equipped with the BLR FastFin™ system kit 412-705-040-101 (or
subsequent).
13. LOWER TAIL FAIRING - REMOVAL
1. Remove sealant from the edges of the lower tail fairing (1, figure 5) with a plastic scraper.
2. Remove the upper tail fairing (paragraph "7. Upper tail fairing - removal")
3. Remove the screws (3 and 5) and the washers (2 and 4) from the lower tail fairing (1).
4. Remove the lower tail fairing (1) from the tail skid and the tailboom.
5. If necessary, remove the screw (7), washers (8), and plug (6) from the lower tail fairing (1).
14. LOWER TAIL FAIRING - CLEANING
MATERIALS REQUIRED
NUMBER NOMENCLATURE
C-330 CLEANER
C-355 DETERGENT
CAUTION
DO NOT USE COMPOUNDS CONTAINING ABRASIVES OR CHLORINATED

HYDROCARBONS. AVOID EXCESSIVE SCRUBBING OR POLISHING OF
PLASTIC PANELS. HEAT BUILDUP MAY DAMAGE PLASTIC PANELS.
REMOVE RINGS, WATCHES, AND HARD OBJECTS FROM HANDS AND

WRISTS BEFORE WASHING TRANSPARENT PANELS.
1. Clean the lower tail fairing (1, figure 5) with large quantities of clean water and a solution of detergent (C-355).
2. Gently free all insects or dirt with soft pads or fingers. Do not use sponges or coarse cloths. Rinse the area continuously
while removing insects or dirt.
3. Flush entire area throughly with clean water.
4. Allow surfaces to air dry.
53-20-01
Rev. 2 Page 11
E-AB412-PT6T-2
5. Minor scratches may be reduced or removed by using cleaner (C-330).
6. Apply cleaner (C-330) with a clean soft cloth or tissue in a circular motion until clean. Polish with another clean, soft,
cotton cloth.
15. LOWER TAIL FAIRING - INSPECTION
NUMBER NOMENCLATURE
COMMERCIAL TAP HAMMER
1. Examine the lower tail faring (1, figure 5) for cracks, damage, delamination, and voids. As required, repair damage
(paragraph "16. Lower tail fairing - repair") or replace the part.
2. Visually examine the attaching hardware for condition. Replace as required.
16. LOWER TAIL FAIRING - REPAIR
MATERIALS REQUIRED
NUMBER NOMENCLATURE
C-323 FAIRING COMPOUND
1. For information on damage repair on the lower tail faring (1, figure 5) other than those specified in step 2., contact
Product Support Engineering.
2. Fill and fair scratches, nicks, or any equivalent superficial damage on the lower tail faring (1) with fairing compound
(C-323). Do a finishing of the area after repair.
17. LOWER TAIL FAIRING - INSTALLATION
MATERIALS REQUIRED
NUMBER NOMENCLATURE
C-308 SEALANT
1. If previously removed, install the plug (6, figure 5) on the lower tail fairing (1) as follows:
a. Apply sealant (C-308) on the outer diameter of the plug (6).
b. While sealant is wet, install the plug (6) on the lower tail fairing (1).
c. Wet install the screws (7) and the washers (8) on the plug (6). Tighten the screws.
2. Move the lower tail fairing (1) over the tail skid and put it in position on the tailboom.
3. Wet install the screws (3 and 5) and the washers (2 and 4) on the lower tail fairing (1) with sealant (C-308). Tighten
the screws.
53-20-01
Page 12 Rev. 2
E-AB412-PT6T-2
4. Install the upper tail fairing (paragraph "11. Upper tail fairing - installation").
5. Seal the edges of the lower tail fairing (1) with sealant (C-308).
18. STRAKES
NOTE
Instructions for the strakes (11, figure 1) apply to helicopters equipped with the BLR
FastFin™ system kit 412-705-040-101 (or subsequent). For helicopters equipped
with the Dual Tailboom Strakes and FastFin™ system Supplemental Type
Certificate (STC), refer to the applicable BLR Aerospace documents.
The strakes (11) consist of an upper and a lower strake riveted along the left side of the tailboom, between Boom Station
(BS) 17.42 and BS 185.15. Each strake is made of four aluminum segments or angles. The free flange of the angles is the
aerodynamic blade, the other is the mounting flange for attachment to the boom skin.
19. STRAKES - INSPECTION
1. Visually examine the upper and lower strakes for cracks, damage, corrosion, deformation, and loose or missing rivets.
As required, repair damage (paragraph "20. Strakes - repair") or replace the part (paragraph "21. Strakes -
replacement").
2. Visually examine sealant around the upper and lower strakes for condition. As applicable, repair voids or replace
sealant in case of deterioration (paragraph "20. Strakes - repair").
20. STRAKES - REPAIR
NUMBER NOMENCLATURE
C-308 SEALANT
C-559 SEALANT
1
NOTE:
1 Use CS 5500 Class B2
1. For information on damage repair and corrosion removal on segments of the upper or lower strake other than those
specified in step 2., contact Product Support Engineering.
2. Lightly sand to remove scratches, nicks, or any equivalent superficial damage from the strakes. Do a finishing of the
area after repair.
NOTE
Sealant (C-308) may have been used as an alternate to sealant (C-559) for
installation of the lower strake.
3. Touch up repair or replace fillet of sealant around the upper or lower strake with sealant (C-559) or sealant (C-308),
as applicable.
53-20-01
Rev. 2 Page 13
E-AB412-PT6T-2
21. STRAKES - REPLACEMENT
For instructions to replace one or more segments of the upper or lower strake, contact Product Support Engineering.
53-20-01
Page 14 Rev. 2
E-AB412-PT6T-2

2. Washer
3. Screw
4. Screw
5. Washer
6. Screw
7. Washer
NOTE:
1 Seal edges of upper tail

fairing after installation.
G6AB1028A
Figure 5. Lower tail fairing - removal and installation
53-20-01
Rev. 2 Page 15
E-AB412-PT6T-2
53-20-01
Page 16 Rev. 2
E-AB412-PT6T-2
53-31-01 FIXED STEP (P/N 212-706-057-1 AND -2)
53-31-01
FIXED STEP (P/N 212-706-057-1 AND -2)
1. FIXED STEP (P/N 212-706-057-1 AND -2) - DESCRIPTION
The fixed step consists of left and right step assembly, struts and attaching hardware. Each step, located below the hinged
panel door and forward portion of the sliding door, is attached to the helicopter fuselage hard points by struts.
2. FIXED STEP (P/N 212-706-057-1 AND -2) - REMOVAL
1. Remove hardware from attach forward strut assembly to lower forward hardpoint (1, figure 1).
2. Loosen nuts on both ends of eyebolt.
3. Remove eyebolt.
4. Remove hardware from attach support assemblies to upper hardpoints (2).
5. Remove hardware from attach strut (3) assemblies to step (4).
3. FIXED STEP (P/N 212-706-057-1 AND -2) - INSTALLATION
1. Prior to installing Fixed Step Kit, 212-706-057-1, ensure strut dimensions as per figure 2.
NOTE
After obtaining the proper dimension for the 212-030-615-5 strut assembly, tighten
jam nuts.
2. Attach strut assemblies to step assembly (4, figure 1) with hardware (3).
3. Attach support assemblies to upper hard points using applicable hardware (2).
4. Position center strut assembly toward lower aft strut assembly, attach eyebolt to center strut assembly and fasten with
applicable bolt, washer and nut (do not tighten).
5. Position aft strut assembly on lower aft hardpoint.
6. Insert eyebolt through lower on lower aft hardpoint and strut assembly (positioned in previous step). Fasten eyebolt
with applicable washer and nut. Tighten nuts on both ends of eyebolt.
7. Attach forward strut assembly to lower forward hardpoint with applicable hardware (1).
8. Make strut adjustments as necessary to ensure that step assembly is in parallel plane with cabin floor.
53-31-01
Page 1
E-AB412-PT6T-2
4. FIXED STEP (P/N 212-706-057-1 AND -2) - INSPECTION
1. Inspect fixed step(s) for structural integrity and security. (Special attention should be directed to areas where step
fittings attach to hardpoints). Ensure that bolts are tight.
53-31-01
Page 2
E-AB412-PT6T-2
G6AB0988A
Figure 1. Fixed step installation
53-31-01
Page 3
E-AB412-PT6T-2
G6AB0989A
Figure 2. Strut dimension diagram
53-31-01
Page 4
E-AB412-PT6T-2
CHAPTER 56 - WINDOWS

Module Page
Number Title Number
56-00-00 WINDOWS AND WINDSHIELDS
1. Windows and windshields - general ....................................................................................................... 1
56-11-01 WINDOWS AND WINDSHIELDS - CABIN ROOF WINDOWS
1. Cabin roof windows - description ........................................................................................................... 1

2. Cabin roof windows - removal ............................................................................................................... 1
3. Cabin roof windows - installation ........................................................................................................... 1
4. Cabin roof windows - inspection ............................................................................................................ 2
56-11-02 WINDOWS AND WINDSHIELDS - UPPER CREW DOOR WINDOWS
1. Upper crew door windows - description ................................................................................................. 1

2. Upper crew door windows - removal ..................................................................................................... 1
3. Upper crew door windows - installation ................................................................................................. 1
4. Upper crew door windows - inspection .................................................................................................. 2
56-11-03 WINDOWS AND WINDSHIELDS - FORWARD CREW DOOR WINDOWS
1. Forward crew door windows - description ............................................................................................. 1

2. Forward crew door windows - removal .................................................................................................. 1
3. Forward crew door windows - installation ............................................................................................. 1
4. Forward crew door windows - inspection................................................................................................ 2
56-11-04 WINDOWS AND WINDSHIELDS - LOWER CREW DOOR WINDOWS
1. Lower crew door windows - description ................................................................................................ 1

2. Lower crew door windows - removal ..................................................................................................... 1
3. Lower crew door windows - installation ................................................................................................ 1
4. Lower crew door windows - inspection .................................................................................................. 1
56-11-05 WINDOWS AND WINDSHIELDS - LOWER NOSE SECTION WINDOWS
1. Lower nose section windows - description ............................................................................................. 1

2. Lower nose section windows - removal ................................................................................................. 1
3. Lower nose section windows - installation ............................................................................................. 1
4. Lower nose section windows - inspection .............................................................................................. 2
56-11-06 WINDOWS AND WINDSHIELDS - WINDSHIELDS
1. Windshields - description ....................................................................................................................... 1

2. Windshields - removal ............................................................................................................................ 1
3. Windshields - installation ....................................................................................................................... 1
4. Windshields - inspection.......................................................................................................................... 3
5. Windshields - cleaning ............................................................................................................................ 3
6. Windshields - repair ................................................................................................................................ 3
56-Index
Rev. 2 Page 1
E-AB412-PT6T-2

Module Page
Number Title Number
56-21-01 WINDOWS AND WINDSHIELDS - CARGO HINGED PANEL DOOR WINDOWS
1. Cargo hinged panel door windows - description .....................................................................................1

2. Cargo hinged panel door windows - removal .........................................................................................1
3. Cargo hinged panel door windows - installation .....................................................................................1
56-21-02 WINDOWS AND WINDSHIELDS - PASSENGER DOOR WINDOWS
1. Passenger door windows - description ....................................................................................................1

2. Passenger door windows - removal .........................................................................................................1
3. Passenger door windows - installation ....................................................................................................1
4. Passenger door windows - inspection ......................................................................................................6
5. Passenger door windows - repair .............................................................................................................7
56-Index
Page 2 Rev. 2
E-AB412-PT6T-2
FIGURES
Figure Page
Number Title Number
56-00-00 WINDOWS AND WINDSHIELDS
Figure 1. Window and windshields................................................................................................................................ 2
56-11-01 WINDOWS AND WINDSHIELDS - CABIN ROOF WINDOWS
Figure 1. Cabin roof windows damage limits ................................................................................................................ 3
56-11-02 WINDOWS AND WINDSHIELDS - UPPER CREW DOOR WINDOWS
Figure 1. Upper crew door windows damage limits ...................................................................................................... 3
56-11-03 WINDOWS AND WINDSHIELDS - FORWARD CREW DOOR WINDOWS
Figure 1. Forward crew door windows damage limits................................................................................................... 3
56-11-04 WINDOWS AND WINDSHIELDS - LOWER CREW DOOR WINDOWS
Figure 1. Lower crew windows damage limits .............................................................................................................. 2
56-11-05 WINDOWS AND WINDSHIELDS - LOWER NOSE SECTION WINDOWS
Figure 1. Lower nose section windows damage limits .................................................................................................. 3
Figure 1. Passenger door window .................................................................................................................................. 5

Figure 2. Passenger door windows damage limits ......................................................................................................... 7
56-Index
Rev. 2 Page 3
E-AB412-PT6T-2
56-Index
Page 4 Rev. 2
E-AB412-PT6T-2
56-0 -0 WINDOWS AND WINDSHIELDS
56-00-00
WINDOWS AND WINDSHIELDS
1. WINDOWS AND WINDSHIELDS - GENERAL
The following paragraphs provide maintenance information for the cabin roof windows, crew door windows, cargo hinged
panel windows, passenger/cargo door windows, lower nose windows, and pilot and copilot windshields.
The windows (figure 1) covered in this chapter consist of cockpit and passenger area transparent panels (windshields and
windows).
56-00-00
Page 1
E-AB412-PT6T-2
G6AB0822A
Figure 1. Window and windshields
56-00-00
Page 2
E-AB412-PT6T-2
56-1 -01 WINDOWS AND WINDSHIELDS - CABIN ROOF WINDOWS
56-11-01
WINDOWS AND WINDSHIELDS - CABIN ROOF WINDOWS
1. CABIN ROOF WINDOWS - DESCRIPTION
The cabin roof windows are made of tinted acrylic plastic.
2. CABIN ROOF WINDOWS - REMOVAL
1. Remove free air temperature gage (Chapter 95).
2. Remove nuts, washers, and screws attaching windows to roof structure.
3. Separate window from sealant using a non-metallic spatula, putty knife, or similar tool (e.g. snap-on P/N YA109A).
4. Carefully remove window from helicopter.
3. CABIN ROOF WINDOWS - INSTALLATION
MATERIALS REQUIRED
NUMBER NOMENCLATURE
C-308 ADHESIVE
1. Prior to installation of cabin roof windows, wash windows with a mild detergent and water solution. Dry with a soft
dry cloth.
2. Remove all sealing compound from mounting flange with a non-metallic putty knife, spatula, or similar tool.
CAUTION
WHEN CLEANING WINDOWS AND MOUNTING FLANGE, USE ONLY TYPE

II ALIPHATIC NAPHTHA (C-305). ALIPHATIC NAPHTHA TYPE I WILL
CLOUD WINDOWS.
3. Wipe clean mounting flange with cloth dampened in aliphatic naphtha (C-305).
4. If a new window is being installed, position window over opening. Trim only enough surplus material from edge of
window to permit proper alignment of window against mounting flange.
NOTE
Do not trim window to final size until all mounting holes have been drilled.
56-11-01
Page 1
E-AB412-PT6T-2
5. Position window against mounting flange and using a No. 4 drill, back drill two holes on each edge of window. Use
holes in mounting flange as template.
6. Secure window to mounting flange with four existing screws, washer, and nuts, lightly tighten. Finish drilling holes in
windows.
7. Measure window and mark proper edge distance required for installation. Remove window and trim window edge to
0,80 inch (20,32 mm).
8. Remove all dust and dirt from windows and mounting flange with a clean cloth moistened in aliphatic naphtha (C-305).
9. Apply a 0,125 inch (3,18 mm) bead of adhesive (C-308).
10. Position window to mounting flange and align holes. Install retaining screws, washers, and nuts.
11. Remove excess sealant from around window with a clean cloth moistened in aliphatic naphtha (C-305).
12. Install free air temperature gage (Chapter 95).
4. CABIN ROOF WINDOWS - INSPECTION
Inspect windows in accordance with figure 1.
56-11-01
Page 2
E-AB412-PT6T-2
G6AB0029A
Figure 1. Cabin roof windows damage limits
56-11-01
Page 3
E-AB412-PT6T-2
56-11-01
Page 4
E-AB412-PT6T-2
56-1 -02 WINDOWS AND WINDSHIELDS - UPPER CREW DOOR WINDOWS
56-11-02
WINDOWS AND WINDSHIELDS - UPPER CREW DOOR WINDOWS
1. UPPER CREW DOOR WINDOWS - DESCRIPTION
The upper crew door windows are made of clear acrylic material.
2. UPPER CREW DOOR WINDOWS - REMOVAL
1. Remove nuts, washers and, screws attaching window to door.
2. Separate window from sealing compound.
3. Remove window from door.
3. UPPER CREW DOOR WINDOWS - INSTALLATION
MATERIALS REQUIRED
NUMBER NOMENCLATURE
C-308 ADHESIVE
1. Prior to installation of upper crew door windows, wash windows with a mild detergent and water solution. Dry with a
soft dry cloth.
2. Remove old sealing compound from mounting flange with a non-metallic putty knife, spatula, or similar tool.
CAUTION
WHEN CLEANING WINDOWS AND MOUNTING FLANGE, USE ONLY TYPE

CLOUD WINDOWS.
3. Wipe and clean mounting flange with cloth dampened in aliphatic naphtha (C-305).
4. If a new window is being installed, position window over opening. Trim only enough surplus material from edge of
window to permit proper alignment of window against mounting flange.
NOTE
5. Position window against mounting flange. Using a No. 4 drill, back drill two holes on each edge of window. Use holes
in mounting flange as template.
56-11-02
Page 1
E-AB412-PT6T-2
6. Secure window to mounting flange with four existing screws, washer, and nuts, lightly tighten. Finish drilling holes in
windows.
7. Measure window and mark proper edge distance required for installation.
8. Remove window and trim window edge per measurements from previous step.
9. Remove all dust and dirt from windows and mounting flange with a clean cloth moistened in aliphatic naphtha (C-305).
10. Apply a 0,125 inch (3,18 mm) bead of adhesive (C-308).
11. Position window to mounting flange, align holes, and install screws, washers, and nuts.
12. Remove excess sealant from around window with a clean cloth moistened in aliphatic naphtha (C-305).
4. UPPER CREW DOOR WINDOWS - INSPECTION
Inspect windows in accordance with figure 1.
56-11-02
Page 2
E-AB412-PT6T-2
G6AB0030A
Figure 1. Upper crew door windows damage limits
56-11-02
Page 3
E-AB412-PT6T-2
56-11-02
Page 4
E-AB412-PT6T-2
56-1 -03 WINDOWS AND WINDSHIELDS - FORWARD CREW DOOR WINDOWS
56-11-03
WINDOWS AND WINDSHIELDS - FORWARD CREW DOOR WINDOWS
1. FORWARD CREW DOOR WINDOWS - DESCRIPTION
The forward crew door windows are made of clear acrylic material.
2. FORWARD CREW DOOR WINDOWS - REMOVAL
1. Drill out rivets using a No. 30 drill.
2. Separate window from sealant using a non-metallic putty knife, spatula, or similar tool.
3. Remove window from helicopter.
3. FORWARD CREW DOOR WINDOWS - INSTALLATION
MATERIALS REQUIRED
NUMBER NOMENCLATURE
C-308 ADHESIVE
1. Remove old sealant from mounting flange with a non-metallic putty knife, spatula, or similar tool.
CAUTION
WHEN CLEANING MOUNTING FLANGE AND WINDOWS, USE ONLY TYPE

CLOUD WINDOWS.
2. Wipe and clean edging and window with aliphatic naphtha (C-305).
3. When installing new window, trim window to final size. Position window into mounting flange and drill mounting
holes.
4. Apply adhesive (C-308) in a bead around window edge.
5. Install rivets to secure window to crew door mounting flange.
6. Remove excess sealant from around edge of window using clean cloth moistened with aliphatic naphtha (C-305).
56-11-03
Page 1
E-AB412-PT6T-2
4. FORWARD CREW DOOR WINDOWS - INSPECTION
Inspect window in accordance with figure 1.
56-11-03
Page 2
E-AB412-PT6T-2
G6AB0033A
Figure 1. Forward crew door windows damage limits
56-11-03
Page 3
E-AB412-PT6T-2
56-11-03
Page 4
E-AB412-PT6T-2
56-1 -04 WINDOWS AND WINDSHIELDS - LOWER CREW DOOR WINDOWS
56-11-04
WINDOWS AND WINDSHIELDS - LOWER CREW DOOR WINDOWS
1. LOWER CREW DOOR WINDOWS - DESCRIPTION
The lower crew door windows are made of clear acrylic material.
2. LOWER CREW DOOR WINDOWS - REMOVAL
1. Remove access door from lower edge of door.
2. Remove screws attaching handle to lower crew door window.
3. Loosen adjustable stop and slide window down and remove through access door opening.
3. LOWER CREW DOOR WINDOWS - INSTALLATION
1. Guide window up through slot in bottom of door and into channels.
2. Check progress of window through opening in aft edge of door.
3. With window in partially open position, engage adjustable stop.
4. Install handle with three screws.
5. Install lower access door.
4. LOWER CREW DOOR WINDOWS - INSPECTION
56-11-04
Page 1
E-AB412-PT6T-2
G6AB0031A
Figure 1. Lower crew windows damage limits
56-11-04
Page 2
E-AB412-PT6T-2
56-1 -05 WINDOWS AND WINDSHIELDS - LOWER NOSE SECTION WINDOWS
56-11-05
WINDOWS AND WINDSHIELDS - LOWER NOSE SECTION WINDOWS
1. LOWER NOSE SECTION WINDOWS - DESCRIPTION
The lower nose section windows are made of clear acrylic material.
2. LOWER NOSE SECTION WINDOWS - REMOVAL
1. Remove nuts, washers, and screws attaching window.
2. Separate window from sealant.
3. Remove window from helicopter.
3. LOWER NOSE SECTION WINDOWS - INSTALLATION
MATERIALS REQUIRED
NUMBER NOMENCLATURE
C-308 ADHESIVE SEALANT
1. Prior to installation of lower nose section windows, wash windows with a mild detergent and water solution. Dry with
a soft dry cloth.
2. Remove old sealant from mounting flange with a putty knife, spatula, or other suitable tool.
CAUTION
WHEN CLEANING WINDOWS, USE ONLY TYPE II ALIPHATIC NAPHTHA

(C-305). ALIPHATIC NAPHTHA TYPE I WILL CLOUD WINDOWS.
3. Wipe and clean mounting flange with cloth damp in aliphatic naphtha (C-305). If an old window is being installed,
clean edges of window using naphtha.
4. Position a new window over opening. Trim surplus edge to permit window to be in mounting position against flange.
NOTE
5. Position window against mounting flange and using a No. 4 drill, back drill two holes on each edge of window.
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6. Secure window to mounting flange with four existing screws, washers, and nuts. Lightly tighten screws. Finish drilling
holes in window.
7. Determine edge distance and mark window. Remove window and trim to 1,04 inches (29 mm) edge distance.
8. Remove all dust and foreign matter from window mating area from window mounting flange using aliphatic naphtha
(C-305).
9. Apply bead of adhesive (C-308) around windows.
10. Position window in mounting flange, align holes, and install screws, washers, and nuts.
11. Remove excess sealant from around window.
4. LOWER NOSE SECTION WINDOWS - INSPECTION
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G6AB0032A
Figure 1. Lower nose section windows damage limits
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56-1 -06 WINDOWS AND WINDSHIELDS - WINDSHIELDS
56-11-06
WINDOWS AND WINDSHIELDS - WINDSHIELDS
1. WINDSHIELDS - DESCRIPTION
The windshield is of three-layer, sandwich-type construction. The outer layer is made of tempered glass. The middle layer
is made of applicable laminated glass. The inner layer may be made of glass or plastic. The windshields are set in
weather-tight sealer and are mounted to the cabin structure with screws, washers, and nuts.
2. WINDSHIELDS - REMOVAL
1. Mark location of wiper stop (approximately BL 7.0). Remove windshield wiper arm and blade (Chapter 30).
2. Noting location of hardware, remove nuts, washers and screws attaching windshield to fuselage.
NOTE
Shims may have been installed to reduce any gaps between windshield frame and
mounting flange. If same windshield is to be reinstalled, mark location of any shims
installed.
3. Separate windshield from sealing compound using a non metallic spatula, putty knife, or similar tool.
4. Carefully remove windshield from helicopter.
3. WINDSHIELDS - INSTALLATION
MATERIALS REQUIRED
NUMBER NOMENCLATURE
1. Remove all sealing compound from mounting flange with a non-metallic putty knife, spatula, or similar tool.
CAUTION

2. Wipe and clean mounting flange with cloth damp in aliphatic naphtha (C-305).
3. Position windshield in mounting position so that it mates with the contour and that no portion of the bevel edge on the
inside surface contacts the frame (minimum 0,010 in (0,254 mm) clearance).
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NOTE
Do not trim windshield to final size until all mounting holes have been drilled.
4. Trim windshield only as required to allow temporary installation. Temporarily secure with heavy tape.
5. Mark the location of all screw holes on the windshield flange.
6. Remove windshield and confirm minimum edge distance of 0,38 in (9,65 mm) for all holes. Readjust position as
required to obtain proper edge distance.
7. Position windshield in place with all marked holes aligned.
8. Starting at the center of the vertical row (center post) and progressing towards the top and bottom, transfer the screw
holes into the windshield flange using a 0,190 to 0,196 in (4,826 to 4,978 mm) drill. Temporarily attach with Clecos.
9. Transfer remaining screw holes starting at the inboard corners, progressing towards the outboard edge. Temporarily
attach with Clecos.
NOTE
If a gap greater than 0,015 in (0,381 mm) exists due to variations in windshield
contour or mounting flange, a shim may be installed.
10. Check for excessive gap between windshield frame and mounting flange over a distance of three screw holes. If gap
is greater than 0,015 in (0,381 mm), install shim material as follows:
a. Prepare shim material from aluminum alloy 2024 T3 with a maximum thickness of 0,063 in (1,600 mm) to
reduce any gaps to a maximum of 0,015 inch (0,381 mm).
b. Install shim between windshield frame and mounting flange. Shim material must be secured with a minimum of
two fasteners.
c. Mark location of shim for proper installation in later steps.
11. Using a No. 4 drill, back-drill two holes on each edge of windshield. Use holes in mounting flange as a template.
12. Secure windshield to mounting flange with four existing screws, washers, and nuts, lightly tighten. Finish drilling
holes in windshield.
13. Confirm proper edge distance, mark windshield and shims (if required), and remove. Trim windshield edge and shims
(if required) to proper size.
14. Remove all dust and foreign matter from windshield mating area and from windshield mounting flange.
15. Apply a small even bead of sealing compound (C-328) to window frame.
16. Position windshield, align holes, and install shims (if required), screws, washers, and nuts.
17. Increase torque slowly and evenly on all screws or nuts to a maximum of 23 lbf·in (2,6 Nm). Verify torque before
sealant dries.
18. Remove excess sealing compound (C-328) from around windshield with aliphatic naphtha (C-305). Touch up paint if
bare metal is evident.
19. Install windshield wiper assemblies (Chapter 30).
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4. WINDSHIELDS - INSPECTION
1. Inspect windshield frame for nicks, dents, scratches, distortion, and holes. Minor scratches, nicks, and non-puncturing
dents are acceptable without repair if the damage does not adversely affect windshield or windshield security.
5. WINDSHIELDS - CLEANING
Wash windshields with a mild detergent and water solution. Dry with a soft clean cloth.
6. WINDSHIELDS - REPAIR
Glass windshield cannot be repaired. Glass windshield must be replaced if there are cracks, or if there is distortion or low
visibility due to cracks.
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56-21-01 WINDOWS AND WINDSHIELDS - CARGO HINGED PANEL DOOR WINDOWS
56-21-01
WINDOWS AND WINDSHIELDS - CARGO HINGED PANEL DOOR
WINDOWS
1. CARGO HINGED PANEL DOOR WINDOWS - DESCRIPTION
The cargo hinged panel door windows are made of clear acrylic material.
2. CARGO HINGED PANEL DOOR WINDOWS - REMOVAL
1. Remove cargo hinged panel door from helicopter (module 52-31-03 paragraph "2. Cargo hinged panels - removal").
2. Remove hardware securing door latch Plexiglas covers.
3. Drill out rivets using a No. 30 drill.
4. Separate window from sealant using a non-metallic putty knife, spatula, or similar tool.
5. Carefully remove window from door panel.
3. CARGO HINGED PANEL DOOR WINDOWS - INSTALLATION
MATERIALS REQUIRED
NUMBER NOMENCLATURE
C-308 ADHESIVE
1. Prior to installation, clean windows with a mild detergent and water solution. Dry with a soft dry cloth.
CAUTION

2. Clean windows and mounting flange with aliphatic naphtha (C-305).
3. If a new window is being installed, drill rivet mounting holes.
4. Apply a bead of adhesive (C-308) on window edges.
5. Mount window in panel and secure using rivets.
6. Install screws securing door latch Plexiglas cover to window.
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56-21-02
WINDOWS AND WINDSHIELDS - PASSENGER DOOR WINDOWS
1. PASSENGER DOOR WINDOWS - DESCRIPTION
The passenger door windows are made of clear acrylic material. The windows are installed in metal frames with silicone
rubber retainers and are designed for emergency egress. EMERGENCY PUSH HERE decals are installed in lower corners.
2. PASSENGER DOOR WINDOWS - REMOVAL
NOTE
Removal is not recommended unless required by window or retainer damage.
Procedures are same for all push-out windows.
1. Remove interior decor/trim as necessary to gain access to window supporting structure.
2. Using mylar, tedlar or similar tape, mask off structure adjacent to window retainer. The mask edge should be pressed
firmly against, but not on, retainer.
3. Remove filler (3, figure 1) (locking strip) from retainer. Discard filler.
CAUTION
DO NOT ALLOW WINDOW TO FALL. STORE WINDOW ON EDGE TO

PREVENT CONTOUR CHANGE.
4. Push window out by pressing at corner as directed by decal.
5. Pull retainer from structure starting at unbounded area at lower corners. Discard retainer.
3. PASSENGER DOOR WINDOWS - INSTALLATION
MATERIALS REQUIRED
NUMBER NOMENCLATURE
C-300 ADHESIVE
C-306 TOLUENE
C-307 ADHESIVE
C-316 ACETONE
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(Cont.d)
NUMBER NOMENCLATURE
C-337 PRIMER
C-347 XYLENE
C-426 MASKING TAPE
C-516 CLEAN CLOTH
NUMBER NOMENCLATURE
T86 LOCKING STRIP (FILLER)

INSERTER TOOL
T87 RETAINER INSTALLATION TOOL
1. If the window was removed to perform a structural repair that may have affected the window opening, measure
window opening. Trim opening as required to the following dimensions (±0.03 in (±0.8 mm):
— 28.00 in (71.1 cm) wide.
— 23.14 in (58.8 cm) high.
CAUTION
ENSURE WINDOW FRAME (5, FIGURE 1) IS CLEAN AND COMPLETELY

FREE OF ANY PAINT FINISHING MATERIAL.
NOTE
Helicopter finishes will not adhere to surfaces where primer and adhesive are
applied.
NOTE
Window opening must be in a protected area, shielded from wind, rain, or other
adverse environmental conditions during installation.
2. Following applicable trimming or initial preparation, remove all residue using a clean cloth (C-516) moistened with
toluene (C-306), xylene (C-347), or acetone (C-316). Wipe dry with a clean cloth (C-516).
3. Temporarily position new retainer (seal) (6) in window frame (5) opening.
4. With the new retainer (seal) (6) positioned in place, apply masking tape (C-426) around its periphery to the surface of
both sides of the door. Remove the retainer.
5. Apply primer (C-337) within masked area of window frame (5). Allow to dry 30 minutes before installing retainer
(seal) (6).
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6. Prepare and fit new retainer (seal) (6) in window frame (5) as follows:
a. Abrade retainer groove (4) with 80 grit abrasive cloth or paper (C-423).
b. Clean retainer groove (4) with a clean cloth (C-516) dampened with toluene (C-306), xylene (C-347), or acetone
(C-316). Wipe dry with a clean cloth (C-516).
NOTE
Retainer filler groove (2) shall be positioned outboard.
c. Position and hold retainer (seal) (6) in place with masking tape (C-426) so that it nests in all four corners of the
opening. Position ends at approximately the 6 o’clock position and trim to length.
d. Mix adhesive (C-300) and apply to both trimmed ends of retainer (seal) (6). Allow to air dry for 15 to 30 minutes
to a strong tack and press the ends together.
CAUTION
WHEN CLEANING WINDOWS, USE TYPE II ALIPHATIC NAPHTHA (C-305).

ALIPHATIC NAPHTHA TYPE I WILL CLOUD WINDOWS.
NOTE
The height and width are very similar on the square window. The window is
normally oriented correctly when the part number is at the bottom.
7. Place window (7) in retainer window groove (1).
CAUTION
IF PROCURED AS A PRE-TRIMMED ITEM, DO NOT CUT OR STRETCH THE

FILLER (LOCKING STRIP) (3) TO LENGTH. THE FULL LENGTH MUST BE
USED.
IF FILLER (LOCKING STRIP) (3) IS PROCURED AS RAW MATERIAL BY
THE FOOT, TEMPORARILY PLACE FILLER (LOCKING STRIP) (3) ON TOP
OF RETAINER FILLER GROOVE (2) AND CUT TO LENGTH USING A SHARP
KNIFE. AFTER TRIMMING, THE FULL LENGTH MUST BE USED.
8. Install filler (locking strip) (3) in retainer filler groove (2), using locking strip insertion tools (8 and 9). Ends of filler
shall meet approximately at the 12 o’clock position in retainer (seal) (6).
9. To avoid adhesive contact with the painted surfaces of the door, verify installation of masking tape (C-426) on both
sides of the door around the periphery of the retainer (seal) (6). Mark lower corner areas not to be bonded on both sides
of the door, as shown in figure 1.
CAUTION
DO NOT APPLY ADHESIVE TO THE RETAINER WINDOW GROOVE (1) ,

FILLER (LOCKING STRIP) (3) , OR LOWER CORNER AREAS SHOWN IN
FIGURE 1.
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10. Using a clean wooden or plastic stick, locally lift the retainer (seal) (6) and inject silicone adhesive (C-307) in a small
bead between the retainer and window frame (5), all around the retainer except in lower corner areas as shown in
figure 1. A small amount of adhesive squeeze-out around the edges is desirable.
CAUTION
DO NOT ALLOW TOLUENE (C-306) OR XYLENE (C-347) TO COME INTO

CONTACT WITH WINDOW (7).
11. Remove excess silicone adhesive using a clean cloth (C-516) dampened with toluene (C-306), xylene (C-347), or
acetone (C-316). Wipe dry with a clean cloth (C-516).
12. Turn the door over and apply silicone adhesive (C-307) to the other side of the retainer (seal) (6) and window frame
(5) per steps 10. and 11.
13. Remove all masking tape from around retainer (seal) (6).
14. Inspect periphery of window (7) and retainer (seal) (6) for gaps between the retainer and window and between the
retainer and window frame (5).
NOTE
Silicone adhesive (C-307) curing is obtained from moisture in the air. If window
installation is performed in a very dry environment, curing may be accelerated by
covering the window with a sealed plastic bag and placing a cloth wet with water in
a sealed compartment on each side of the window. Make sure no water makes direct
contact with the retainer.
15. Placard the window (7) with a “DO NOT DISTURB” placard and allow to dry. Do not remove the placard or release
the helicopter for flight until the silicone adhesive has cured for a minimum of 24 hours at room temperature.
16. If not already installed, apply “EMERGENCY PUSH HERE” decals on lower corners of window designated for
emergency egress (Chapter 11).
17. Install interior decor/trim (if applicable).
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28.0
(71.1 cm)
23.14
(58.8 cm)
1. Retainer window groove

2. Retainer filler groove
3. Filler (locking strip)
4. Retainer groove
5. Window frame
6. Retainer (seal)
7. Window
8. Locking strip (filler) insertion tool CP293 or equivalent
9. Retainer installation tool No. LT112 or equivalent
NOTE:
1
1 Tool may be obtain from:
C.R. Laurence Co. Inc.
2080 Lonestar Drive
Dallas, Tx 75212
G6AB0025B
Figure 1. Passenger door window
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4. PASSENGER DOOR WINDOWS - INSPECTION
MATERIALS REQUIRED
NUMBER NOMENCLATURE
C-439 ALUMINUM FOIL TAPE
C-516 CLEAN CLOTH
1. Inspection - windows installed (figure 2).
CAUTION
NO REPAIRS ARE ALLOWED ON RETAINER (6, figure 1) AND FILLER (3).
a. Visually inspect retainer (6) and filler (3) for cuts, cracks, or signs of deterioration (swelling). Replace if damage
is found.
b. Verify retainer (6) is securely bonded to both sides of window frame (5) except in radius area of two lower
corners. Replace if any bond separation is found.
c. Inspect window (7) for cracking, crazing, or reduced transparency. Replace damaged windows.
NOTE
Retainers (6, figure 1) and fillers (3) shall be replaced when window is removed
from retainer.
2. Inspection - windows removed.
a. Mark both lower corners of window frame as shown in figure 1. Mask these lower corner areas where the bond
is prohibited with aluminum foil tape (C-439). Apply tape on both sides of the door.
b. Remove all old adhesive and finish from unmasked portion of window frame (5) using stiff fiber brush and a
clean cloth (C-516) dampened with aliphatic naphtha (C-305).
c. Use 360 grit abrasive cloth or paper (C-423) to remove any primer from unmasked area of window frame (5).
d. Remove the tape from the lower corners of the window frame.
e. Inspect edge of window frame (5) for scratches, cracks, or other damage. Any scratches less than 0.004 in (0.10
mm) deep and 1.0 in (25.40 mm) long may be polished out. Repairs must not be closer than 3.0 in (76.2 mm)
from adjacent repairs. An area may only be repaired once.
CAUTION

f. Inspect window (7) for chamfered, nicked or notched edge, cracking, crazing, or reduced transparency. Replace
damaged windows.
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E-AB412-PT6T-2
5. PASSENGER DOOR WINDOWS - REPAIR
Repair window (7, figure 1) in accordance with figure 2.
Scratches and pits are permitted in this area, providing the structural integrity of the window is not impaired.
Cracks, holes, or other damage may be repaired by stop drilling, patching or other approved methods provided
structural integrity is not impaired (refer to FAA Advisory Circular 43.13-1, Aircraft Inspection and Repair)
G6AB0026B
Figure 2. Passenger door windows damage limits
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E-AB412-PT6T-2
CHAPTER 62 - MAIN ROTOR

Module Page
Number Title Number
62-00-00 MAIN ROTOR HUB AND BLADES
1. Main rotor hub and blades - general ....................................................................................................... 1
62-11-01 MAIN ROTOR BLADES
1. Main rotor blades - description ............................................................................................................... 1

2. Main rotor blades - removal .................................................................................................................... 1
3. Main rotor blades - installation ............................................................................................................... 2
4. Main rotor blades - cleaning ................................................................................................................... 5
5. Main rotor blades - inspection ................................................................................................................ 5
6. Main rotor blades - repair ....................................................................................................................... 6
7. Main rotor blades - polyurethane protective tape ................................................................................... 7
7-1. Polyurethane protective tape - cleaning and surface preparation .................................................. 7
7-2. Polyurethane protective tape - wet application method ................................................................. 7
7-3. Polyurethane protective tape - dry application method ................................................................. 8
7-4. Polyurethane protective tape - inspection ...................................................................................... 8
7-5. Polyurethane protective tape - edge sealing (optional)................................................................... 9
7-6. Polyurethane protective tape - removal ......................................................................................... 9
62-21-01 MAIN ROTOR HUB
1. Main rotor hub - description ................................................................................................................... 1

2. Main rotor hub - removal ........................................................................................................................ 1
3. Main rotor hub - installation .................................................................................................................. 10
4. Main rotor hub - cleaning ..................................................................................................................... 14
5. Main rotor hub - inspection .................................................................................................................. 14
6. Main rotor hub - repair .......................................................................................................................... 14
62-31-01 MAIN ROTOR CONTROLS
1. Main rotor controls - description ............................................................................................................ 1
62-31-02 MAIN ROTOR CONTROLS - SWASHPLATE AND SUPPORT ASSEMBLY
1. Swashplate and support assembly - description ..................................................................................... 1

2. Swashplate and support assembly - removal .......................................................................................... 1
3. Swashplate and support assembly - installation ..................................................................................... 1
4. Swashplate and support assembly - cleaning........................................................................................... 4
5. Swashplate and support assembly - inspection ....................................................................................... 4
6. Swashplate and support assembly - repair .............................................................................................. 4
62-31-03 MAIN ROTOR CONTROLS - MAIN ROTOR PITCH LINK ASSEMBLIES
1. Main rotor pitch link assemblies - description ........................................................................................ 1

2. Main rotor pitch link assemblies - removal ............................................................................................ 1
3. Main rotor pitch link assemblies - installation ........................................................................................ 1
4. Main rotor pitch link assemblies - cleaning ............................................................................................ 8
5. Main rotor pitch link assemblies - inspection ......................................................................................... 8
62-Index
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Module Page
Number Title Number
6. Main rotor pitch link assemblies - repair ................................................................................................8
62-31-04 MAIN ROTOR CONTROLS - HUB AND SLEEVE ASSEMBLY
1. Hub and sleeve assembly - description ...................................................................................................1

2. Hub and sleeve assembly - removal ........................................................................................................1
3. Hub and sleeve assembly - installation ...................................................................................................6
4. Hub and sleeve assembly - cleaning .......................................................................................................8
5. Hub and sleeve assembly - inspection .....................................................................................................8
6. Hub and sleeve assembly - inspection of teflon lined bearings (installed) ............................................12
7. Hub and sleeve assembly - repair ..........................................................................................................12
62-31-05 MAIN ROTOR CONTROLS - REPHASING LEVERS
1. Rephasing levers - removal .....................................................................................................................1

2. Rephasing levers - installation ................................................................................................................1
62-31-06 MAIN ROTOR CONTROLS - DRIVE LINK ASSEMBLY
1. Drive link assembly - removal ................................................................................................................1

2. Drive link assembly - installation ............................................................................................................1
62-31-07 MAIN ROTOR CONTROLS - SWASHPLATE LINK ASSEMBLY
1. Swashplate link assembly - removal .......................................................................................................1

2. Swashplate link assembly - installation ..................................................................................................5
62-31-08 MAIN ROTOR CONTROLS - COLLECTIVE PITCH DRIVE PLATE SET
1. Collective pitch drive plate set - removal ................................................................................................1

2. Collective pitch drive plate set - installation ...........................................................................................1
62-31-09 MAIN ROTOR CONTROLS - COLLECTIVE LEVER ASSEMBLY
1. Collective lever assembly - removal .......................................................................................................1

2. Collective lever assembly - installation (helicopters configured with collective
lever pin p/n 412-010-422-101) ..............................................................................................................1
3. Collective lever assembly - installation (helicopters configured with collective
lever pin p/n 412-010-422-103) ..............................................................................................................5
4. Collective lever assembly - cleaning .......................................................................................................6
5. Collective lever assembly - inspection ....................................................................................................6
6. Collective lever assembly - repair ............................................................................................................7
62-Index
Page 2 Rev. 2
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FIGURES
Figure Page
Number Title Number
62-11-01 MAIN ROTOR BLADES
Figure 1. Main rotor blade installation........................................................................................................................... 4

Figure 2. Main rotor blade ........................................................................................................................................... 10
Figure 3. Polyurethane protective tape - size and location .......................................................................................... 11
Figure 1. Main rotor hub (sheet 1 of 6).......................................................................................................................... 3

Figure 2. Main rotor hub stand - tool application .......................................................................................................... 9
Figure 1. Main rotor controls ......................................................................................................................................... 2
Figure 1. Swashplate and support .................................................................................................................................. 3
Figure 1. Main rotor pitch link (sheet 1 of 2)................................................................................................................. 2

Figure 2. Main rotor pitch link assembly initial dimensions ......................................................................................... 6
Figure 3. Main rotor pitch link assembly ....................................................................................................................... 7
Figure 1. Hub and sleeve (sheet 1 of 3) ......................................................................................................................... 3

Figure 2. Main rotor pitch link assembly initial dimensions ....................................................................................... 10
Figure 3. Collective drive plate set - damage limits .................................................................................................... 11
Figure 4. Swashplate link and drive link bearings - work aid...................................................................................... 13
Figure 5. Hub and sleeve assembly teflon bearing inspection ..................................................................................... 14
Figure 1. Rephasing lever installation............................................................................................................................ 4
Figure 1. Drive link ........................................................................................................................................................ 3
Figure 1. Swashplate link (sheet 1 of 3)......................................................................................................................... 2
Figure 1. Collective pitch drive plate set ....................................................................................................................... 3
Figure 1. Collective lever (sheet 1 of 2)......................................................................................................................... 3
62-Index
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62-Index
Page 4 Rev. 2
E-AB412-PT6T-2
62-0 -0 MAIN ROTOR HUB AND BLADES
62-00-00
MAIN ROTOR HUB AND BLADES
1. MAIN ROTOR HUB AND BLADES - GENERAL
The main rotor hub and blade consists of the hub, four main rotor blades and four pitch horns. Each main rotor blade is
connected to hub by either two fixed diameter bolts or one fixed diameter bolt on leading edge side of rotor blade and an
expandable bolt on trailing edge side of rotor blade. The purpose of expandable bolts (when used) is to facilitate removal of
bolts when rotor blades are folded. The main rotor droop restraint assembly attaches to lower damper bridges and to attach
lugs of lower cone seat, (four places) and will minimize yoke flexing during static rotor blade droop.
To minimize storage requirements, 2 of the blades can be folded so that 1 parallels the forward blade and 1 the aft blade
when folded, the blades do not extend beyond the width of the forward fuselage.
NOTE
Use of expandable rotor blade bolt instead of standard rotor blade retention bolt is
optional.
62-00-00
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62-00-00
Page 2
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62-1 -01 MAIN ROTOR BLADES
62-11-01
MAIN ROTOR BLADES
1. MAIN ROTOR BLADES - DESCRIPTION
The main rotor blades are constructed of fiberglass with a honeycomb core, stainless steel tip cap and outboard abrasion
strip, and a titanium inboard abrasion strip. The glass fiber spar is made up of four spar caps and a nose block, constructed
of spanwise oriented unidirectional glass fibers, all bonded between inner and outer glass fiber torque wraps. The rotor
blades are covered with fiberglass skins.
2. MAIN ROTOR BLADES - REMOVAL
NUMBER NOMENCLATURE
T24 BLADE BOLT TOOL
T42 SLING
NOTE
Removal procedure for main rotor blade (3, figure 1) is given. Removal procedure
for the other three rotor blades is the same.
1. Inspect rotor blade (3, figure 1) and spindle (1) for color code markings. If color code markings are missing, apply new
marking prior to removal (Chapter 11).
CAUTION
USE HOIST WITH MINIMUM CAPACITY OF 1000 LB (454 KG).
2. Attach sling (T42) (4) to hoist with minimum capacity of 1000 lb (454 kg). Position hoist directly over center of gravity
of rotor blade to be removed. Attach sling straps around rotor blade. Take up slack with hoist.
CAUTION
MAIN ROTOR BLADES AND HUB COMPONENTS ARE COLOR CODED.

AFTER EXPANDABLE BOLT (10, FIGURE 1) IS ADJUSTED AT INITIAL
INSTALLATION, IT SHALL BE KEPT WITH SAME ROTOR BLADE AND
HUB SPINDLE, OR EXPANDABLE BOLT SHALL BE READJUSTED.
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NOTE
For helicopters with expandable rotor blade bolts installed, accomplish following
steps 3. and 4. For helicopters with standard rotor blade bolts installed in both rotor
blade spindle holes, accomplish step 5. for both bolts.
3. Remove safety lock hair pin (12) from lower end of expandable bolt (10).
4. Raise bolt handle (9) to reduce diameter of bolt (10). Remove bolt (10).
5. Cut and remove lockwire. Remove plug (8) and lock (7) from lower end of rotor blade bolt (2). Remove nut (6) and
washer (5). Remove rotor blade bolt (2) using rotor blade bolt tool (T24) (13).
6. Slide rotor blade (3) from spindle (1). Lower rotor blade and place in a suitable blade rack.
3. MAIN ROTOR BLADES - INSTALLATION
MATERIALS REQUIRED
NUMBER NOMENCLATURE
C-405 LOCKWIRE
C-561 GREASE
NUMBER NOMENCLATURE
T24 BLADE BOLT TOOL
T42 SLING
CAUTION
USE HOIST WITH A MINIMUM CAPACITY OF 1000 LB (454 KG).
MAIN ROTOR BLADES AND HUB COMPONENTS ARE COLOR CODED.

AFTER EXPANDABLE BOLT (10, FIGURE 1) IS ADJUSTED AT INITIAL
INSTALLATION, IT SHALL BE KEPT WITH THE SAME ROTOR BLADE AND
HUB SPINDLE, OR EXPANDABLE BOLT SHALL BE READJUSTED.
NOTE
When replacing main rotor blade assembly (412-015-200-101) with main rotor blade
assembly (412-015-300-101), blades shall be installed in pairs and in same yoke and
spindle of hub and blade assembly.
1. Attach sling (T42) (4, figure 1) to a suitable hoist and position directly over center of blade (3).
2. Attach straps of sling (T42) (4) around blade (3). Hoist and align blade with hub.
3. Guide blade (3) into spindle (1) per color code and align bolt holes.
62-11-01
Page 2 Rev. 2
E-AB412-PT6T-2
4. Apply grease (C-561) to mating surfaces of blade bolts (2) and (if being used) expandable bolts (10).
WARNING
S TA N D A R D B L A D E B O LT S M AY B E I N S TA L L E D I N L I E U O F
E X PA N D A B L E B O LT S I N B L A D E T R A I L I N G E D G E B O LT H O L E .
HOWEVER, STANDARD AND EXPANDABLE BLADE BOLTS SHALL NOT
BE INTERMIXED ON SAME HUB.
5. Install rotor blade bolt (2) through spindle (1) and rotor blade (3) in leading edge bolt hole. Use blade bolt tool (T24)
to install bolt (2). Do not install nut (6) at this time. If standard bolt is being installed in aft hole, repeat procedure for
trailing edge bolt.
CAUTION
EXPANDABLE BOLT (10), BLADE (3) AND SPINDLE ARE COLOR CODED.
EXPANDABLE BOLT (10) AND ROTOR BLADE (3) SHALL BE INSTALLED
IN SAME SPINDLE FROM WHICH REMOVED. IF FOR ANY REASON
EXPANDABLE BOLT (10), ROTOR BLADE (3) AND SPINDLE
COMBINATION ARE CHANGED, EXPANDABLE BOLT (10) SHALL BE
ADJUSTED AS DESCRIBED BELOW.
6. For helicopters with expandable bolt installed in aft blade hole, accomplish the following:
a. Raise bolt handle (9) on expandable bolt (10).
b. Install expandable bolt (10) in spindle (1) and blade (3) in trailing edge hole with handle positioned as shown in
view A-A.
c. Push down on bolt handle (9). Force required to push handle down should be 50 to 75 lb (222 to 334 N) measured
at end of handle. If force is within limits, latch spring clip of bolt handle (9) on core pin of expandable bolt (10).
d. Install safety lock hair pin (12) to hold bolt handle (9) in down position. If force required to push handle down
is not within limits, accomplish the following step.
e. Adjust expandable bolt (10) only if force required to latch bolt handle (9) is not within 50 to 75 lb (222 to 334
N) measured at end of handle. Install expandable bolt (10) in correct spindle (1) and blade (3) combination.
Adjust adjustment nut (11) in increments and push bolt handle (9) down until force required is within limits
noted above. When expandable bolt (10) is adjusted within limits, install safety lock hair pin (12) to hold handle
(9) in down position.
7. For standard blade bolts, accomplish the following:
a. Install washer (5) and nut (6).
b. Torque nut (6) 70 to 90 ft-lbf (95 to 122 Nm).
c. Install lock (7) on nut (6) and install plug (8) to secure lock (7) on nut (6).
d. Torque plug (8) 200 to 250 in-lbf (22.60 to 28.25 Nm). Secure plug (8) to lock (7) using lockwire (C-405).
8. After all four main rotor blades are installed, track main rotor blades (Chapter 18) and perform functional check flight.
62-11-01
Rev. 2 Page 3
E-AB412-PT6T-2
Torque 70 to 90 ft-lbf
(95 to 122 Nm)
Torque 200 to 250 in-lbf

(22.60 to 28.25 Nm)
Lockwire (C-405)
4.0 in
(101.6 mm)
NOTE:
For operators not requiring
blade folding use blade bolt
(2), washer (5), nut (6), lock
(7) and plug (8), in lieu of
expandable bolt (10).
NOTE:
Minimum capacity for hoist is 1000 lb (454 kg)
1. Spindle 8. Plug (AN814-4L)

2. Blade bolt 9. Bolt handle
3. Blade 10. Expandable bolt
4. Sling (T101626) 11. Adjustment nut
5. Washer (206-010-154-3) 12. Safety lock hair pin
6. Nut 13. Blade bolt tool (T101266)
7. Lock
G6AB0576C
Figure 1. Main rotor blade installation
62-11-01
Page 4 Rev. 2
E-AB412-PT6T-2
4. MAIN ROTOR BLADES - CLEANING
MATERIALS REQUIRED
NUMBER NOMENCLATURE
C-318 CLEANING COMPOUND
C-412 WAX
1. Wipe main rotor blades with cloth damp with aliphatic naphtha (C-305) or drycleaning solvent (C-304).
2. Wash rotor blades with a mild solution of cleaning compound (C-318) and water. Rinse rotor blades with clean water
and wipe dry with clean cloths.
CAUTION
DO NOT USE SILICONE TYPE WAXES. SILICONE WAXES MAY

INTERFERE WITH FUTURE REPAIRS OR REFINISHING.
NOTE
Waxing is not required for blades P/N 412-015-300-109 and subsequent or for any
blade finished with polyurethane paint.
3. Coat rotor blades with wax (C-412).
5. MAIN ROTOR BLADES - INSPECTION
1. Inspect leading edge abrasion strip (3, figure 2) and splice covers (4 and 10) as follows:
a. Return main rotor blade to AgustaWestland for replacement of leading edge abrasion strip under the following
conditions:
(1) Leading edge deformation due to abrasion.
(2) Edge voids deeper than 0.50 in (12.7 mm).
(3) Holes, cracks or tears.
b. Nicks, scratches or sharp dents not exceeding 0.012 in (0.305 mm) are acceptable if polished smooth. Non-sharp
dents not exceeding 0.015 in (0.381 mm) are acceptable. If damage exceeds inspection requirements replace
abrasion strip (3) and/or splice covers (4 or 10).
2. Inspect fretting pads (9) for cracks and adhesive voids. If cracks are found or edge voids are in excess of 0.25 in
(6.35 mm), notify AgustaWestland Maintenance Personnel.
NOTE
Some main rotor blades are equipped with only one trim tab (outboard), or two trim
tabs (inboard and outboard), or three trim tabs (inboard, mid and outboard).
62-11-01
Rev. 2 Page 5
E-AB412-PT6T-2
3. Inspect inboard, mid and outboard trim tabs (6, 7 and 8) and tip assembly (5) for damage, debonding or corrosion
(E-AB412-PT6T-3).
4. Inspect rotor blade bolt retention bushings (1) (E-AB412-PT6T-3).
5. Inspect main rotor blade bonded assembly (2) as follows:
a. Inspect for cracks. If crack(s) are found notify AgustaWestland Maintenance Personnel.
b. Nicks, scratches, gouges or dents on fiberglass surfaces are acceptable without repair provided fibers are not
broken or cause delamination. If fibers are broken or delaminations develop, refer to E-AB412-PT6T-3 manual.
c. Scratches, gouges or nicks that penetrate one or more layers of upper and lower skins (12 and 14), but do not
damage core (15) may be repaired (E-AB412-PT6T-3).
d. Holes in skin outboard of station 90,0 may be repaired (E-AB412-PT6T-3).
e. Nicks or notches in extreme trailing edge strip (13) of blade less than 0.120 in (3.048 mm) in depth are acceptable
if polished out over distance of at least 2.0 in (50.8 mm) each side of nick or notch.
f. Nicks or scratches in erosion shield (11, detail A) are acceptable provided there is no penetration. Excessive
damage requires erosion shield replacement at AgustaWestland authorized repair station.
NOTE
A void is defined as any unbounded area. Many definitions of voids are often used,
such as lack of adhesive, gas pocket, misfit, etc. This manual makes no distinction
among these definitions, but groups all such unbounded areas under the general
term, void. Inspect for voids using a small steel tapping hammer similar to
AgustaWestland tool number T-75449-2 on all surfaces.
6. Inspect for voids under leading edge abrasion strips (3) and skin of main rotor blade bonded assembly (2). If any voids
are found, refer to E-AB412-PT6T-3 manual for limitation and authorized repair.
7. Inspect paint condition. Refer to E-AB412-PT6T-3 for refinish procedures.
6. MAIN ROTOR BLADES - REPAIR
MATERIALS REQUIRED
NUMBER NOMENCLATURE
C-411 STEEL WOOL
1. Polish out all acceptable nicks and scratches on leading edge abrasion strip (3, figure 2), using 180 grit or finer abrasive
cloth or paper (C-423). Polish to a surface finish, removing only enough material to remove the nicks or scratches. The
use of steel wool (C-411) on abrasion strips to polish out defects is acceptable. Acceptable dents need not be filled or
fired.
2. Repair rotor blade bolt retention bushings (1) (E-AB412-PT6T-3).
3. Polish out all acceptable nicks and scratches on fiberglass surfaces and erosion shield (11) with 200 grit abrasive cloth
or paper (C-423). Lightly abrade painted surfaces immediately surrounding polished areas.
4. Polish out nicks, scratches and notches in trailing edge strip (13) which do not extend forward more than 0.10 in (2.54
mm) with 200 grit or finer abrasive cloth or paper (C-423). Fair repair out a minimum of 2.0 in (50.8 mm) each side.
62-11-01
Page 6 Rev. 2
E-AB412-PT6T-2
5. Fill all acceptable edge voids (E-AB412-PT6T-3).
6. Touch up finish of repaired areas (E-AB412-PT6T-3).
7. MAIN ROTOR BLADES - POLYURETHANE PROTECTIVE TAPE
Use of polyurethane tape is optional with individual operator. Its use is recommended for protection against abrasion of
leading edge of blade in areas of high sand and dust conditions. The tape affords medium protection against rain. It may be
removed and replaced with new tape as often as necessary.
Refer to figure 2 for tape size and location.
7-1. POLYURETHANE PROTECTIVE TAPE - CLEANING AND SURFACE PREPARATION
MATERIALS REQUIRED
NUMBER NOMENCLATURE
C-434 TAPE
C-516 CLEAN CLOTH
C-558 ADHESIVE PROMOTER
1. Dampen a clean cloth (C-516) with isopropyl alcohol (C-385) and wipe the blade surface.
2. Wipe dry with a clean cloth (C-516) before the isopropyl alcohol (C-385) evaporates from the surface.
3. Mask application area with 1.0 in masking tape (C-434).
4. Sand surface in a spanwise direction only with 220 or 240 grit abrasive paper (C-423).
5. Thoroughly wipe with a clean cloth (C-516) and isopropyl alcohol (C-385) until there is no trace of residue and wipe
dry with clean cloth (C-516).
6. Apply a thin, uniform coat of adhesive promoter (C-558) to the blade surface, using the minimum amount that will
fully coat the surface. Allow to dry thoroughly (5 minutes minimum).
7-2. POLYURETHANE PROTECTIVE TAPE - WET APPLICATION METHOD
MATERIALS REQUIRED
NUMBER NOMENCLATURE
C-557 BLADE TAPE
62-11-01
Rev. 2 Page 7
E-AB412-PT6T-2
1. Mix the wetting solution as follows: thoroughly mix four drops of liquid detergent (not soap) in a pint (1/2 liter)
solution of 25% isopropyl alcohol (C-385) and 75% water.
2. Mark correct position of tape on blade surface (figure 3).
3. Remove liner and flood adhesive side with wetting solution.
4. Thoroughly spray blade surface with wetting solution.
5. Position blade tape (C-557) on blade surface and spray wetting solution on film surface (prevents squeegee from
sticking).
6. Squeegee from leading edge to trailing edge of blade using firm, overlapping strokes to smooth out film. Dry entire
area with cloth. Work out blisters with the plastic squeegee.
7. To apply next section of blade tape (C-557), repeat steps 3. through 6.
8. Allow applied blade tape (C-557) to dwell overnight (12 hours).
9. If blisters are present after the application, puncture tape at one end of blister with a pin or needle and press out with
squeegee or thumb toward puncture.
7-3. POLYURETHANE PROTECTIVE TAPE - DRY APPLICATION METHOD
MATERIALS REQUIRED
NUMBER NOMENCLATURE
C-557 BLADE TAPE
1. Remove half of liner from adhesive side of blade tape (C-557).
2. Align blade tape (C-557) and press one edge to blade surface with finger.
3. Squeegee from leading edge to trailing edge of blade using firm overlapping strokes to smooth out tape.
4. Remove remaining half of liner and repeat step 3.
7-4. POLYURETHANE PROTECTIVE TAPE - INSPECTION
1. After each mission, when practical, inspect the tape on the leading edge of main rotor blades. If any of the following
conditions exist, replace tape.
— Wear-through of tape
— Void or blistering of tape
62-11-01
Page 8 Rev. 2
E-AB412-PT6T-2
7-5. POLYURETHANE PROTECTIVE TAPE - EDGE SEALING (OPTIONAL)
MATERIALS REQUIRED
NUMBER NOMENCLATURE
C-149 EDGE SEALER
C-434 TAPE
C-557 BLADE TAPE
1. Prepare blade tape (C-557) for edge sealing by applying a strip of tape (C-434) across the top of the blade tape (C-557)
1/32 in (0.79 mm) back from the edge. Apply a second strip of tape (C-434) 1/8 in (3.17 mm) forward of the edge of
the blade tape (C-557). This will provide a neat, defined area for the application of the epoxy edge sealant.
2. Apply a bead of edge sealer (C-149) between both strips of tape (C-434). With a fitted rubber glove, use a finger to
spread and smooth the sealant bead between the strips of tape.
3. Allow the adhesive to partially cure, approximately 30 minutes. Remove the tape (C-434) to allow the edges of the
adhesive to flow smoothly on the surface and the blade tape (C-557) to make a tapered edge. The 30-minute cure time
can be adjusted up or down depending if the ambient temperature is higher or lower than 72°F (22°C).
7-6. POLYURETHANE PROTECTIVE TAPE - REMOVAL
1. Pull on tape by keeping the angle of removal perpendicular (90°C) to the surface and pull at a moderate speed.
— If the angle is more or less, there is a greater chance of adhesive transferring from the tape to the surface.
— The same problem is possible if the tape is removed too slowly. If removed too quickly, the tape may tear or
sliver.
— At 60-120°F (15-49°C), the adhesive is firm enough for clean removal without tearing or slivering.
— Removal at hotter temperature increases the potential for adhesive transfer.
— At colder temperature, the tape is more brittle with increased chance for silvering.
— For minor adhesive transfer rub the adhesive with your finger into a ball and wipe it off. Or, dab up the adhesive
with another piece of tape.
— For major adhesive transfer that is tacky, use common cleaning agents such as 3M citrus base cleaner, mineral
spirits, or industrial solvents.
— For hard adhesive on hard surfaces, scrape with a plastic/plexiglas scraper or sand with fine grit paper. Use
caution to prevent surface damage.
62-11-01
Rev. 2 Page 9
E-AB412-PT6T-2
1. Blade bolt retention bushings

2. Main rotor blade bonded assembly
3. Abrasion strip
4. Splice cover (inboard)
5. Tip assembly
6. Outboard trim tab
7. Mid trim tab
8. Inboard trim tab
9. Fretting pad
10. Splice cover (outboard)
11. Erosion shield
12. Upper skin
13. Trailing edge strip
14. Lower skin
15. Core
16. Spar
G6AB0577B
Figure 2. Main rotor blade
62-11-01
Page 10 Rev. 2
E-AB412-PT6T-2
G6AB0578A
Figure 3. Polyurethane protective tape - size and location
62-11-01
Rev. 2 Page 11
E-AB412-PT6T-2
62-11-01
Page 12 Rev. 2
E-AB412-PT6T-2
62-21-01
MAIN ROTOR HUB
1. MAIN ROTOR HUB - DESCRIPTION
The main rotor hub consists of two titanium yokes, each of which mounts two steel spindles in elastomeric bearings and
elastomeric dampers. Each spindle has two spindle lugs for mounting a rotor blade. Rotor blade pitch control is achieved by
means of a pitch horn attached to inboard end of each spindle. The opposite end of each pitch horn is attached to a pitch link.
The pitch links are attached to the rotating controls. The main rotor hub is attached to mast by a procedure which does not
require application of large torque values to hub retaining nut. The cap assembly, which secures main rotor hub to mast, is
threaded onto mast and is also bolted to hub with eight bolts.
2. MAIN ROTOR HUB - REMOVAL
NUMBER NOMENCLATURE
NAS6208-9 (PART OF T23) BOLT
T101356-3 (PART OF T23) SHAFT WELDMENT
T101263-105 (PART OF T23) ADAPTER
T13 TRANSPORTATION STAND
T14 ADAPTER
T27 JACKSCREW
T42 SLING ASSEMBLY
T62 SUPPORT ASSEMBLY
1. Inspect main rotor hub, main rotor blades, and pitch links for color code markings. If any color code markings (dots)
are missing, apply new markings (Chapter 11).
2. Remove main rotor blades (module 62-11-01 paragraph "2. Main rotor blades - removal").
3. Remove bolt (13, figure 1) and washers (14) securing pitch link (19) to pitch horn (15). Secure pitch link (19) to main
rotor mast (8). Disconnect remaining three pitch links (19). Secure pitch links (19) to main rotor mast (8).
4. Cut and remove lockwire from bolts (9).
62-21-01
Rev. 2 Page 1
E-AB412-PT6T-2
CAUTION
WHEN REMOVING SEALANT FROM HUB, USE PLASTIC OR BRASS

TOOLS ONLY.
6. Remove sealant from threaded holes in lower cone (11) of main rotor hub (5) adjacent to where bolts (9) were removed.
Remove sealant with plastic or brass tools to prevent damage to rotor hub.
7. Install three jackscrews (T27) in lower cone (11) of main rotor hub (5) where sealant was removed. If jackscrew set
(T27) is not available, use three 1/4 X 28 UNF threaded bolts approximately 2.5 in (63.5 mm) long. Tighten jackscrews
(or bolts) evenly and push lower cone (11) out of lower cone seat of main rotor hub (5).
8. Remove sealant from joint between cap assembly (3) and main rotor hub (5) with sharp plastic scraper.
9. Cut and remove lockwire from bolts (1).
11. Remove cap assembly (3).
NOTE
Cap assembly (3) consists of two major parts, upper cap and nut which threads onto
mast. After eight bolts (1) and bead of sealant is removed, cap assembly (3) can be
removed with a wrench attached to flat area at top of cap assembly.
12. Place sling (T42) (2, figure 2) on a hoist with minimum capacity of 1000 pounds (454 kg). Hoist sling (2) into position
above main rotor hub (1). Position sling straps around main rotor hub (1) as shown on figure 2.
13. Check that adapter (6) with support assembly (5), adapter (4), and bolt (3) are installed on maintenance transport stand
(7).
NOTE
If adapter (6) with support (5), adapter (4) and bolt (3) are installed on maintenance
transport stand (7), proceed to step 14. If not installed, perform steps 13. and 14.
14. Install adapter (6) on maintenance transport stand (7).
15. Install adapter (4) on support assembly (5) and secure with bolt (3).
16. Hoist main rotor assembly (1) approximately 2.0 in (50 mm) and remove upper cone (4, figure 1).
17. Hoist main rotor hub (5) clear of main rotor mast (8).
18. Align main rotor hub assembly (1, figure 2) with adapter (4) and lower main rotor hub assembly (1) into position on
maintenance transport stand (7).
19. Remove sling (2) from main rotor hub assembly (1).
62-21-01
Page 2 Rev. 2
E-AB412-PT6T-2
1. Bolt 11. Lower cone

2. Washer (140-007-30S20A30) 12. Upper cone seat
3. Cap assembly 13. Bolt
4. Upper cone 14. Steel washer
5. Main rotor hub 15. Pitch horn
6. Blade bolt 16. Steel washer
7. Expandable blade bolt 17. Nut
8. Main rotor mast 18. Cotter pin
9. Bolt 19. Pitch link
10. Washer (140-007-24S17A3)
NOTES:
1 Refer to DETAIL D for torquing instruction.
2 Refer to DETAIL E for torquing instruction.

3. Refer to DETAIL C for droop restraint rigging dimensions.
4 Verify that the thickness of pitch horn (15) and two washers
(14 and 16) exceeds the grip length of bolt (13). If not, add one
NAS1149C0532R washer between nut (17) and washer (16)
(Post BT 412-71).
G6AB0579B
Figure 1. Main rotor hub (sheet 1 of 6)
62-21-01
Rev. 2 Page 3
E-AB412-PT6T-2
20. Damper bridge 36. Clevis

21. Bolt 37. Washer (AN960-716)
22. Washer (AN960-616) 38. Bolt
23. Cotter pin 39. Bolt
24. Nut 40. Washer (MS9482-10)
25. Washer (412-018-064-101) 41. Bolt
26. Washer (140-00733S40C4) 42. Washer (AN960-516)
27. Race 43. Arm
28. Lower cone seat 44. Weight
29. Nut 45. Nut
30. Bolt 46. Nut
31. Bolt 47. Cotter pin
32. Clevis 48. Bolt
33. Nut 49. Washer (MS9482-11)
34. Bushing (412-018-062-109) 50. Cam
35. Nut
G6AB0580B
62-21-01
Page 4 Rev. 2
E-AB412-PT6T-2
CAM WINDOW
DIMENSION B
SEE NOTES 2
AND 3
LOWER DETENT POSITION
DIMEN
SION
SEE N A OUTBD
OTE 1
FLEXURE SHOWN IN STATIC

DROOP POSITION WITH DROOP
RESTRAINT ENGAGED
FOUR PLACES
(ARM AND WEIGHT REMOVED FOR CLARITY)
DETAIL C
NOTES
1. Droop restraint arm length (dimension A) to be adjusted with weight, brackets and associated hardware removed per rigging
procedures.
2. Dimension B is to be set per rigging instructions following setting of arm length (dimension A) and prior to reinstallation of
weight, brackets and associated hardware. For each restraint arm, dimension B is to be measured on both leading and trailing
edge clevis tangs and measured difference is to be 0.030 in (0.762 mm) maximum.
3. Pivot stop rigging dimension to be set after adjusting (dimension A) per rigging procedures.
G6AB0581B
62-21-01
Rev. 2 Page 5
E-AB412-PT6T-2
G6AB0582A
62-21-01
Page 6 Rev. 2
E-AB412-PT6T-2
SEE DETAIL F
1 Apply corrosion preventive compound (C-101).
2 Apply grease (C-561) on faying surfaces.
3 Seat all around using sealant (C-396).
4 Small passageway must remain at lower cone split to vent space

between mast and hub.
G6AB0583B
62-21-01
Rev. 2 Page 7
E-AB412-PT6T-2
G6AB0584A
62-21-01
Page 8 Rev. 2
E-AB412-PT6T-2
1. Main rotor hub assembly

2. Sling (T101626)
3. Bolt (NAS6208-9) (Part of T101263-101)
4. Adapter (T101263-105) (Part of T101263-101)
5. Support assembly (214-782-003-001 or T101356-3)
6. Adapter SWE 13875-30
7. Maintenance transportation stand SWE 13875
G6AB0585B
Figure 2. Main rotor hub stand - tool application
62-21-01
Rev. 2 Page 9
E-AB412-PT6T-2
3. MAIN ROTOR HUB - INSTALLATION
MATERIALS REQUIRED
NUMBER NOMENCLATURE
C-396 or C-308 SEALANT
C-405 LOCKWIRE
C-447 LOCKWIRE
C-561 GREASE
NUMBER NOMENCLATURE
T42 SLING ASSEMBLY
1. Place sling assembly (T42) (2, figure 2) on a hoist with minimum capacity of 1000 pounds (454 kg) or more.
2. Hoist sling (2) into position above main rotor hub assembly (1).
3. Position sling (2) straps around hub as shown on figure 2.
4. Hoist main rotor hub assembly (1) clear of adapter (4).
CAUTION
ENSURE GREASE DOES NOT COME IN CONTACT WITH TEFLON OF CONE

OR MATING SURFACES WITH TEFLON.
5. Apply a thin coat of grease (C-561) to mating surfaces of main rotor mast (8, figure 1) lower cone (11), main rotor hub
(5), upper cone (4), and cap assembly (3).
6. Apply grease (C-561) to main rotor mast (8) and splined plate splines.
7. Position lower cone (11) on main rotor mast (8) with beveled side up.
8. Hoist main rotor hub (5) into position above main rotor mast (8).
9. Align master tooth of splined plate in main rotor hub (5) with master tooth of main rotor mast (8) splines.
10. Carefully lower main rotor hub (5) onto main rotor mast (8) until the upper cone seat (12) is supported by splines on
main rotor mast.
11. Remove sling (2, figure 2) from main rotor hub (5, figure 1).
62-21-01
Page 10 Rev. 2
E-AB412-PT6T-2
12. Install upper cone (4) which was previously coated with grease (C-561), on main rotor mast (8) with beveled side
down.
13. Apply a thin coat of grease (C-561) under the heads and to the shanks of bolts (9).
14. Slide lower cone (11) into position and install bolts (9) with washers (10) under bolt heads. Do not torque bolts (9) at
this time.
15. Install cap assembly (3) on main rotor mast (8), and torque cap assembly to approximately 25 ft-pounds (33.8 Nm) to
ensure cone is seated.
16. Loosen cap assembly until holes in cap assembly flange are aligned with threaded holes in upper cone seat (12). If cap
assembly has been loosened less than half the distance between holes, loosen one additional hole for installation of
bolts (1).
17. Apply a bead of sealant (C-396 or C-308) around cap assembly (3) where cap assembly joins main rotor hub (5).
18. Apply a thin coat of grease (C-561) under the heads and to shanks of eight bolts (1).
19. Install eight bolts (1) with washers (2) under bolt heads, and torque bolts (1) in sequence as per detail D.
20. Secure bolts (1) in pairs using lockwire (C-447).
21. Apply a thin coat of corrosion preventive compound (C-101) to head of bolts (1).
22. Check torque of bolts (1) after every flight during rotor smoothing process until torque is maintained.
23. Torque bolts (9) in sequence and steps (detail E), and secure bolt heads in pairs using lockwire (C-405).
24. Apply a thin coat of corrosion preventive compound (C-101) to head of bolts (9) and washers.
25. Check torque of bolts (9) after every flight during rotor smoothing process until torque is maintained.
26. Fill threaded holes in lower cone seat of main rotor hub (5) in area above bolts (9), area at lower cone (11) to main
rotor mast (8) interface, and gap between lower cone and cone seat with sealant (C-396 or C-308) .
NOTE
Small passageway must remain open at lower cone split to vent space between mast
and hub.
27. Position pitch link (19) in pitch horn (15).
28. Coat bolt (13) with grease (C-561).
29. Install bolt (13), washer (14), washer (16), and nut (17) with head of bolt (13) in direction of rotation.
NOTE
Verify that the thickness of the pitch horn (15) and two washers (14 and 16) exceeds
the spindle length of the bolt (13). If not, add one NAS1149C0532R washer between
nut (17) and washer (16).
30. Torque nut (17) 100 to 140 in-lbs (11.30 to 15.82 Nm). Install cotter pin (18).
31. Repeat steps 27. through 29. for installation of remaining pitch links.
62-21-01
Rev. 2 Page 11
E-AB412-PT6T-2
NOTE
Main rotor hub can remain on maintenance transportation stand (7, figure 2) or be
installed on helicopter for accomplishment of rigging procedures.
32. Install main rotor blades (module 62-11-01 paragraph "3. Main rotor blades - installation").
CAUTION
PROPER RIGGING IS EXTREMELY IMPORTANT AND MUST BE

PERFORMED UNDER IDEAL CONDITIONS. MAIN ROTOR BLADE
MOVEMENT, SUCH AS CAUSED BY WIND MUST BE MINIMIZED. IT IS
RECOMMENDED THE FOLLOWING RIGGING PROCEDURES BE
PERFORMED IN A HANGER WITH MAIN ROTOR HUB AND BLADE
ASSEMBLY EITHER ON HELICOPTER OR INSTALLED ON MAINTENANCE
TRANSPORTATION STAND (1, FIGURE 2) WITH BLADE TIPS
UNSUPPORTED. IF MAINTENANCE TRANSPORTATION STAND (1) IS
USED, DISREGARD REFERENCES IN RIGGING PROCEDURE REGARDING
BLADE POSITION RELATIVE TO HELICOPTER. OUTDOOR RIGGING MAY
BE PERFORMED PROVIDING WIND VELOCITY IS FIVE (5) KNOTS OR
LESS.
33. Manually rotate rotor until blade corresponding to first droop restraint arm to be rigged is pointing forward over nose
of helicopter. Rigging procedure is to be performed while blade is at normal static droop.
34. Cut and remove lockwire from bolt (30, figure 1).
35. Loosen nut (29) on pivot adjusting bolt (30) and turn bolt inward until it bottoms; do not torque nut.
36. Cut and remove lockwire from nut (35).
37. Adjust droop restraint arm length (dimension A, figure 1, detail C) as follows:
NOTE
Dimension A is established using bolt (38) without bushing (34) installed to obtain
length baseline.
a. Manually hold droop restraint arm to position 7/16 in holes of outboard clevis (36) into outboard radius of cam
(50) lower detent. Using bolt, verify bolt will install freely through both clevis tangs while passing through lower
detent of cam window. If bolt does not pass through, turn clevis as necessary, until bolt freely installs.
b. Manually stabilize forward blade at tip during steps c. and d. Do not support blade.
c. Lengthen arm by turning clevis (36) outward in one-half turn increments (installing bolt each time) until first
instance occurs where bolt will not freely install. This establishes “length baseline”.
d. Turn clevis inward one half turn from “length baseline”. Bolt should install freely. With bolt loosely in place,
attempt to swing droop restraint arm upward into upper portion of cam window. If bolt hits cam window surface
and arm is restrained in cam lower detent, length adjustment is correct. If bolt clears cam window surface and
arm swings up freely, turn clevis outward one-half turn.
e. Square up clevis (36) with cam (50) by pushing clevis upward until both clevis tangs are in contact with the cam
mounting flange.
f. Torque nut (35) 375 to 400 in-lbs (42.36 to 45.19 Nm).
g. Ensure that clearance exists between clevis (36) and cam (50).
62-21-01
Page 12 Rev. 2
E-AB412-PT6T-2
38. Adjust pivot adjusting bolt (30) to achieve dimension B, 0.60 to 0.70 in (measured from face of cam plate mounting
flange to outboard upper corner of each clevis tang) (figure 1, detail C). Dimension B on same clevis may vary 0.030 in
(0.762 mm) maximum leading edge side to trailing edge side.
39. Torque nut (29) 25 to 35 in-lbs (2.82 to 3.95 Nm).
40. Recheck Dimension B. Repeat step 37., if necessary.
41. Secure nut (29) to lower cone seat (28) and nut (35) to clevis (32) with lockwire (C-405).
42. Install weight (44) to arms (43); secure with bolt (41), washers (42) and nut (45). Bolt head must be installed in
direction of rotation.
NOTE
It may be necessary to raise blade slightly to allow installation of bolt (38) through
bushing (34).
43. Install bushing (34) inside cam (50).
44. Position arms (43) on clevis (36) and align arms with bolt holes on clevis.
45. Position clevis (36) to align bolt holes in flange of clevis with bushing (34) in cam (50).
NOTE
Bolt head of bolts (38) should be installed in direction of rotation.
46. Install bolt (38) with washer (37) under head of bolt through arm (43), clevis (36), bushing (34) in cam (50), and
through arm (43).
47. Install washers (37) and nuts (46) on bolt (38).
48. Install bolts (39) with two washers (40) under each head of bolts through arm (43) into clevis (36).
49. Torque nut (46) 37 to 42 ft-lbs (50 to 57 Nm). Install cotter pin (47).
50. Torque bolts (39) 25 to 35 in-lbs (2.82 to 3.95 Nm). Secure with lockwire (C-405) to arm (43).
51. Torque nut (45) 50 to 70 in-lbs (5.65 to 7.91 Nm).
52. Manually raise blade and allow droop restraint arm to fall into lower detent of cam window.
53. Repeat steps 33. through 52. for remaining droop restraint arms.
62-21-01
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E-AB412-PT6T-2
NOTE
During first rotor run up following installation of main rotor droop restraint, have an
observer visually verify all droop restraint arms disengage prior to RPM reaching
idle. Normal disengagement occurs at 80 to 100 RPM (25 to 30 percent Nr). Arm
disengagement may be observed by using a fixed reference point (cowling surface,
etc.) to gage droop restraint arm position as RPM increases, or a strobe light of
sufficient intensity may be used. A noticeable vibration will be detectable at idle if
arm disengagement does not occur during application of collective with neutral
cyclic. If vibration occurs, shut down helicopter and verify droop restraint arm
rigging by repeating steps 33. through 44.
54. Ensure main rotor rigging is within limits (Chapter 67).
4. MAIN ROTOR HUB - CLEANING
MATERIALS REQUIRED
NUMBER NOMENCLATURE
1. Clean main rotor hub with cloths damp with drycleaning solvent (C-304).
5. MAIN ROTOR HUB - INSPECTION
For detailed inspection of main rotor hub components, refer to E-AB412-PT6T-3 manual.
6. MAIN ROTOR HUB - REPAIR
For detailed repair procedures of main rotor hub components, refer to E-AB412-PT6T-3 manual.
62-21-01
Page 14 Rev. 2
E-AB412-PT6T-2
62-31-01
MAIN ROTOR CONTROLS
1. MAIN ROTOR CONTROLS - DESCRIPTION
The two major assemblies of main rotor controls are hub and sleeve assembly (7, figure 1) and swashplate and support
assembly (5). The four pitch links (1), four rephasing levers (2), one drive link (3), three swashplate links (6) and collective
lever (4), are also included in main rotor control installation. The function of main rotor controls is to transmit cyclic and
collective input forces to the main rotor hub and blade assembly by means of the hub and sleeve (7), swashplate and support
(5), and interconnecting links and tubes.
62-31-01
Page 1
E-AB412-PT6T-2
G6AB0827A
Figure 1. Main rotor controls
62-31-01
Page 2
E-AB412-PT6T-2
62-31-02
MAIN ROTOR CONTROLS - SWASHPLATE AND SUPPORT ASSEMBLY
1. SWASHPLATE AND SUPPORT ASSEMBLY - DESCRIPTION
The swashplate and support assembly consists of the outer rotating ring mounted through a duplex bearing set on the inner
non-rotating ring. The inner ring is connected to the swashplate support by a gimbal ring assembly. Servo actuator control
tubes connect to two trunnions on the inner ring assembly to tilt the ring in the desired direction. The outer ring assembly
tilts with the inner ring assembly, but rotates independently with the rotating controls.
2. SWASHPLATE AND SUPPORT ASSEMBLY - REMOVAL
1. Remove main rotor hub and blade assemblies (module 62-11-01 paragraph "2. Main rotor blades - removal" and
module 62-21-01 paragraph "2. Main rotor hub - removal").
2. Remove hub and sleeve assembly (module 62-31-04 paragraph "2. Hub and sleeve assembly - removal").
3. Remove cotter pin (9, figure 1), nut (8), washers (7 and 6), bolt (3) with washer (4) from clevis (5) and separate clevis
(5) from trunnion (2).
4. Remove cotter pin (17) and remove nut (16) and washers (14 and 15) from bolt (12).
5. Remove bolt (12) and washer (13) from clevis (11) and separate clevis (11) from trunnion (10).
6. Remove cotter pin (26) and remove nut (25) and washers (24 and 23) from bolt (21).
7. Remove bolt (21) and washer (22) from clevis (20) and separate clevis (20) from trunnion (27).
8. Remove lockwire from bolts (19) and remove bolts (19) and washers (18).
9. Carefully remove swashplate and support assembly (1) from transmission.
3. SWASHPLATE AND SUPPORT ASSEMBLY - INSTALLATION
MATERIALS REQUIRED
NUMBER NOMENCLATURE
C-405 LOCKWIRE
62-31-02
Page 1
E-AB412-PT6T-2
NOTE
A thin coat of corrosion preventive compound (C-104) should be applied to shanks
and under bolt heads of all rotating control bolts prior to installation.
A thin coat of corrosion preventive compound (C-101) should be applied to all
rotating control nuts, washers, and bolt heads after installation.
1. Carefully lower swashplate and support assembly (1, figure 1) over mast and position on mast bearing plate on top of
transmission.
2. Apply a thin coat of corrosion preventive compound (C-104) under the heads and to shanks of bolts (19).
3. Install bolts (19) with washers (18) under bolt heads. Torque bolts (19) 130 to 140 in.-lbs. (14,69 to 15,82 Nm).
4. Secure bolts (19) in pairs using lockwire (C-405).
5. Apply a thin coat of corrosion preventive compound (C-101) to the heads of bolts (19) and washers (18).
6. Install hub and sleeve assembly (module 62-31-04 paragraph "3. Hub and sleeve assembly - installation").
7. Position clevis (5) on trunnion (2).
8. Apply a thin coat of corrosion preventive compound (C-104) under the head and to shank of bolt (3).
9. Install bolt (3) with washer (4) under bolt head.
10. Install nut (8) with washers (6 and 7) as required to attain proper thread engagement for cotter pin (9). Install cotter
pin (9).
11. Apply a thin coat of corrosion preventive compound (C-101) to the head of bolt (3), washer (4), nut (8) with washers
(6 and 7), and cotter pin (9).
15. Install nut (16) with washers (14 and 15) as required to attain proper thread engagement for cotter pin (17). Install
cotter pin (17).
16. Apply a thin coat of corrosion preventive compound (C-101) to the head of bolt (12), washer (13), nut (16) with
washers (14 and 15), and cotter pin (17).
20. Install nut (25) with washers (23 and 24) as required to attain proper thread engagement for cotter pin (26). Install
cotter pin (26).
21. Apply a thin coat of corrosion preventive compound (C-101) to the head of bolt (21), washer (22), nuts (25) with
washers (23) and (24), and cotter pin (26).
62-31-02
Page 2
E-AB412-PT6T-2
G6AB0586A
Figure 1. Swashplate and support
62-31-02
Page 3
E-AB412-PT6T-2
4. SWASHPLATE AND SUPPORT ASSEMBLY - CLEANING
MATERIALS REQUIRED
NUMBER NOMENCLATURE
NOTE
Do not allow solvent to saturate trunnion bearings, gimbal ring bearings or thrust
bearing in swashplate inner ring.
1. Clean swashplate and support assembly (1, figure 1) with clean cloth damp with drycleaning solvent (C-304).
5. SWASHPLATE AND SUPPORT ASSEMBLY - INSPECTION
NOTE
If records or physical appearance indicate swashplate and support assembly has been
involved in an accident or incident, refer to E-AB412-PT6T-6 for inspection
requirements.
Refer to E-AB412-PT6T-3 manual for instructions to inspect swashplate and support assembly.
6. SWASHPLATE AND SUPPORT ASSEMBLY - REPAIR
Refer to E-AB412-PT6T-3 manual for repair limits and procedures.
62-31-02
Page 4
E-AB412-PT6T-2
62-31-03
MAIN ROTOR CONTROLS - MAIN ROTOR PITCH LINK ASSEMBLIES
1. MAIN ROTOR PITCH LINK ASSEMBLIES - DESCRIPTION
The pitch links are composed of a tube, two swaged inserts, two adjustable rod end bearings with lock nuts, a nameplate and
decal. The pitch link assemblies connect the semi-circular pitch horn on the blade spindle to the rephasing levers on hub and
sleeve.
2. MAIN ROTOR PITCH LINK ASSEMBLIES - REMOVAL
1. Removal of pitch link with elastomeric lower rod end bearing:
a. With boost off, center cyclic and pull collective up as high as possible.
b. Remove lockwire from bolt (23, figure 1) and remove bolt (23) with washer (24) from rephasing lever (25).
c. Remove cotter pin (22), nut (21), washer (20), and bushing (19) from bolt (17).
d. Remove bolt (17) with washer (18) and bushing (19) from rephrasing lever (25).
e. Remove cotter pin (11), nut (10), and washer (9) from bolt (6).
f. Remove bolt (6) with washer (7) and separate pitch link (13) from pitch horn (5) and rephasing lever (25).
g. Repeat steps a. through d. to remove remaining pitch links.
2. Removal of pitch link with uniball teflon lined bearing:
a. With boost off, center cyclic and pull collective up as high as possible.
b. Remove cotter pin (30, detail B), nut (31), bolt (17), washer (34), long bushing (32), bracket (33), and short
bushing (35) from rephasing lever (25).
c. Remove cotter pin (11), nut (10), washers (9 and 7), bolt (6), and separate pitch link (13) from pitch horn (5) and
rephasing lever (25).
d. Repeat steps a. through c. to remove the remaining pitch links.
3. MAIN ROTOR PITCH LINK ASSEMBLIES - INSTALLATION
MATERIALS REQUIRED.
NUMBER NOMENCLATURE
C-405 LOCKWIRE
62-31-03
Rev. 1 Page 1
E-AB412-PT6T-2
1. Main rotor hub 11. Cotter pin 21. Nut

2. Pitch horn (upper yoke) 12. Nut 22. Cotter pin
3. Pitch horn (lower yoke) 13. Pitch link 23. Bolt
4. Pitch horn (lower yoke) 14. Nut 24. Steel washer
5. Pitch horn (upper yoke) 15. Rod end bearing 25. Rephasing lever
6. Bolt 16. Pitch link 26. Pitch link
7. Steel washer 17. Bolt 27. Pitch link
8. Rod end bearing 18. Washer (140-007-25S-20C4) 28. Upper yoke
9. Steel washer 19. Bushing 29. Lower yoke
10. Nut 20. Thin steel washer
NOTE:
1 Verify that the thickness of pitch horn (5) and two washers (7 and 9) exceeds the
grip length of the bolt (6). If not, add one NAS1149C0532R washer between nut
(10) and washer (9) (post SB 412-65).
G6AB0587B
Figure 1. Main rotor pitch link (sheet 1 of 2)
62-31-03
Page 2 Rev. 1
E-AB412-PT6T-2
30. Cotter pin

31. Nut
32. Long bushing
33. Bracket
34. Washer
35. Short bushing
36. Anti-rotation pin
G6AB0588B
Figure 1. Main rotor pitch link (sheet 2 of 2)
62-31-03
Rev. 1 Page 3
E-AB412-PT6T-2
NOTE
The two shorter pitch links (16 and 26, figure 1) are installed on pitch horns (3 and
4) of lower yoke (29). The longer pitch links (13 and 27) are installed on pitch horns
(2 and 5) and can be identified for installation in correct position by color code
markings or pitch link tube dimensions (figure 2).
rotating control nuts, washers, and bolt heads after their installation.
1. If not previously accomplished, adjust pitch link to initial setting dimensions (figure 2).
NOTE
Steps 2.a. through 2.c. are required for pitch links with lower elastomeric rod ends
only.
2. Select pitch link to be installed by color code or pitch link tube dimension. Refer to NOTE preceding step 1. above.
During installation of pitch links, ensure links are installed such that any elastomeric bearing has zero torsional preload
at flat pitch when swashplate is level with respect to mast. This may be accomplished as follows:
a. Center cyclic to maintain swashplate level in respect to mast.
b. Lower collective lever until down stop is contacted.
c. Rotate rotor until lower link of control system in which link (swashplate link or pitch link) is being installed is
directly forward of mast and over center line of helicopter (within 10). All links of control system shall be
installed in this manner to ensure any cyclic input to swashplate will not be a significant factor.
3. To install pitch link with elastomeric bearing proceed as follows:
a. Install link so elastomeric bearing is within one serration of being parallel to mast.
NOTE
All bolts installed in rotating controls are to be installed with heads in direction of
rotation.
b. Position upper end of pitch link (12, figure 1) in pitch horn (5).
c. Apply a thin coat of corrosion preventive compound (C-104) under the head and to shank of bolt (6).
d. Install bolt (6), washer (7 and 9), and nut (10).
NOTE
Verify that the thickness of the pitch horn (5) and two washers (7 and 9) exceeds the
spindle length of the bolt (6). If not, add one NAS1149C0532R washer between nut
(10) and washer (9).
e. Torque nut (10) 100 to 140 lbf·in (11,30 to 15,82 Nm). Install cotter pin (11).
f. Apply a thin coat of corrosion preventive compound (C-101) to the head of bolt (6) and washer (7), washer (9),
nut (10), and cotter pin (11).
g. Position rod end bearing (15) on rephasing lever (25) with serrated face of lower rod end bearing facing bushing
(19) as shown on detail A.
h. Apply a thin coat of corrosion preventive compound (C-104) under the head and to shank of bolt (17).
62-31-03
Page 4 Rev. 1
E-AB412-PT6T-2
i. Install bolt (17) with washer (18) under bolt head.
j. Install bushing (19), washer (20) and nut (21). Do not torque nut (21) at this time.
k. Ensure serrations of bushing (19) and rod end bearing (15) are properly engaged.
l. Install bolt (23) and washer (24), and torque bolt (23) 30 to 40 lbf·in (3,39 to 4,52 Nm).
m. Secure bolt (23) to bushing (19) with lockwire (C-405).
n. Torque nut (21) 165 to 200 lbf·in (18,64 to 22,50 Nm). Install cotter pin (22).
o. Apply a thin coat of corrosion preventive compound (C-101) to head of bolt (17), washer (18), washer (20), nut
(21), cotter pin (22), washer (24), and bolt (23).
4. To install pitch link with uniball teflon lined bearing:
NOTE
All bolts in rotating controls are to be installed with heads in direction of rotation.
a. Position upper end of pitch link (13, figure 1) in pitch horn (5).
b. Apply a thin coat of corrosion preventive compound (C-104) under the head and to shank of bolt (6).
c. Install bolt (6), washer (7 and 9), and nut (10).
d. Torque nut (10) 100 to 140 lbf·in (11,30 to 15,82 Nm). Install cotter pin (11).
e. Apply a thin coat of corrosion preventive compound (C-101) to the head of bolt (6) and washer (7), washer (9),
nut (10), and cotter pin (11).
f. Install short bushing (35) into inside flange of bracket (33). Detail B (pitch link lower end).
g. Position bracket (33) at end of rephasing lever (25) arm in alignment with rod end (15) and anti-rotation pin (36).
h. Install long bushing (32) into side of bracket (33) with head of bushing opposite direction of rotation as shown
in detail B.
i. Apply a thin coat of corrosion preventive compound (C-104) under the head and to shank of bolt (17).
j. Install washer (34) under head of bolt (17). Push bolt (17) through bushings in bracket (33), rod end (15), and
rephasing lever (25).
k. Install nut (31).
l. Torque nut (31) 165 to 200 lbf·in (18,64 to 22,60 Nm). Install cotter pin (30).
5. Repeat steps 3. or 4., as applicable, to install remaining pitch links.
6. Center rod end bearing (8) in pitch horn clevis (5).
7. Torque nut (12) 120 to 150 lbf·in (13,56 to 16,95 Nm).
8. Secure nut (12) to insert (3, figure 3) with lockwire (C-405).
9. Center rod end bearing (15, figure 1) in rephasing lever clevis (25).
10. Torque nut (14) 120 to 150 lbf·in (13,65 to 16,95 Nm).
11. Secure nut (14) to insert (6, figure 3) with lockwire (C-405).
12. Repeat steps 1. through 10. to install remaining pitch links.
62-31-03
Rev. 1 Page 5
E-AB412-PT6T-2
NOTES:
1 After initial setting: Exposed threads on rod and bearings (dimensions “C” and “D”) must be equal within
two threads.
After installation and rigging: Maximum exposed threads shall not exceed eleven at dimensions “C” and
eight at dimension “D”.
G6AB0589B
Figure 2. Main rotor pitch link assembly initial dimensions
62-31-03
Page 6 Rev. 1
E-AB412-PT6T-2
1. Rod end bearing

2. Nut
3. Insert
4. Name plate
5. Decal
6. Insert
7. Nut
8. Rod end bearing
9. Tube
G6AB0590B
Figure 3. Main rotor pitch link assembly
62-31-03
Rev. 1 Page 7
E-AB412-PT6T-2
4. MAIN ROTOR PITCH LINK ASSEMBLIES - CLEANING
MATERIALS REQUIRED
NUMBER NOMENCLATURE
NOTE
Do not immerse rod end bearing (8 and 15, figure 1) in solvent (C-304).
1. Wipe pitch link (13) with clean cloth damp with drycleaning solvent (C-304).
2. Dry with filtered, compressed air.
5. MAIN ROTOR PITCH LINK ASSEMBLIES - INSPECTION
1. Inspect pitch link assemblies (13, 16, 26, and 27, figure 1) for damage in accordance with E-AB412-PT6T-3 manual.
2. Inspect bushings (19) for cracks and damage (E-AB412-PT6T-3).
3. Inspect bolts (6, 17, and 23) for thread damage distortion and corrosion.
4. Inspect rod end bearings (8 and 15) for wear (E-AB412-PT6T-3).
6. MAIN ROTOR PITCH LINK ASSEMBLIES - REPAIR
MATERIALS REQUIRED
NUMBER NOMENCLATURE
C-210 PAINT
NOTE
Repair is restricted to polishing out damage and replacing rod end bearings, decal,
and nameplates.
1. Polish out mechanical and corrosion damage within limits (E-AB412-PT6T-3).
2. Apply chemical film material (C-100) to all bare aluminum areas (Appendix I).
3. Apply paint (C-210) to areas where metal is exposed (Appendix I).
4. Touch up paint to match existing finish (Appendix I).
5. Replace rod end bearing (1 and 8, figure 3) if rod end bearings are worn beyond limits (E-AB412-PT6T-3) as follows:
62-31-03
Page 8 Rev. 1
E-AB412-PT6T-2
a. Loosen nut (2) and remove rod end bearing (1) from tube (9).
b. Remove nut (2) from rod end bearing (1).
c. Apply light coat of corrosion preventive compound (C-104) to threads of new rod end bearing.
d. Install nut (2) on rod end bearing (1).
e. Install rod end bearing (1) on tube (9).
f. Repeat steps a. through e. to replace opposite rod end bearing (8).
g. Adjust pitch link to initial setting dimension (figure 2).
h. Tighten nut (2, figure 3) enough to hold set dimensions. Do not torque nut at this time.
62-31-03
Rev. 1 Page 9
E-AB412-PT6T-2
62-31-03
Page 10 Rev. 1
E-AB412-PT6T-2
62-31-04
MAIN ROTOR CONTROLS - HUB AND SLEEVE ASSEMBLY
1. HUB AND SLEEVE ASSEMBLY - DESCRIPTION
The hub and sleeve assembly consists of four rephasing levers and a rotating hub splined to mast and mounted through ball
bearings on upper end of non-rotating collective sleeve. The collective hub and sleeve operates between the swashplate and
support assembly and mast, and is actuated by collective lever attached to lower end. The inboard ends of rephasing levers
are connected to the hub. On helicopters code [A][B], one rephasing lever is connected to the drive link and three rephasing
levers are connected to swashplate links. On helicopters code [C][D] and helicopters modified by S.B. 412-70 and S.B.
412-76, the rephasing levers are connected to two drive links and two swashplate links. The outboard ends of rephasing
levers are connected to pitch horns by four pitch links which transmit collective and cyclic control motions to the main rotor
hub and blade assembly.
2. HUB AND SLEEVE ASSEMBLY - REMOVAL
1. Remove main rotor hub and blade assemblies (module 62-11-01 paragraph "2. Main rotor blades - removal" and
module 62-21-01 paragraph "2. Main rotor hub - removal").
2. Cut and remove lockwire from dust boot (3, figure 1). Remove dust boot (3) and spacer (2) from mast (1).
3. Prior to removal of hub and sleeve assembly, measure spline wear on collective pitch drive plate set (4) (paragraph "5.
Hub and sleeve assembly - inspection").
4. Remove four pitch link assemblies (5) from rephasing levers (6, 7, 35, and 36) (module 62-31-03 paragraph "2. Main
rotor pitch link assemblies - removal").
5. Cut and remove lockwire from bolt (25) and remove bolt (26) with washer (26).
6. Remove cotter pin (29), nut (30), washer (27), bolt (21), washer (22) and anti-torque bushing (23).
7. Separate swashplate link (33) from outer ring (31).
8. Repeat steps 5., 6., and 7. to disconnect opposite swashplate link (34) and (41), if installed.
9. Remove cotter pin (12), nut (13), and safety washer (11). Separate rephrasing lever drive link (8) from outer ring (31).
10. Remove washer (15) from stud on outer ring (31).
11. Remove cotter pin (39, detail B), nut (40) and safety washer (38). Separate swashplate link (41) from outer ring (31).
Repeat for opposite swashplate link, if installed.
12. Remove washer (37) from stud on outer ring (31).
13. Cut and remove lockwire from bolt (16) and remove bolt (16), washer (17), collective lever pin (18), shim (19), or
shim (20).
14. Index shim (19) and if installed, shim (20), for reinstallation in same location.
15. Repeat steps 13. and 14. to remove opposite collective lever pin (18) on collective levers.
62-31-04
Rev. 2 Page 1
E-AB412-PT6T-2
16. Cut and remove lockwire from four screws (10) and remove four screws (10) and remove bearing and liner (9)
17. Repeat step 16. to remove opposite bearing and liner (9).
18. Remove collective pitch drive plate set (4) (module 62-31-08 paragraph "1. Collective pitch drive plate set - removal").
19. Carefully lift hub and sleeve assembly from swashplate.
62-31-04
Page 2 Rev. 2
E-AB412-PT6T-2
G6AB0591B
Figure 1. Hub and sleeve (sheet 1 of 3)
62-31-04
Rev. 2 Page 3
E-AB412-PT6T-2
1. Mast 22. Washer (140-007-25S-20C4)

2. Spacer 23. Anti-torque bushing
3. Dust boot 24. Bushing
4. Collective pitch drive plate set 25. Bolt
5. Pitch link 26. Steel washer
6. Rephasing lever 27. Steel washer
7. Rephasing lever 28. Interrupter bracket
8. Rephasing lever drive link 29. Cotter pin
9. Bearing and liner assembly 30. Nut
10. Screw 31. Outer ring
11. Safety washer 32. Collective sleeve
12. Cotter pin 33. Swashplate link
13. Nut (412-010-406-111)
14. Collective lever 34. Swashplate link
15. Washer (140-009D41S60) 35. Rephasing lever
16. Bolt 36. Rephasing lever
17. Steel washer 37. Washer (140-009D41S60)
18. Collective lever pin 38. Safety washer
19. Shim (Helicopter equipped 39. Cotter pin
with collective lever pin P/N 40. Nut
412-010-422-101) 41. Swashplate link
20. Shim (Helicopter equipped (412-010-406-113)
with collective lever pin P/N 42. Liner
412-010-422-103) 43. Bearing
21. Bolt
G6AB0592B
62-31-04
Page 4 Rev. 2
E-AB412-PT6T-2
NOTE:
Apply sealant MIL -R-46082, TYPE I (C-352) to faying surfaces as indicated by shading.
1 Ensure that no sealant is allowed to enter the bearing.
G6AB0593B
62-31-04
Rev. 2 Page 5
E-AB412-PT6T-2
3. HUB AND SLEEVE ASSEMBLY - INSTALLATION
MATERIALS REQUIRED
NUMBER NOMENCLATURE
C-308 SEALANT
C-325 ADHESIVE
C352 SEALANT
C-405 LOCKWIRE
C-561 GREASE
NOTE

rotating control nuts, washers, and bolt heads after there installation.
1. Apply grease (C-561) to splines of mast and collective pitch drive plate set (4, figure 1).
2. Remove collective pitch drive plate set (4) from hub and sleeve if not previously accomplished (module 62-31-08
paragraph "2. Collective pitch drive plate set - installation").
3. Carefully position hub and sleeve assembly on mast (1) and lower hub and sleeve assembly into swashplate.
4. If replacing bearing (43), proceed as follows:
a. Clean all faying surfaces with denatured alcohol (C-326).
b. Refer to detail C. Apply sealant (C-352) sparingly to outside diameter of bearing (42) in liner (43).
c. While sealant is still wet, install bearing (42) in liner (43).
5. Refer to detail C. Clean all faying surfaces with denatured alcohol (C-326). Apply sealant (C-352) sparingly to faying
surfaces of liner (42), collective sleeve (32) and screws (10).
6. While sealant is still wet, position bearing and liner assembly (9) on collective sleeve (32) and install four screws (10).
7. Torque screws (10) evenly 20 to 25 in-lbf (2.26 to 2.82 Nm).
8. Secure screws (10) together in pairs using lockwire (C-405).
9. Repeat steps 4. through 8. to install opposite bearing and liner (9).
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E-AB412-PT6T-2
10. Install pin (18) (module 62-31-09 paragraph "2. Collective lever assembly - installation (helicopters configured with
collective lever pin p/n 412-010-422-101)" or paragraph "3. Collective lever assembly - installation (helicopters
configured with collective lever pin p/n 412-010-422-103)").
11. Install washer (15) on stud of outer ring (31) and position rephrasing lever drive link (8) on swashplate outer ring (31).
12. Install safety washer (11), with raised lip toward drive link bearing, and nut (13).
13. Torque nut (13) 480 to 690 in-lbf (54.23 to 77.96 Nm). Install cotter pin (12).
14. If second drive link is installed, repeat steps 11. through 13., then proceed to steps 19. or 20., as required.
15. Install washer (37) on stud of outer ring (31).
16. Position swashplate link (41) on outer ring (31).
17. Install safety washer (38), with raised lip toward swashplate link bearing, and nut (40).
19. To install swashplate link assembly with elastomeric bearings, proceed as follows:
a. Position swashplate link (33) on outer ring (31) with serrated face of rod end bearing toward anti-torque bushing
(23) (detail A).
b. Install anti-torque bushing (23) with serrated face of bushing in contact with serrated face of rod end bearing
(detail A).
c. Apply a thin coat of corrosion preventive compound (C-104) under the head and to shank of bolt (21).
d. Install bolt (21) with washer (22) under head of bolt.
e. Install washer (27) and nut (30) on bolt (20). Do not torque nut at this time.
f. Apply a thin coat of corrosion preventive compound (C-104) under the head and to shank of bolt (25).
g. Install bolt (25) with washer (26) under head of bolt.
h. Torque bolt (25) 30 to 40 in-lbf (3.39 to 4.52 Nm).
i. Secure bolt (25) to bushing (23) using lockwire (C-405).
j. Torque nut (30) 165 to 200 in-lbf (18.64 to 22.60 Nm). Install cotter pin (29).
k. Apply a thin coat of corrosion preventive compound (C-101) to nut (30), to head of bolt (21) and washer (22),
and to head of bolt (25) and washer (26).
20. To install swashplate link assembly with uniball teflon lined bearing, proceed as follows:
a. Install lower end of swashplate link (33) with head of bolt (21) in direction of rotation.
b. Apply a thin coat of corrosion preventive compound (C-104) under the head and to the shank of bolt (21).
c. Install washer (22) under bolt head (21).
d. Slide bushing (24) into swashplate outer ring (31).
e. Install bolt (21) with washer (10) through bushing (24), swashplate link (33), and outer ring (31).
f. Install interrupter bracket (28) and nut (30).
g. Torque nut (30) 165 to 200 in-lbf (18.64 to 22.60 Nm) and secure with cotter pin (29).
62-31-04
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E-AB412-PT6T-2
21. Repeat steps 13.a. through 13.k. to install remaining swashplate link.
CAUTION
ENSURE THAT NO SEALANT IS ALLOWED TO ENTER BEARINGS
22. Install collective pitch driveplate set (4) (module 62-31-08 paragraph "2. Collective pitch drive plate set - installation")
23. Install dust boot (3) and spacer (2).
24. Bond flap and closure of boot (3) together at junction using adhesive (C-325).
25. Seal spacer (2) where ends come together with sealant (C-308).
26. Secure boot to mast (1) and collective pitch drive plate set (4) using lockwire (C-405).
27. Lubricate hub and sleeve assembly (Chapter 12).
28. Confirm control rigging is within limits (Chapter 67).
4. HUB AND SLEEVE ASSEMBLY - CLEANING
MATERIALS REQUIRED
NUMBER NOMENCLATURE
C-304 SOLVENT
CAUTION
DO NOT IMMERSE HUB AND SLEEVE ASSEMBLY IN SOLVENT.
1. Clean hub and sleeve assembly with clean cloth damp with solvent (C-304).
5. HUB AND SLEEVE ASSEMBLY - INSPECTION
NOTE
If records or physical appearance indicate hub and sleeve assembly has been
involved in an accident or incident, refer to E-AB412-PT6T-6 for inspection
requirements.
1. Inspect hub and sleeve assembly teflon lined rod end bearings (installed) as required by E-AB412-PT6T-6 Manual and
figure 2.
2. Inspect boot (3, figure 1) for tears, cracks, and deterioration.
62-31-04
Page 8 Rev. 2
E-AB412-PT6T-2
NOTE
The hub and sleeve assembly must be installed on main rotor mast to accomplish the
following step.
3. Inspect spacer (2) for damage and deterioration.
4. Measure spline wear on collective drive plate set (7, figure 3).
5. Inspect safety washers (11 and 38, figure 1) for distortion and cracks. Superficial damage is acceptable without repair.
6. Hold collective sleeve (32) and rotate hub. Check bearing set by feel for looseness and/or binding. If looseness and/or
binding is detected, inspect in accordance with procedures contained in E-AB412-PT6T-3 manual.
7. Inspect anti-torque bushing (23) for damage or distortion and wear which would prevent locking rod end bearing.
8. For remainder of hub and sleeve components, inspect in accordance with procedures contained in E-AB412-PT6T-3
manual.
62-31-04
Rev. 2 Page 9
E-AB412-PT6T-2
DIMENSIONS DIMENSION METRIC

PITCH LINK FOR
A B A B
UPPER YOKE 20.770 in 16.64 in 527.558 mm 422.65 mm

20.750 in 16.61 in 527.050 mm 421.89 mm
LOWER YOKE 19.025 in 14.985 in 483.235 mm 380.619 mm

19.005 in 15.015 in 482.727 mm 381.381 mm
NOTES:
1 After initial setting: Exposed threads on rod and bearings (dimensions “C” and “D”) must be equal within two threads.
After installation and rigging: Maximum exposed threads shall not exceed eleven at dimensions “C” and eight at dimension
“D”.
G6AB0589C
Figure 2. Main rotor pitch link assembly initial dimensions
62-31-04
Page 10 Rev. 2
E-AB412-PT6T-2
1. Mast
2. Magnet
3. Dial indicator
4. Indicator probe
5. Bolt
6. Hub assembly
7. Drive plate set
NOTES:
Attach dial indicator (3) to mast (1) with magnet (2). Position indicator probe (4) in contact
with a flat of bolt (5) (Flange attaching bolt). Move hub (6) back and forth, in plane of rotation
and measure amount of play.
Maximum acceptable radial play allowed between mast (1) and plate set drive (7) is 0.040 in
(1.01 mm).
G6AB0594B
Figure 3. Collective drive plate set - damage limits
62-31-04
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E-AB412-PT6T-2
6. HUB AND SLEEVE ASSEMBLY - INSPECTION OF TEFLON LINED BEARINGS

(INSTALLED)
1. Fabricate work aid as shown on figure 4, Detail A.
NOTE
Inspection procedure is typical for all four pitch change links.
2. Hook work aid (2, figure 5) on pitch horn (3) and pull down to relieve loading. Pitch change link loading occurs from
main rotor elastomeric bearings.
3. Grasp pitch link (4) and move in a direction to permit a check for axial looseness of the pitch link rod end bearings
(teflon lined) (1 and 9). Maximum acceptable axial wear in pitch link rod end bearings (teflon lined) (1 and 9) is 0.015
in (0.381 mm).
4. Grasp swashplate link (8) and attempt to move axially. Maximum acceptable axial wear in swashplate link rod end
bearing (teflon lined) (7) is 0.015 in (0.381 mm).
5. Grasp drive link (5) and attempt to move axially. Maximum acceptable axial wear in drive link rod end bearing (teflon
lined) (6) is 0.015 in (0.381 mm).
6. Replace pitch link rod end bearings (1 and 9) exceeding maximum acceptable wear (E-AB412-PT6T-3).
7. Replace swashplate link rod end bearing (7) exceeding maximum acceptable in swashplate link rod end bearing
(E-AB412-PT6T-3).
8. Replace drive link rod end bearing (6) exceeding maximum acceptable wear (E-AB412-PT6T-3).
7. HUB AND SLEEVE ASSEMBLY - REPAIR
NOTE
Repair of hub and sleeve assembly is restricted to polishing out mechanical and
corrosion damage and installation of new parts such as bearing and liner assembly,
drive link assembly, swashplate link assembly, and rephasing lever drive assembly.
Refer to E-AB412-PT6T-3 manual for mechanical and corrosion damage limits and
repair procedures and limits.
62-31-04
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E-AB412-PT6T-2
G6AB0595A
Figure 4. Swashplate link and drive link bearings - work aid
62-31-04
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E-AB412-PT6T-2
1. Pitch link rod end bearing (teflon lined)

2. Work aid
3. Pitch horn
4. Pitch link
5. Drive link
6. Drive link bearing (teflon lined)
7. Swashplate link rod end bearing (teflon lined)
(on lower end of swashplate link)
8. Swashplate link
9. Pitch link rod end bearing (teflon lined)
G6AB0596B
Figure 5. Hub and sleeve assembly teflon bearing inspection
62-31-04
Page 14 Rev. 2
E-AB412-PT6T-2
62-31-05
MAIN ROTOR CONTROLS - REPHASING LEVERS
1. REPHASING LEVERS - REMOVAL
NOTE
On helicopters codes [A] [B], one rephasing lever is connected to the drive link and
three rephasing levers are connected to swashplate links. On helicopters codes [C]
[D], the rephasing levers are connected to two drive links and two swashplate links.
1. Remove rephasing lever (2, figure 1) with swashplate (3) link attached as follows:
a. Remove pitch link (1) with uniball or elastomeric rod end bearings from rephasing lever (2) (module 62-31-03
paragraph "2. Main rotor pitch link assemblies - removal").
b. Remove swashplate link (3) with uniball or elastomeric rod ends from rephasing lever (2) (module 62-31-07
paragraph "1. Swashplate link assembly - removal").
c. Remove cotter pin (4), nut (5), washer (6), bolt (7), washer (8), and washers (9 and 10). Discard cotter pin (4).
d. Lift rephasing lever (2) from hub (11).
e. Repeat step 1. for remaining rephasing levers with swashplate links attached.
2. Remove rephasing lever (12) with drive link (13) attached, as follows:
a. Remove pitch link (14) with uniball or elastomeric rod end bearings from rephasing lever (12) (module 62-31-03
paragraph "2. Main rotor pitch link assemblies - removal").
b. Remove drive link (13) from rephasing lever (12) (module 62-31-06 paragraph "1. Drive link assembly -
removal").
c. Remove cotter pin (15), nut (16), washer (17), bolt (18), washer (19), and washers (20 and 21)).
d. Lift rephasing lever (12) from hub (22).
e. Repeat step 2. for remaining drive link, if installed.
2. REPHASING LEVERS - INSTALLATION
MATERIALS REQUIRED
NUMBER NOMENCLATURE
62-31-05
Page 1
E-AB412-PT6T-2
WARNING
IT IS POSSIBLE TO INSTALL REPHASING LEVER (2) INVERTED. ENSURE

REPHASING LEVER (2) IS INSTALLED ON HUB (10) WITH SHORT ARM
FOR ATTACHMENT OF SWASHPLATE LINK (3) ON SIDE IN DIRECTION OF
ROTATION OF MAST WHICH WILL AFFECT FLIGHT CONTROL RIGGING.
NOTE
On helicopters codes [A] [B], one rephasing lever is connected to the drive link and
three rephasing levers are connected to swashplate links. On helicopters codes [C]
[D], the rephasing levers are connected to two drive links and two swashplate links.
1. Install rephasing lever (2, figure 1) with swashplate link as follows:
NOTE
Refer to figure 1 for correct usage of washer (10).
a. Position rephasing lever (2, figure 1) on hub (11) with washers (9 and 10).
c. Install bolt (7) with washer (8) under bolt head.
d. Install washer (6) and nut (4).
e. Torque nut (5) 24 to 34 ft.-lbs. (32,54 to 46,10 Nm). Install cotter pin (4).
f. Apply a thin coat of corrosion preventive compound (C-101) on nut (5) and washer (6) and to head of bolt (7)
and washer (8).
g. Install swashplate link (3) on rephasing lever (2) (module 62-31-07 paragraph "2. Swashplate link assembly -
installation").
h. Install pitch link (1) on rephasing lever (2) (module 62-31-03 paragraph "3. Main rotor pitch link assemblies -
installation").
i. Repeat step 1. for remaining rephasing levers (12) with swashplate links (3) installed.
WARNING
IT IS POSSIBLE TO INSTALL REPHASING LEVER (12) INVERTED. ENSURE

REPHASING LEVER (12) IS INSTALLED ON HUB (22) WITH SHORT ARM
FOR ATTACHMENT OF DRIVE LINK (13) ON SIDE IN DIRECTION OF
ROTATION OF MAST.
2. Install rephasing lever (12) with drive link (13) as follows:
NOTE
a. Position rephasing lever (12, figure 1) on hub (22) with washers (20 and 21).
c. Install bolt (18) with washer (19) under bolt head.
62-31-05
Page 2
E-AB412-PT6T-2
d. Install washer (17) and nut (16).
e. Torque nut 24 to 34 ft.-lbs. (32,54 to 46,10 Nm). Install cotter pin (15).
f. Apply a thin coat of corrosion preventive compound (C-101) on nut (16) and washer (17) and to head of bolt
(18) and washer (19).
62-31-05
Page 3
E-AB412-PT6T-2
On helicopters codes [C] [D] modified by S.B. 412-70

and S.B. 412-76 drives links are installed on both sides.
G6AB0597A
Figure 1. Rephasing lever installation
62-31-05
Page 4
E-AB412-PT6T-2
62-31-06
MAIN ROTOR CONTROLS - DRIVE LINK ASSEMBLY
1. DRIVE LINK ASSEMBLY - REMOVAL
1. Remove cotter pin (19, figure 1), nut (18), and safety washer (17).
2. Remove cotter pin (12), nut (13), washers (14, 15, 23, and 2), spacer (16), and bolt (1).
3. Remove cotter pin (4), nut (5), washers (6, 9, 10, and 7), spacer (11), and bolt (8).
4. Remove drive link (20).
2. DRIVE LINK ASSEMBLY - INSTALLATION
MATERIALS REQUIRED
NUMBER NOMENCLATURE
NOTE

rotating control nuts, washers, and bolt heads after their installation.
1. Position washer (21, figure 1) on stud (22).
2. Position drive link (20) on stud (22).
3. Install washer (17), with raised lip toward drive link (20). Install nut (18). Do not torque nut at this time.
4. Apply a thin coat corrosion preventive compound (C-104) under the head and to shank of bolt (8).
5. Assemble spacer (11), washer (9), washer (10) (if applicable) on drive link bearing and install bolt (8) with washer (7)
under bolt head.
6. Install washer (6) and nut (5). Do not torque nut at this time.
7. Apply a thin coat corrosion preventive compound (C-104) under the head and to shank of bolt (1).
NOTE
62-31-06
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E-AB412-PT6T-2
8. Assemble spacer (16) and washer (23) on drive link bearing and install bolt (1) with washer (2) under bolt head.
9. Install washers (15 and 14) and nut (13). Torque nut (13) 165 to 200 in-lbs (18.64 to 22.60 Nm). Install cotter pin (12).
12. Apply a thin coat of corrosion preventive compound (C-101) on head of bolt (8 and 1), nut (13) and washer (14), nut
(5) and washer (6), and nut (18) and washer (17).
62-31-06
Page 2 Rev. 2
E-AB412-PT6T-2
NOTES
1 Helicopters code [C] use washer P/N 412-010-423-103.
2 Not used on helicopters code [C].
3 Helicopters with drive link 412-010-445-111 installed, use washer 412-010-423-107.
1. Bolt 9. Drive washer (412-010-423-101) 17. Safety washer

2. Washer (104-007-25S20C4) 10. Drive washer (412-010-423-101) 18. Nut
3. Rephasing lever 11. Spacer (412-010-418-101) 19. Cotter pin
4. Cotter pin 12. Cotter pin 20. Drive link
5. Nut 13. Nut 21. Washer (140-009D-41S60)
6. Washer (140-009D-25S40) 14. Washer (140-009D25S72) 22. Stud
7. Washer (140-007-25S36C4) 15. Drive washer (412-010-423-101) 23. Drive washer (412-010-423-101)
8. Bolt 16. Spacer
G6AB0598B
Figure 1. Drive link
62-31-06
Rev. 2 Page 3
E-AB412-PT6T-2
62-31-06
Page 4 Rev. 2
E-AB412-PT6T-2
62-31-07
MAIN ROTOR CONTROLS - SWASHPLATE LINK ASSEMBLY
1. SWASHPLATE LINK ASSEMBLY - REMOVAL
On helicopters codes [A] [B], three rephasing levers are connected to swashplate links. On helicopters codes [C] [D], only
two swashplate links are used.
1. Remove swashplate link with elastomeric rod end bearings as follows:
a. Cut and remove lockwire from bolt (7, figure 1) and remove bolt (7) and washer (6).
b. Cut and remove lockwire from bolt (12) and remove bolt (12) and washer (13).
c. Remove cotter pin (16), nut (15), washer (14), bolt (9), washer (10) and anti-torque bushing (11).
d. Remove cotter pin (2), nut (3), washer (1), bolt (18), washer (21), and anti-torque bushing (5).
e. Remove swashplate link assembly (19).
f. Repeat step a. through step e. to remove opposite swashplate link assembly.
2. Remove swashplate link with uniball teflon lined bearing as follows:
a. Remove cotter pin (50, detail E), nut (49), interrupter bracket (48), bolt (9), bushing (47), and washer (10).
Discard cotter pin (50).
b. Remove cotter pin (43, detail D), nut (42), washer (41), short bushing (44), long bushing (39), and bracket (40).
c. Remove swashplate link assembly (45).
d. Repeat steps a. through c. to remove opposite swashplate link assembly.
3. Remove third swashplate link (helicopters codes [A] [B] only) as follows:
NOTE
Steps a. and b. are for swashplate links with elastomeric rod end bearings installed.
For swashplate links with uniball rod end bearings, perform step 2.b. from above in
lieu of steps a. and b.
a. Cut and remove lockwire from bolt (25) and remove bolt (25) and washer (24).
b. Remove cotter pin (36), nut (37), washer (35), bolt (31) with washer (34) under bolt head, and anti-torque
bushing (23).
c. Remove cotter pin (29) from nut (30) and remove nut (30) with safety washer (28).
d. Remove swashplate link assembly (32).
e. Remove washer (27) from stud of outer ring (26).
62-31-07
Rev. 2 Page 1
E-AB412-PT6T-2

2. Cotter pin
3. Nut
4. Rephasing lever driver
5. Anti-torque bushing
6. Steel washer
7. Bolt
8. Outer ring
9. Bolt
10. Washer (140-007-25S20C4)
12. Bolt
13. Steel washer
14. Steel washer
15. Nut
16. Cotter pin
17. Rod end bearing
18. Bolt
19. Swashplate link assembly
(412-010-406-111)
20. Rod end bearing
21. Washer (140-007-25S20C4)
NOTES:
Install rod end bearings (17,20 and 33) with serrated faces toward bushings (5,11 and 23) as
shown in detail A.
G6AB0599B
Figure 1. Swashplate link (sheet 1 of 3)
62-31-07
Page 2 Rev. 2
E-AB412-PT6T-2
22. Rephasing lever driver

24. Steel washer
25. Bolt
26. Outer ring
27. Washer (140-009D41S60)
28. Safety washer
29. Cotter pin
30. Nut
31. Bolt
32. Swashplate link (412-010-406-113)
33. Rod end bearing
34. Washer (140-007-25S20C4)
35. Steel washer
36. Cotter pin
37. Nut
G6AB0600B
62-31-07
Rev. 2 Page 3
E-AB412-PT6T-2
38. Bolt (20-057-6-52D)

39. Long bushing (412-010-461-105)
40. Bracket (412-310-401-101)
41. Washer (140-007-25S40C4)
42. Nut (MS14144L6)
43. Cotter pin (MS24665-302)
44. Short bushing (412-010-461-101)
45. Swashplate link (412-010-406-115)
46. Anti-rotation pin (ref)
47. Bushing (412-010-462-101)
48. Interrupter bracket (reuse)
49. Nut (MS14144L6)
50. Cotter pin (MS24665-302)
G6AB0601B
62-31-07
Page 4 Rev. 2
E-AB412-PT6T-2
2. SWASHPLATE LINK ASSEMBLY - INSTALLATION
MATERIALS REQUIRED
NUMBER NOMENCLATURE
C-405 LOCKWIRE
NOTE

rotating control nuts, washers, and bolt heads after installation.
1. If swashplate link assembly (19 or 32, figure 1) is to be installed in same position it was removed from without
changing dimensions, proceed to step 3.
CAUTION
IF NEW OR REPLACEMENT LINK ASSEMBLY IS BEING INSTALLED,

COMPLIANCE WITH INSTRUCTIONS IN STEP 2. IS MANDATORY TO
ENSURE ADEQUATE ROD END BEARING THREAD ENGAGEMENT IS
MAINTAINED.
2. If new or replacement swashplate link assembly (19 or 32) is to be installed, adjust link to dimensions outlined in
E-AB412-PT6T-3 manual.
3. To install swashplate link assembly with elastomeric bearing proceed as follows:
a. Apply a thin coat of corrosion preventive compound (C-104) under the head and to shank of bolt (7).
b. Position bushing (5) in rephrasing lever driver (4) and loosely install bolt (7) with washer (6).
c. Position swashplate link (19) 90  5 to centerline of rephasing lever driver (4).
d. Ensure serrations of anti-torque bushing (5) and swashplate link assembly (19) are properly engaged.
e. Apply a thin coat of corrosion preventive compound (C-104) under the head and to shank of bolt (18).
f. Install bolt (18) with washer (21) under bolt head and washer (1) and nut (3). Do not torque at this time.
g. Apply a thin coat of corrosion preventive compound (C-104) under the head and to shank of bolt (12).
h. Position anti-torque bushing (11) in outer ring (8) and loosely install bolt (12) and washer (13).
i. Position swashplate link driver (19) in outer ring (8).
j. Ensure serrations of bushing (11) and link (19) are properly engaged.
k. Apply a thin coat of corrosion preventive compound (C-104) under the head and to shank of bolt (9).
l. Install bolt (9) with washer (10) under bolt head, washer (14), and nut (15).
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E-AB412-PT6T-2
m. Torque nut (3) 165 to 200 in-lbs (18.64 to 22.60 Nm) and install cotter pin (2).
n. Torque bolt (7) 30 to 40 in-lbs (3.39 to 4.60 Nm). Secure bolt (7) to bushing (5) using lockwire (C-405).
o. Torque nut (15) 165 to 200 in-lbs (18.64 to 22.60 Nm), and install cotter pin (16).
p. Torque bolt (12) 30 to 40 in-lbs (3.39 to 4.60 Nm). Secure bolt (12) to bushing (11) using lockwire (C-405).
q. Apply a thin coat of corrosion preventive compound (C-101) to nut (3) and washer (1), head of bolt (7) and
washer (6), nut (15) and washer (14), and head of bolt (12) and washer (13).
r. Repeat steps a. through q. to install opposite swashplate link assembly.
4. To install swashplate link with uniball teflon lined bearing proceed as follows:
NOTE
The upper end of swashplate link assembly (45) incorporating anti-rotation pin (46)
rod end must be installed first.
a. Position short bushing (44) in bracket (40).
b. Position bracket (40) at end of rephasing lever driver (4) arm in alignment with swashplate link (45) anti-rotation
pin (46).
NOTE
Long bushing (39) passes through bracket (40), rephasing lever driver (4) bushings,
and bottoms against swashplate link (45) upper rod end.
c. Install long bushing (39) into side of bracket (40) with head of bushing in direction of rotation.
d. Apply a thin coat of corrosion preventive compound (C-104) under the head and to shank of bolt (38).
e. Install bolt (38) with head in direction of rotation through long bushing (39), swashplate link (45) and short
bushing (44). Install washer (41) and nut (42) finger tight.
f. Install lower end of swashplate link (45) with head of bolt (9) in direction of rotation.
g. Apply a thin coat of corrosion preventive compound (C-104) under the head and to shank of bolt (9).
h. Install washer (10) under bolt head (9).
i. Slide bushing (47) into swashplate outer ring (8).
j. Apply a thin coat of corrosion preventive compound (C-104) under the head and to shank of bolt (9).
k. Install bolt (9) with washer (10) through bushing (47), rod end (17), and swashplate outer ring (8).
l. Install interrupter bracket (48) and nut (49).
m. Torque nut (49) 165 to 200 in-lbs (18.64 to 22.60 Nm) and secure with cotter pin (50).
n. Torque nut (42) 165 to 200 in-lbs (18.64 to 22.60 Nm) and secure with cotter pin (43).
o. Apply a thin coat of corrosion preventive compound (C-101) to nut (49), head of bolt (9) and washer (10), and
nut (42) and washer (41).
5. Install third swashplate link (helicopters codes [A] [B] only) as follows:
a. Install washer (27) on stud of outer ring (26).
b. Position swashplate link assembly (32) on outer ring (26) and install safety washer (28) and nut (30).
c. Torque nut (30) 480 to 690 in-lbs (54.2 to 77.9 Nm) and install cotter pin (29).
62-31-07
Page 6 Rev. 2
E-AB412-PT6T-2
NOTE
Steps 5.d. through 5.i. are for swashplate links with elastomeric rod end bearings.
For swashplate links with uniball rod end bearings, perform steps 4.a. through 4.d. in
lieu of steps 5.d. through 5.i.
d. Position anti-torque bushing (23) in rephasing lever driver (22) and loosely install bolt (25) with washer (24).
e. Position swashplate link assembly (32) 90  5 to centerline of rephasing lever driver (22).
f. Ensure serrations of bushing (23) and swashplate link assembly (32) are properly engaged.
g. Install bolt (31) with washer (34) through rod end bearing (33).
h. Install washer (35) and nut (37) on bolt (31).
i. Torque bolt (25) 30 to 40 in-lbs (3.39 to 4.60 Nm), and secure bolt (25) to bushing (23) using lockwire (C-405).
j. Torque nut (37) 165 to 200 in-lbs (18.64 to 22.60 Nm) and install cotter pin (36).
62-31-07
Rev. 2 Page 7
E-AB412-PT6T-2
62-31-07
Page 8 Rev. 2
E-AB412-PT6T-2
62-31-08
MAIN ROTOR CONTROLS - COLLECTIVE PITCH DRIVE PLATE SET
1. COLLECTIVE PITCH DRIVE PLATE SET - REMOVAL
NOTE
The collective pitch drive plate set is a serial numbered, matched set.
1. Cut and remove lockwire from dust boot (2, figure 1) and remove dust boot (2) and spacer (1).
2. Remove eight nuts (10), aluminum washers (9), bolts (3), and aluminum washers (4).
3. Remove dust boot flange (5).
CAUTION
EXERCISE CARE WHEN REMOVING PLATE SET HALVES (6 AND 11) OR

SHIM (7) TO PREVENT DAMAGE.
4. Remove plate set halves (6 and 11).
5. If collective pitch drive plate set is not to be installed immediately, secure shim (7) to hub (8).
2. COLLECTIVE PITCH DRIVE PLATE SET - INSTALLATION
MATERIALS REQUIRED
NUMBER NOMENCLATURE
C-405 LOCKWIRE
CAUTION
SHIM (7, FIGURE 1) SHALL BE OF CORRECT THICKNESS TO GIVE 0.003

TO 0.005 IN (0.076 TO 0.127 MM) PINCH ON HUB BEARINGS. IF IT IS NOT
KNOWN WHETHER SHIM (7) IS OF CORRECT THICKNESS, REFER TO
E-AB412-PT6T-3 MANUAL TO ESTABLISH SHIM THICKNESS.
62-31-08
Rev. 2 Page 1
E-AB412-PT6T-2
NOTE

rotating control nuts, washers, and bolt heads after there installation.
1. Position plate set halves (6 and 11) on hub (8) and align as shown on detail A.
2. Position dust boot flange (5) on plate set halves.
3. Apply a thin coat of corrosion preventive compound (C-104) under the heads and to shanks of bolts (3).
4. Install bolts (3) with washers (4) under the heads of bolts, washers (9), and nuts (10). Torque nuts (10) 50 to 70 in-lbs
(5.65 to 7.91 Nm).
5. Apply a thin coat of corrosion preventive compound (C-101) to nut (49), head of bolts (3) and washers (4), and nuts
(10) and washers (9).
6. Install boot (2) and spacer (1). Secure boot (2) to mast (12) and boot flange (5) with lockwire (C-405).
62-31-08
Page 2 Rev. 2
E-AB412-PT6T-2
1. Spacer
2. Dust boot
3. Bolt
4. Aluminum washer
5. Dust boot flange
6. Plate set half
7. Shim
8. Hub
9. Aluminum washer
10. Nut
11. Plate set half
12. Mast
G6AB0602B
Figure 1. Collective pitch drive plate set
62-31-08
Rev. 2 Page 3
E-AB412-PT6T-2
62-31-08
Page 4 Rev. 2
E-AB412-PT6T-2
62-31-09
MAIN ROTOR CONTROLS - COLLECTIVE LEVER ASSEMBLY
1. COLLECTIVE LEVER ASSEMBLY - REMOVAL
1. Remove cotter pin (12, figure 1), nut (13), washer (10), washer (11), bolt (7), washer (8) and separate clevis (9) from
trunnion (6). Discard cotter pin (12).
2. Cut and remove lockwire from bolt (17) and remove bolt (17) and washer (18).
NOTE
When removing shims (20 or 23), reinstall shims in the same location and order of
removal.
3. Remove collective lever pin (19) and shims (20) or (23).
4. Repeat steps 2. and 3. to remove opposite collective lever pin (19).
NOTE
When removing washers (3 and 15) and spacers (4 and 16), reinstall in the same
location and order of removal.
5. Remove cotter pin (1), nut (2), washer (3), bolt (14), washer (15), spacers (4 and 16). Discard cotter pin (1).
6. Carefully remove collective lever assembly (5) from support (22).
2. COLLECTIVE LEVER ASSEMBLY - INSTALLATION (HELICOPTERS CONFIGURED

WITH COLLECTIVE LEVER PIN P/N 412-010-422-101)
MATERIALS REQUIRED
NUMBER NOMENCLATURE
C-352 SEALANT
C-405 LOCKWIRE
NOTE
It is possible to install collective lever (5, figure 1) in inverted position. Ensure
collective lever (5) is installed with slotted area for installation of trunnion (6) facing
down as illustrated.
1. Install collective lever (5, figure 1) on support (22) as follows:
2. Install bolt (14) with washer (15) under bolt head, and then install bushing (16).
62-31-09
Rev. 2 Page 1
E-AB412-PT6T-2
3. Install bushing (4), washer (3), and nut (2) on bolt (14).
NOTE
If shims (20, figure 1) have been set aside and are to be installed in same location as
removed, proceed to step 11. If new shims (20) are to be installed, accomplish steps
6. through 10.
5. Position collective lever pins (19), without shims (20), through either side of collective lever (5) into bearing (21).
6. Temporally install bolts (17) and washers (18).
7. Push collective lever (5) to one side and hold pressure.
8. Measure gap between bearing and liner (21) and shoulder of collective lever pin.
9. Prepare two shims (20) of equal thickness to within 0.005 in (0.127 mm). Total thickness of two shims shall be equal
to value recorded in step 8., add 0 to 0.004 in (0.102 mm). Maintaining these dimensions will result in a 0.000 to 0.002
in (0.000 to 0.051 mm) clamp up on each bearing when pins are installed.
10. Remove collective lever pin (19).
11. Clean lever bore (24), inside diameter of bearing (21) and outside diameter of pins (19) with denatured alcohol
(C-326).
CAUTION
ENSURE THAT NO SEALANT IS ALLOWED TO ENTER BEARINGS.
12. Refer to detail C. Coat all faying surfaces of shims (20), pins (19), lever bores (24), washers (18) and bolts (17) with
sealant (C-352).
NOTE
Accomplish following steps while sealant (C-352) is still wet.
13. Position collective lever pin (19) in each side of collective lever (5). Position shim (20), indexed at time of removal,
or new shim prepared at step 9., on each pin (19).
14. Carefully position collective lever (5), collective lever pins (19) and shims (20) on swashplate support assembly (22).
15. Ensure shim (20) is in position and insert pin (19) into bearing (21).
16. Install bolt (17) with washer (18), and torque bolt (17) 30 to 40 in-lbf (3.39 to 4.52 Nm).
17. Secure bolt (17) to pin (19) using lockwire (C-405).
18. Install opposite collective lever pin (19) in same manner.
19. Position clevis (9) on trunnion (6), and install bolt (7) with washer (8) under bolt head.
20. Install nut (13) with washers (10 and 11) as required to attain proper thread engagement for cotter pin (12), and install
cotter pin (12).
62-31-09
Page 2 Rev. 2
E-AB412-PT6T-2
(HELICOPTERS EQUIPPED WITH

COLLECTIVE LEVER PIN
P/N 412-010-422-101)
C
1. Cotter pin 15. Washer (140-007-335-28C4)
2. Nut 16. Spacer
3. Washer (AN960-816) 17. Bolt
4. Spacer 18. Steel washer
5. Collective lever 19. Collective lever pin
6. Trunnion 20. Shim (helicopters equipped with
7. Bolt collective lever pin P/N
8. Washer (AN960-C516) 412-010-422-101)
9. Clevis 21. Bearing and liner
10. Washer (AN960-C516) 22. Support
11. Washer (AN960-C516L) 23. Shim (helicopters equipped with
12. Cotter pin collective lever pin P/N (HELICOPTERS EQUIPPED WITH
13. Nut 412-010-422-103) COLLECTIVE LEVER PIN P/N
14. Bolt 24. Collective lever bore 412-010-422-103)
G6AB0610B
Figure 1. Collective lever (sheet 1 of 2)
62-31-09
Rev. 2 Page 3
E-AB412-PT6T-2
HELICOPTER EQUIPPED WITH

COLLECTIVE LEVER PIN 412-010-422-101
HELICOPTER EQUIPPED WITH

COLLECTIVE LEVER PIN 412-010-422-103
SEALANT (C-352)
NOTES:
1 Ensure that no sealant is allowed to enter the bearing.
2 Apply sealant MIL-R-46082, type I (C-352) to faying surfaces as indicated by shading.
G6AB0611B
Figure 1. Collective lever (sheet 2 of 2)
62-31-09
Page 4 Rev. 2
E-AB412-PT6T-2
3. COLLECTIVE LEVER ASSEMBLY - INSTALLATION (HELICOPTERS CONFIGURED

WITH COLLECTIVE LEVER PIN P/N 412-010-422-103)
MATERIALS REQUIRED
NUMBER NOMENCLATURE
C-352 SEALANT
C-405 LOCKWIRE
NOTE
It is possible to install collective lever (5, figure 1) in inverted position. Ensure
collective lever (5) is installed with slotted area for installation of trunnion (6) facing
down as illustrated.
1. Install collective lever (5, figure 1) on support (22) as follows:
2. Install bolt (14) with washer (15) under bolt head, and then install bushing (16).
3. Install bushing (4), washer (3), and nut (2) on bolt (14).
5. Position collective lever pins (19), without shims (23), through either side of collective lever (5) into bearing (21).
6. Install bolts (17) and washers (18) finger tight.
7. Push collective lever (5) to one side and hold pressure.
8. Measure distance between collective lever (5) and hold down flange of collective lever pins (19). Record dimension
and remove collective lever pins.
9. Prepare two shims (23, detail B) of equal thickness to within 0.005 in (0.127 mm). Total thickness of two shims shall
be equal to value recorded in step 7. minus up to 0.004 in (0.102 mm). Maintaining these dimensions will result in a
0.000 to 0.002 in (0.000 to 0.051 mm) clamp up on each bearing when pins are installed.
10. Clean lever bores (24), inside diameter of bearing (21) and outside diameter of pins (19) with denatured alcohol
(C-326).
CAUTION
ENSURE THAT NO SEALANT IS ALLOWED TO ENTER BEARINGS.
11. Refer to detail C. Coat all faying surfaces of shims (23), pins (19), lever bores (24), washer (18) and bolts (17) with
sealant (C-352).
NOTE
Accomplish following steps while sealant (C-352) is still wet.
12. Install shims (23) prepared in step 9. equally on pins (19) and install pins in each side of collective lever (5).
62-31-09
Rev. 2 Page 5
E-AB412-PT6T-2
13. Ensure end of each pin is engaged in collective lever sleeve bearings (21).
CAUTION
WHEN INSTALLING BOLT (17), ENSURE THAT THE BOLT (17) HAS NOT
BOTTOMED OUT IN THE COLLECTIVE LEVER OR THE GRIP HAS
BECOME THREAD BOUND. EITHER CONDITION WOULD RESULT IN
LOWER THAN SPECIFIED TORQUE ON THE PIN EVEN THOUGH TORQUE
HAS BEEN VERIFIED.
15. Torque bolts (17) 30 to 40 in-lbf (3.39 to 4.52 Nm) and secure bolts with lockwire (C-405).
16. Position clevis (9) on trunnion (6). Install bolt (7) with washer (8) under bolt head.
17. Install nut (13) with washers (10 and 11) as required to attain proper thread engagement for cotter pin (12). Install cotter
pin (12).
4. COLLECTIVE LEVER ASSEMBLY - CLEANING
MATERIALS REQUIRED
NUMBER NOMENCLATURE
CAUTION
DO NOT IMMERSE COLLECTIVE LEVER ASSEMBLY IN SOLVENT.
1. Carefully clean collective lever (5, figure 1) with clean cloth damp in solvent (C-304).
2. Dry collective lever (5) with filtered, compressed air.
5. COLLECTIVE LEVER ASSEMBLY - INSPECTION
1. Inspect collective lever pins (19, figure 1) for damage, cracks, and distortion. Damage in excess of superficial marks
are not acceptable.
62-31-09
Page 6 Rev. 2
E-AB412-PT6T-2
6. COLLECTIVE LEVER ASSEMBLY - REPAIR
MATERIALS REQUIRED
NUMBER NOMENCLATURE
C-210 PAINT
1. Polish out mechanical and corrosion damage with fine to medium grades of abrasive cloth or paper (C-423). Do not
exceed limits defined in E-AB412-PT6T-3 manual.
2. Apply chemical film material to all bare aluminum areas.
3. Apply paint (C-210) to areas where metal is exposed.
4. Touch up paint to match existing finish.
5. Replace trunnion which does not meet requirements defined in E-AB412-PT6T-3 manual.
62-31-09
Rev. 2 Page 7
E-AB412-PT6T-2
62-31-09
Page 8 Rev. 2
E-AB412-PT6T-2
CHAPTER 63 - MAIN ROTOR DRIVE

Module Page
Number Title Number
63-00-00 MAIN ROTOR DRIVE
1. Main rotor drive - general ....................................................................................................................... 1

2. Main rotor drive - metal particle contamination ..................................................................................... 1
2-1. Metal particle contamination - inspection ..................................................................................... 1
2-2. Metal particle contamination - identification ................................................................................ 1
63-00-01 SERVICEABILITY CHECKS
1. Serviceability checks - transmission, tail rotor gearbox and intermediate gearbox ............................... 1
2. Serviceability checks - transmission ....................................................................................................... 1
3. Serviceability checks - intermediate or tail gearbox................................................................................ 2
63-11-01 ENGINE TO TRANSMISSION (MAIN) DRIVESHAFT
1. Engine to transmission (main) driveshaft - description .......................................................................... 1

2. Engine to transmission (main) driveshaft - removal ............................................................................... 1
3. Engine to transmission (main) driveshaft - disassembly/assembly ........................................................ 1
4. Engine to transmission (main) driveshaft - installation .......................................................................... 2
5. Engine to transmission (main) driveshaft - troubleshooting ................................................................... 6
6. Engine to transmission (main) driveshaft - cleaning .............................................................................. 6
7. Engine to transmission (main) driveshaft - inspection ........................................................................... 9
8. Engine to transmission (main) driveshaft - repair ................................................................................ 10
9. Engine to transmission (main) driveshaft - lubrication ........................................................................ 10
10. Engine to transmission (main) driveshaft - balancing ........................................................................... 11
63-11-02 ENGINE TO DRIVESHAFT CURVIC COUPLING ADAPTER
1. Engine to driveshaft curvic coupling adapter - removal ......................................................................... 1

2. Engine to driveshaft curvic coupling adapter - installation .................................................................... 1
3. Engine to driveshaft curvic coupling adapter - inspection ..................................................................... 2
4. Engine to driveshaft curvic coupling adapter - repair ............................................................................. 2
63-21-01 MAIN ROTOR MAST
1. Main rotor mast - description .................................................................................................................. 1

2. Main rotor mast - removal ...................................................................................................................... 1
3. Main rotor mast - installation .................................................................................................................. 5
4. Main rotor mast - cleaning ...................................................................................................................... 7
5. Main rotor mast - inspection and repair .................................................................................................. 7
6. Main rotor mast - torque tube assembly alignment ................................................................................ 7
63-22-01 TRANSMISSION
1. Transmission - description ...................................................................................................................... 1

2. Transmission - removal .......................................................................................................................... 1
3. Transmission - installation ...................................................................................................................... 5
4. Transmission - inspection ..................................................................................................................... 10
5. Transmission - troubleshooting ............................................................................................................. 11
63-Index
Rev. 3 Page 1
E-AB412-PT6T-2

Module Page
Number Title Number
63-22-02 TRANSMISSION - BUILD-UP
1. Build-up - description ..............................................................................................................................1
63-22-03 TRANSMISSION - ALTERNATE RUN-IN PROCEDURES
1. Alternate run-in procedures - description ................................................................................................1
63-23-01 TRANSMISSION OIL SYSTEM COMPONENTS - PLANETARY OIL JETS
1. Planetary oil jets - description .................................................................................................................1

2. Planetary oil jets - removal ......................................................................................................................1
3. Planetary oil jets - installation .................................................................................................................1
4. Planetary oil jets - cleaning .....................................................................................................................2
5. Planetary oil jets - inspection ..................................................................................................................2
6. Planetary oil jets - repair .........................................................................................................................2
63-23-02 TRANSMISSION OIL SYSTEM COMPONENTS - OIL JET NO. 1
1. Oil jet No. 1 - removal ............................................................................................................................1

2. Oil jet No. 1 - installation ........................................................................................................................1
3. Oil jet No. 1 - cleaning ............................................................................................................................1
4. Oil jet No. 1 - inspection .........................................................................................................................1
5. Oil jet No. 1 - repair ................................................................................................................................1

5. Oil jet No. 2 - repair ................................................................................................................................1

5. Oil jet No. 3 - repair .................................................................................................................................2

5. Oil jet No. 4 - repair ................................................................................................................................2
63-Index
Page 2 Rev. 3
E-AB412-PT6T-2

Module Page
Number Title Number
2. Oil jet No. 5 - installation ....................................................................................................................... 1

3. Oil jet No. 5 - cleaning ............................................................................................................................ 1
4. Oil jet No. 5 - inspection ......................................................................................................................... 1
5. Oil jet No. 5 - repair ................................................................................................................................ 1
1. Oil jet No. 6 - removal ............................................................................................................................ 1

4. Oil jet No. 6 - inspection ......................................................................................................................... 1
5. Oil jet No. 6 - repair ................................................................................................................................ 1
1. Oil jet No. 7 - removal ............................................................................................................................ 1

4. Oil jet No. 7 - inspection.......................................................................................................................... 2
5. Oil jet No. 7 - repair ................................................................................................................................ 2
63-23-09 TRANSMISSION OIL SYSTEM COMPONENTS - OIL PRESSURE REGULATING VALVE
1. Oil pressure regulating valve - removal .................................................................................................. 1

2. Oil pressure regulating valve - installation ............................................................................................. 1
3. Oil pressure regulating valve - cleaning ................................................................................................. 1
4. Oil pressure regulating valve - inspection ............................................................................................... 2
5. Oil pressure regulating valve - repair ..................................................................................................... 2
63-23-10 TRANSMISSION OIL SYSTEM COMPONENTS - OIL TEMPERATURE MANIFOLD
1. Oil temperature manifold - removal ....................................................................................................... 1

2. Oil temperature manifold - installation ................................................................................................... 1
63-23-11 TRANSMISSION OIL SYSTEM COMPONENTS - OIL PRESSURE TRANSMITTER
1. Oil pressure transmitter - removal .......................................................................................................... 1

2. Oil pressure transmitter - installation ...................................................................................................... 1
3. Oil pressure transmitter - inspection ....................................................................................................... 1
63-23-12 TRANSMISSION OIL SYSTEM COMPONENTS - OIL PRESSURE SWITCH
1. Oil pressure switch - removal ................................................................................................................. 1

2. Oil pressure switch - installation ............................................................................................................ 1
3. Oil pressure switch - inspection .............................................................................................................. 1
63-23-13 TRANSMISSION OIL SYSTEM COMPONENTS - OIL PRESSURE MANIFOLD
1. Oil pressure manifold - removal ............................................................................................................. 1

2. Oil pressure manifold - installation ........................................................................................................ 1
3. Oil pressure manifold - cleaning ............................................................................................................. 1
4. Oil pressure manifold - inspection .......................................................................................................... 1
5. Oil pressure manifold - repair .................................................................................................................. 2
63-Index
Rev. 3 Page 3
E-AB412-PT6T-2

Module Page
Number Title Number
63-23-14 TRANSMISSION OIL SYSTEM COMPONENTS - FILLER NECK, SCUPPER, AND

MOUNTING BRACKET
1. Filler neck, scupper, and mounting bracket - removal ............................................................................1

2. Filler neck, scupper, and mounting bracket - installation .......................................................................1
3. Filler neck, scupper, and mounting bracket - cleaning ...........................................................................2
4. Filler neck, scupper, and mounting bracket - inspection .........................................................................2
63-23-15 TRANSMISSION OIL SYSTEM COMPONENTS - OIL PUMP
1. Oil pump - removal .................................................................................................................................1

2. Oil pump - installation..............................................................................................................................2
63-23-16 TRANSMISSION OIL SYSTEM COMPONENTS - OIL PUMP INLET SCREEN
1. Oil pump inlet screen - removal ..............................................................................................................1

2. Oil pump inlet screen - installation .........................................................................................................1
3. Oil pump inlet screen - cleaning .............................................................................................................1
4. Oil pump inlet screen - inspection............................................................................................................2
63-23-17 TRANSMISSION OIL SYSTEM COMPONENTS - SUMP INTERNAL FILTER [A] [B] [C]
1. Sump internal filter [A] [B] [C] - removal ..............................................................................................1

2. Sump internal filter [A] [B] [C] - installation .........................................................................................1
3. Sump internal filter [A] [B] [C] - inspection ...........................................................................................1
4. Sump internal filter [A] [B] [C] - cleaning .............................................................................................2
63-23-18 TRANSMISSION OIL SYSTEM COMPONENTS - FULL FLOW DEBRIS MONITOR [D]
1. Full flow debris monitor - removal .........................................................................................................1

2. Full flow debris monitor - installation .....................................................................................................1
3. Full flow debris monitor - inspection .......................................................................................................2
4. Full flow debris monitor - cleaning .........................................................................................................2
63-23-19 TRANSMISSION OIL SYSTEM COMPONENTS - SIGHT GLASSES
1. Sight glasses - description .......................................................................................................................1

2. Sight glasses - removal ............................................................................................................................1
3. Sight glasses - installation .......................................................................................................................1
4. Sight glasses - cleaning ...........................................................................................................................1
5. Sight glasses - inspection ........................................................................................................................2
63-24-01 TRANSMISSION OIL COOLING SYSTEM
1. Transmission oil cooling system - description ........................................................................................1

2. Transmission oil cooling system - external oil filter ...............................................................................1
2-1. External oil filter - description .......................................................................................................1
2-2. External oil filter - removal ............................................................................................................1
2-3. External oil filter - installation ........................................................................................................2
2-4. External oil filter - cleaning ...........................................................................................................2
2-5. External oil filter - inspection .........................................................................................................5
63-Index
Page 4 Rev. 3
E-AB412-PT6T-2

Module Page
Number Title Number
63-24-02 TRANSMISSION OIL COOLING SYSTEM - THERMAL BYPASS VALVE
1. Thermal bypass valve - description ........................................................................................................ 1

2. Thermal bypass valve - removal ............................................................................................................. 1
3. Thermal bypass valve - installation ........................................................................................................ 1
4. Thermal bypass valve - cleaning ............................................................................................................ 2
63-24-03 TRANSMISSION OIL COOLING SYSTEM - OIL DRAIN VALVES
1. Oil drain valves - description .................................................................................................................. 1

2. Oil drain valves - removal ...................................................................................................................... 1
3. Oil drain valves - installation .................................................................................................................. 1
4. Oil drain valves - cleaning ...................................................................................................................... 2
5. Oil drain valves - inspection ................................................................................................................... 2
63-24-04 TRANSMISSION OIL COOLING SYSTEM - TRANSMISSION OIL COOLER AND BLOWER
1. Transmission oil cooler and blowers - description ................................................................................. 1
63-25-01 TRANSMISSION QUILLS - MAIN INPUT QUILL
1. Main input quill - description ................................................................................................................. 1

2. Main input quill - removal ...................................................................................................................... 1
3. Main input quill - installation .................................................................................................................. 2
4. Main input quill - cleaning ...................................................................................................................... 4
5. Main input quill - inspection ................................................................................................................... 4
6. Main input quill - repair........................................................................................................................... 5
63-25-02 TRANSMISSION QUILLS - MAIN INPUT QUILL MAGNETIC SEAL (412-040-111)
1. Main input quill magnetic seal - removal (helicopters codes [A] [B] [C]) ............................................. 1
2. Main input quill magnetic seal - removal (helicopters code [D]) ........................................................... 8
3. Main input quill magnetic seal - installation (helicopters codes [A] [B] [C]) ........................................ 9
4. Main input quill magnetic seal - installation (helicopters code [D]) .................................................... 11
5. Main input quill magnetic seal - cleaning ............................................................................................. 13
6. Main input quill magnetic seal - inspection .......................................................................................... 13
7. Main input quill magnetic seal - repair ................................................................................................. 13
63-25-03 TRANSMISSION QUILLS - MAIN INPUT QUILL SEAL (2820-3655)
1. Main input quill seal - removal ............................................................................................................... 1

2. Main input quill seal - installation .......................................................................................................... 1
3. Main input quill seal - cleaning .............................................................................................................. 5
4. Main input quill seal - inspection ........................................................................................................... 5
5. Main input quill seal - repair ................................................................................................................... 5
63-25-04 TRANSMISSION QUILLS - NO. 1 HYDRAULIC PUMP DRIVE QUILL
1. No. 1 hydraulic pump drive quill - description ....................................................................................... 1

2. No. 1 hydraulic pump drive quill - removal ........................................................................................... 1
3. No. 1 hydraulic pump drive quill - installation ....................................................................................... 1
4. No. 1 hydraulic pump drive quill - cleaning ........................................................................................... 2
63-Index
Rev. 3 Page 5
E-AB412-PT6T-2

Module Page
Number Title Number
5. No. 1 hydraulic pump drive quill - inspection ........................................................................................2

6. No. 1 hydraulic pump drive quill - repair ................................................................................................4
1. No. 2 hydraulic pump drive quill - description .......................................................................................1

2. No. 2 hydraulic pump drive quill - removal ............................................................................................1
3. No. 2 hydraulic pump drive quill - installation .......................................................................................1
4. No. 2 hydraulic pump drive quill - cleaning ...........................................................................................2
5. No. 2 hydraulic pump drive quill - inspection ........................................................................................2
6. No. 2 hydraulic pump drive quill - repair ................................................................................................2
63-25-06 TRANSMISSION QUILLS - ROTOR TACHOMETER GENERATOR
1. Rotor tachometer generator - description ................................................................................................1

2. Rotor tachometer generator - removal ....................................................................................................1
3. Rotor tachometer generator - installation ................................................................................................1
4. Rotor tachometer generator - cleaning .....................................................................................................2
5. Rotor tachometer generator - inspection .................................................................................................2
6. Rotor tachometer generator - repair ........................................................................................................2
63-25-07 TRANSMISSION QUILLS - TAIL ROTOR DRIVE QUILL
1. Tail rotor drive quill - description ...........................................................................................................1

2. Tail rotor drive quill - removal ................................................................................................................1
3. Tail rotor drive quill - installation ...........................................................................................................3
4. Tail rotor drive quill - cleaning ...............................................................................................................3
5. Tail rotor drive quill - inspection ............................................................................................................4
6. Tail rotor drive quill - repair ....................................................................................................................5
63-25-08 TRANSMISSION QUILLS - ROTOR BRAKE QUILL
1. Rotor brake quill - description ................................................................................................................1

2. Rotor brake quill - removal .....................................................................................................................1
3. Rotor brake quill - installation ................................................................................................................3
4. Rotor brake quill - cleaning .....................................................................................................................4
5. Rotor brake quill - inspection ..................................................................................................................4
6. Rotor brake quill - repair .........................................................................................................................4
63-25-09 TRANSMISSION QUILLS - UTILITY HYDRAULIC PUMP AND ROTOR BRAKE DRIVE
QUILL [B] [C]
1. Utility hydraulic pump and rotor brake drive quill [B][C] - description ................................................1
2. Utility hydraulic pump and rotor brake drive quill [B][C] - removal .....................................................1
3. Utility hydraulic pump and rotor brake drive quill [B][C] - installation .................................................2
4. Utility hydraulic pump and rotor brake drive quill [B][C] - inspection ..................................................3
5. Utility hydraulic pump and rotor brake drive quill [B][C] - repair .........................................................3
63-26-01 TRANSMISSION QUILL PORT COVERS
1. Transmission quill port covers - description ...........................................................................................1

2. Transmission quill port covers - removal ................................................................................................1
3. Transmission quill port covers - installation ...........................................................................................1
63-Index
Page 6 Rev. 3
E-AB412-PT6T-2

Module Page
Number Title Number
63-27-01 ROTOR BRAKE SYSTEM
1. Rotor brake system - description ............................................................................................................ 1

2. Rotor brake system - operational check .................................................................................................. 1
3. Rotor brake system - troubleshooting ..................................................................................................... 1
4. Rotor brake system - inspection .............................................................................................................. 2
5. Rotor brake system - bleeding ................................................................................................................ 3
5-1. Bleeding - brake assembly P/N 9450103........................................................................................ 4
5-2. Bleeding - brake assembly P/N 9450103-1 ................................................................................... 4
63-27-02 ROTOR BRAKE SYSTEM - MASTER CYLINDER
1. Master cylinder - removal ....................................................................................................................... 1

2. Master cylinder - installation ................................................................................................................... 2
3. Master cylinder - inspection ................................................................................................................... 2
4. Master cylinder - repair and replacement ............................................................................................... 2
63-27-03 ROTOR BRAKE SYSTEM - BRAKE ASSEMBLY
1. Brake assembly - description .................................................................................................................. 1

2. Brake assembly - removal (P/N 9450103) .............................................................................................. 1
3. Brake assembly - removal (P/N 9450103-1) .......................................................................................... 1
4. Brake assembly - installation (P/N 9450103) ......................................................................................... 2
5. Brake assembly - installation (P/N 9450103-1) ...................................................................................... 3
6. Brake assembly - brake lining installation .............................................................................................. 4
7. Brake assembly - inspection ................................................................................................................... 5
8. Brake assembly - repair .......................................................................................................................... 5
9. brake assembly - microswitch actuator adjustment ................................................................................ 6
63-27-04 ROTOR BRAKE SYSTEM - DISC
1. Disc - removal ......................................................................................................................................... 1

2. Disc - installation .................................................................................................................................... 1
3. Disc - inspection ..................................................................................................................................... 2
63-27-05 ROTOR BRAKE SYSTEM - FLANGE ADAPTER
1. Flange adapter - removal ........................................................................................................................ 1

2. Flange adapter - installation .................................................................................................................... 1
63-31-01 TRANSMISSION MOUNTS - AFT ISOLATION MOUNT AND FRICTION DAMPERS
1. Aft isolation mount and friction dampers - description .......................................................................... 1

2. Aft isolation mount and friction dampers - removal ............................................................................... 1
3. Aft isolation mount and friction dampers - installation .......................................................................... 1
4. Aft isolation mount and friction dampers - inspection (transmission mount) ........................................ 3
5. Aft isolation mount and friction dampers - inspection (aft mount friction dampers) ............................. 3
63-31-02 TRANSMISSION MOUNTS - FORWARD ISOLATION MOUNTS
1. Forward isolation mounts - removal ....................................................................................................... 1

2. Forward isolation mounts - installation .................................................................................................. 1
63-Index
Rev. 3 Page 7
E-AB412-PT6T-2

Module Page
Number Title Number
3. Forward isolation mounts - inspection ....................................................................................................1
63-31-03 TRANSMISSION MOUNTS - LIFT LINK
1. Lift link - removal ...................................................................................................................................1

2. Lift link - installation ...............................................................................................................................1
3. Lift link - cleaning ...................................................................................................................................2
4. Lift link - inspection and repair ...............................................................................................................2
63-31-04 TRANSMISSION MOUNTS - LIFT LINK FITTING
1. Lift link fitting - description ....................................................................................................................1

2. Lift link fitting - removal ........................................................................................................................1
3. Lift link fitting - installation ....................................................................................................................1
4. Lift link fitting - cleaning ........................................................................................................................1
5. Lift link fitting - inspection and repair ....................................................................................................1
63-41-01 TRANSMISSION OIL SYSTEM COMPONENTS - MAST BEARING ELECTRIC CHIP

DETECTOR
1. Mast bearing electric chip detector - description ....................................................................................1

2. Mast bearing electric chip detector - removal .........................................................................................1
3. Mast bearing electric chip detector - installation ....................................................................................1
4. Mast bearing electric chip detector - cleaning .........................................................................................2
5. Mast bearing electric chip detector - inspection ......................................................................................2
63-41-02 TRANSMISSION OIL SYSTEM COMPONENTS - MAIN INPUT GEAR QUILL ELECTRIC
CHIP DETECTOR
1. Main input gear quill electric chip detector - description .......................................................................1

2. Main input gear quill electric chip detector - removal ............................................................................1
3. Main input gear quill electric chip detector - installation .......................................................................1
4. Main input gear quill electric chip detector - inspection..........................................................................2
5. Main input gear quill electric chip detector - cleaning ............................................................................2
63-41-03 TRANSMISSION OIL SYSTEM COMPONENTS - SUMP CASE ELECTRICAL CHIP

DETECTOR [A] [B] [C]
1. Sump case electrical chip detector [A] [B] [C] - description ..................................................................1
2. Sump case electrical chip detector [A] [B] [C] - removal .......................................................................1
3. Sump case electrical chip detector [A] [B] [C] - installation ..................................................................1
4. Sump case electrical chip detector [A] [B] [C] - cleaning ......................................................................2
5. Sump case electrical chip detector [A] [B] [C] - inspection ...................................................................2
63-Index
Page 8 Rev. 3
E-AB412-PT6T-2
FIGURES
Figure Page
Number Title Number
63-00-00 MAIN ROTOR DRIVE
Figure 1. Drive system ................................................................................................................................................... 2

Figure 2. Analysis of drive system chip detector debris (sheet 1 of 3).......................................................................... 3
Figure 1. Engine-to-transmission (main) driveshaft (sheet 1 of 2) ................................................................................ 4

Figure 2. Main driveshaft - damage limits (sheet 1 of 2)............................................................................................... 7
63-11-02 ENGINE TO DRIVESHAFT CURVIC COUPLING ADAPTER
Figure 1. Engine to driveshaft curvic coupling adapter ................................................................................................. 3

Figure 2. Engine to driveshaft curvic coupling wrench set - tool application ............................................................... 4
Figure 1. Main rotor mast (sheet 1 of 2) ........................................................................................................................ 3

Figure 2. Mast driving adapter to transmission top case dimension requirements ...................................................... 10
63-22-01 TRANSMISSION
Figure 1. Transmission................................................................................................................................................... 3
Figure 2. Transmission removal and installation (sheet 1 of 2)..................................................................................... 6
Figure 3. Transmission assembly................................................................................................................................... 9
63-22-02 TRANSMISSION - BUILD-UP
Figure 1. Transmission build-up (sheet 1 of 4) .............................................................................................................. 3
Figure 1. Planetary oil jet ............................................................................................................................................... 3
Figure 1. Oil jet No. 1 .................................................................................................................................................... 2
Figure 1. Oil jet No. 2 .................................................................................................................................................... 2
Figure 1. Oil jet No. 3 .................................................................................................................................................... 2
Figure 1. Oil jet No. 4 .................................................................................................................................................... 2
63-Index
Rev. 3 Page 9
E-AB412-PT6T-2
FIGURES (CONT.D)
Figure Page
Number Title Number
Figure 1. Oil jet No. 5.....................................................................................................................................................2
Figure 1. Oil jet No. 6.....................................................................................................................................................2
Figure 1. Oil jet No. 7.....................................................................................................................................................2
Figure 1. Oil pressure regulator valve ............................................................................................................................2
Figure 1. Oil temperature manifold ................................................................................................................................3
Figure 1. Oil pressure transmitter ...................................................................................................................................2
Figure 1. Oil pressure switch..........................................................................................................................................2
Figure 1. Oil pressure manifold......................................................................................................................................2
63-23-14 TRANSMISSION OIL SYSTEM COMPONENTS - FILLER NECK, SCUPPER, AND

MOUNTING BRACKET
Figure 1. Filler neck, scupper, and mounting bracket ....................................................................................................3
Figure 1. Transmission oil pump....................................................................................................................................3
Figure 1. Oil pump screen ..............................................................................................................................................3

Figure 2. Oil pump inlet screen - damage limits ............................................................................................................4
Figure 1. Sump internal filter (helicopters codes [A] [B] [C]).......................................................................................3

Figure 2. Sump internal filter assembly (helicopters codes [A] [B] [C]) .......................................................................4
Figure 3. Sump internal filter - damage limits (helicopters codes [A] [B] [C]) .............................................................5
63-Index
Page 10 Rev. 3
E-AB412-PT6T-2
FIGURES (CONT.D)
Figure Page
Number Title Number
Figure 1. Full flow debris monitor (helicopters code [D])............................................................................................. 3
Figure 1. Sight glasses ................................................................................................................................................... 2
Figure 1. Transmission oil cooling system .................................................................................................................... 3

Figure 2. Transmission external oil filter....................................................................................................................... 4
Figure 1. Thermal oil bypass valve ................................................................................................................................ 2
Figure 1. Oil drain valve ................................................................................................................................................ 3
Figure 1. Main input quill .............................................................................................................................................. 6

Figure 2. Pusher set, T40, application............................................................................................................................ 7
Figure 3. Main input quill assembly .............................................................................................................................. 8
63-25-02 TRANSMISSION QUILLS - MAIN INPUT QUILL MAGNETIC SEAL (412-040-111)
Figure 1. Main input quill magnetic seal (sheet 1 of 2) ................................................................................................. 3

Figure 2. Tool application (sheet 1 of 2)........................................................................................................................ 5
Figure 3. Main input quill curvic coupling adapter and magnetic seal assembly .......................................................... 7
Figure 1. Main input quill seal (2820-3655) .................................................................................................................. 3
Figure 1. No. 1 Hydraulic pump drive quill................................................................................................................... 3

Figure 2. No. 1 Hydraulic pump drive quill assembly................................................................................................... 5
Figure 1. Hydraulic pump drive quill............................................................................................................................. 3
Figure 1. Rotor tachometer generator ............................................................................................................................ 3
63-Index
Rev. 3 Page 11
E-AB412-PT6T-2
FIGURES (CONT.D)
Figure Page
Number Title Number
Figure 1. Tail rotor drive quill ........................................................................................................................................2
Figure 1. Rotor brake quill .............................................................................................................................................2
63-25-09 TRANSMISSION QUILLS - UTILITY HYDRAULIC PUMP AND ROTOR BRAKE DRIVE
QUILL [B] [C]
Figure 1. Utility hydraulic pump and rotor brake disc drive quill [B] [C] .....................................................................4
Figure 1. Quill port covers..............................................................................................................................................2
Figure 1. Rotor brake system..........................................................................................................................................6
Figure 1. Rotor brake system - master cylinder arrangement.........................................................................................3
Figure 1. Rotor brake system (sheet 1 of 2) ...................................................................................................................7

Figure 2. Rotor brake assembly (sheet 1 of 3)................................................................................................................9
Figure 3. Rotor brake assembly - damage limits (sheet 1 of 2)....................................................................................12
Figure 1. Rotor brake assembly - brake disc (sheet 1 of 2) ............................................................................................3

Figure 2. Rotor brake disc inspection arbor ...................................................................................................................5
Figure 1. Rotor brake disc - flange adapter ....................................................................................................................2
Figure 1. Transmission aft isolation mounts and friction dampers ................................................................................2

Figure 2. Isolation mount inspection work aid - tool application...................................................................................4
Figure 1. Forward isolation mount .................................................................................................................................2
Figure 1. Transmission lift link ......................................................................................................................................3
63-Index
Page 12 Rev. 3
E-AB412-PT6T-2
FIGURES (CONT.D)
Figure Page
Number Title Number
Figure 1. Lift link fitting ................................................................................................................................................ 2
63-41-01 TRANSMISSION OIL SYSTEM COMPONENTS - MAST BEARING ELECTRIC CHIP

DETECTOR
Figure 1. Mast bearing electric chip detector................................................................................................................. 3

Figure 2. Electric chip detector (typical) - damage limits.............................................................................................. 4
63-41-02 TRANSMISSION OIL SYSTEM COMPONENTS - MAIN INPUT GEAR QUILL ELECTRIC
CHIP DETECTOR
Figure 1. Main input gear quill electric chip detector.................................................................................................... 3

Figure 2. Electric chip detector (typical) - damage limits.............................................................................................. 4
63-41-03 TRANSMISSION OIL SYSTEM COMPONENTS - SUMP CASE ELECTRICAL CHIP

DETECTOR [A] [B] [C]
Figure 1. Sump case electric chip detector [A] [B] [C] ................................................................................................. 3
Figure 2. Sump case electric chip detector [A] [B] [C] - damage limits ....................................................................... 4
63-Index
Rev. 3 Page 13
E-AB412-PT6T-2
TABLES
Table Page
Number Title Number
Table 1. Troubleshooting - engine-to-transmission (main) driveshaft..........................................................................6

Table 2. Main driveshaft TEMP-PLATE condition and corrective action ...................................................................9
Table 1. Troubleshooting - rotor brake system .............................................................................................................1
63-Index
Page 14 Rev. 3
E-AB412-PT6T-2
63-0 -0 MAIN ROTOR DRIVE
63-00-00
MAIN ROTOR DRIVE
1. MAIN ROTOR DRIVE - GENERAL
This chapter contains maintenance instructions for the drive system components (figure 1) which transmit power from the
engine to the main rotor assembly and to transmission mounted accessories. This includes the engine-to-transmission (main)
driveshaft, transmission and related components, and main rotor mast assembly.
2. MAIN ROTOR DRIVE - METAL PARTICLE CONTAMINATION
2-1. METAL PARTICLE CONTAMINATION - INSPECTION
Metal particles found in transmission oil, screens, filters, or accumulated on chip detectors may indicate impending failure
of an internal part of the transmission. The presence of metal particles is not necessarily an indication the transmission, or
component part, is no longer serviceable (refer to module 63-00-01 "SERVICEABILITY CHECKS"). The quantity, source,
form, and type of metal, together with the service history of the particular component, must be taken into consideration. The
time accumulated since the gearbox was new or overhauled, previous failures, and type of operation are important factors
in determining further serviceability. The particles found may be steel, aluminum, magnesium, or phenolic in various shapes
and quantities. Refer to figure 2 for disposition of metal particle contaminated transmissions.
2-2. METAL PARTICLE CONTAMINATION - IDENTIFICATION
CAUTION
WHEN PARTICLES FOUND ARE READILY IDENTIFIABLE AS FRAGMENTS

OF TRANSMISSION PARTS SUCH AS GEARS, HARDWARE, BEARINGS,
LOCKWIRE, OR OTHER INTERNAL COMPONENTS, REPLACE
TRANSMISSION, MAST ASSEMBLY, OIL COOLER, AND EXTERNAL OIL
FILTER ELEMENTS. CLEAN AND THOROUGHLY FLUSH ALL OIL LINES
WITH OPERATING OIL (CHAPTER 12).
Visual inspection of color and hardness may identify particles. When a particle cannot be positively identified by visual
means, perform the following tests with a permanent magnet, concentrated hydrochloric acid and concentrated nitric acid.
1. STEEL. Isolate steel particles with a permanent magnet.
2. ALUMINUM. Identify aluminum particles by reaction to hydrochloric acid. When a particle of aluminum is immersed
in into hydrochloric acid, the solution will fizz vigorously and the particles will gradually disintegrate. A black residue
will remain.
NOTE
Magnesium and aluminum react similarly in hydrochloric acid. When in doubt, drop
particle in nitric acid. Aluminum does not react noticeably in nitric acid while
magnesium does.
3. COPPER OR BRONZE. Particles of copper or bronze will form a bright green cloud in nitric acid.
63-00-00
Rev. 2 Page 1
E-AB412-PT6T-2
MAIN ROTOR HUB
ENGINE
1. Mast assembly
2. Transmission
3. Input quill
4. Engine to transmission
5. Tail rotor driveshaft
6. Tail rotor driveshaft (short section)
11. Tail rotor gearbox
12. Intermediate gearbox
13. Hanger assembly
14. Hanger assembly
15. Hanger assembly
16. Hanger assembly
17. Tail rotor drive quill
18. Hydraulic pump and tachometer (system 1)
19. Cover
20. Hydraulic pump drive quill (system 2)
G6AB0823B
Figure 1. Drive system
63-00-00
Page 2 Rev. 2
E-AB412-PT6T-2
The following information contained in this figure is provided for the eventuation of contamination found on the drive system chip detec-
tors.
It is possible to depict the shapes of all possible particulates contamination, especially those particles not generated within a gearbox,
as a result of component wear or failure. However, the following basic assumptions will permit a rather accurate assessment of any
debris found, even through the particles may be severely distorted as a result of passing through gear meshes.
DESCRIPTION:
Material, from the surfaces of gear teeth or rolling element bearings, is quite hard. Particles broken from these surfaces may
have razor-sharp edges but rarely have sharp pointed ends. With few exceptions, surfaces of such particles will not appear
smeared (as if cut by a shear) under magnification; a grainy appearance on the fracture surfaces is more common.
When damaged by passing through gear meshes, these hard particles tend or break up with relatively little deformation.
Foreign ferrous material introduced into gearboxes is often much soften than the surfaces of gear teeth and bearings. The same
is true of most nongear and nonbearing components within gearboxes. The softer materials are usually quite ductile and malle-
able, i.e., particles from such materials can be readily bent or rolled into a wide range of shapes without fracturing.
Fragments of the softer material are capable of being torn or sheared from the parent component without suffering brittle frac-
ture (easily broken or snapped). Instead, during separation the fragments are distorted and stretched such that they often
exhibit surfaces that appear stretched. Ends of soft material fragments are often sharp-pointed; the ductile nature of the material
permits such a condition.
Each type of debris has been identified as significant debris or insignificant debris at the beginning of the explanation of signifi-
cance to aid in troubleshooting.
CAUTION
RECURRING ACCUMULATION OF INSIGNIFICANT DEBRIS WILL

REQUIRE OVERHAUL/REPAIR OF GEARBOX.
TYPICAL APPEARANCE DESCRIPTION SIGNIFICANCE
A few moderately-sized and/or SIGNIFICANT DEBRIS

numerous small nearly-flat flakes:
This is a classic indication of rolling
Under magnification one side of element bearing failure. Although
flakes appears very smooth. Flakes less common, this can also indicate
are silvery in color with an occa- spalling of gear teeth.
sional black side.
Common term for this condition is OVERHAUL/REPAIR
flakes. GEARBOX
G6AB0417B
Figure 2. Analysis of drive system chip detector debris (sheet 1 of 3)
63-00-00
Rev. 2 Page 3
E-AB412-PT6T-2
Irregularly-shaped ferrous chunks of SIGNIFICANT DEBRIS

various sizes and shapes:
Existence of this type of debris most
Under magnification, one or more likely indicates gear and/or bearing
sides of particles appears rough and damage within the drive system
grainy. Color of particles is sil- component.
very-gray often with one or more
sides black. OVERHAUL/REPAIR
This condition has no common term. GEARBOX
Spiral curls or comma-shaped parti- INSIGNIFICANT DEBRIS

cles:
Particles are fragments of chips or
When examined under magnifica- shavings produced during the match-
tion, particles are often smooth and ing of ferrous components. Such
shiny on their convex surfaces and contamination is often introduced
quite rough on the other surfaces and into the drive system components on
edges. Color of particles is usually tools, during dusting operations
dull gray on rough surfaces. within the component assembly area
Common term for condition is manu- using compressed air.
facturing debris. No corrective action is required fol-
lowing discovery of such material.
Hair-like ferrous debris: INSIGNIFICANT DEBRIS
May have rectangular or triangular Debris commonly are scrapings, pro-

cross sections. Generally 0.030 in duced as components, and are inter-
(0.76 mm) or less in thickness. ference-fitted together during
Length may range from 0.10 in (2.54 assembly of the drive system compo-
mm) to over 1.0 in (25.4 mm). Color nents. Debris of this general shape is
of debris is usually light gray also produced, after long term opera-
although one or more sides may have tion, at the corners of wear surfaces
a black appearance. of such parts as transmission plane-
Common term of condition is hairs. tary supports. This type debris can be
introduced into the component dur-
ing periodic servicing.
Hairs can appear on chip detectors at
any point in the life of the drive sys-
tem component. However, discovery
of such material does not necessitate
any corrective action.
G6AB0418B
63-00-00
Page 4 Rev. 2
E-AB412-PT6T-2
Irregular-shaped ferrous particles: INSIGNIFICANT DEBRIS
Usually triangular in cross sections. Particles of this type are commonly

Often spike-like in appearance. the result of tool slippage during
Under magnification, one side of tri- assembly of the drive system compo-
angular section will usually appear nent. An example would be the sliver
sheared. Color may be silvery-gray of metal torn from the edge of a
or black with one or more particles screw slot as a screwdriver blade
of this type on a chip detector at any slips out of place.
one time is rare. This type of debris would most likely
Common term for condition is manu- appear during the first 50 hours of
facturing debris. operation following component
assembly or extensive maintenance.
No corrective actions are required
following discovery of such material.
Tiny whisker-like particles or groups INSIGNIFICANT DEBRIS

of dark microscopic particles:
Generally microscopic wear particles
When removed with tape or paper produced by normal wear within
towel, apparently-large chips drive system component. Particles
disappear into a black smudge. are often grouped by the field of the
Common term for condition is chip detector magnet to assume the
smudge or fuzz. shape of apparently large chips.
Such material is common in
gearboxes having several hundred
operating hours. In such cases, this
condition does not necessitate
corrective action.
Appearance of this type of debris in
relatively new or
recently-overhauled gearboxes may
indicate bearing or gear micropitting.
In such cases detector should be
inspected more frequently for signs
of progressing damage.
G6AB0419B
63-00-00
Rev. 2 Page 5
E-AB412-PT6T-2
63-00-00
Page 6 Rev. 2
E-AB412-PT6T-2
63-0 -01 SERVICEABILITY CHECKS
63-00-01
SERVICEABILITY CHECKS
1. SERVICEABILITY CHECKS - TRANSMISSION, TAIL ROTOR GEARBOX AND

INTERMEDIATE GEARBOX
Perform the following procedures when any doubt exists as to the serviceability of a transmission, tail rotor gearbox, or
intermediate gearbox after finding metal particles in operating oil.
2. SERVICEABILITY CHECKS - TRANSMISSION
1. Drain transmission, oil cooler, and connecting lines.
2. Insert a magnet into pump screen boss of plug to check for additional contamination.
3. Flush oil cooler and connecting lines with clean approved oil (Chapter 12).
4. Clean and install chip detector plug, pump inlet screen, and sump oil filter. Replace external oil filter element.
CAUTION
NOTE CONDITION OF PACKINGS, SEALS, AND GASKETS BEFORE

INSTALLATION. REPLACE IF DAMAGED.
5. Service transmission with oil (Chapter 12).
6. Ground run helicopter (refer to E-AB412-PT6T-1) for one hour at 100% Nr with maximum pitch which can be applied
without becoming airborne and tail rotor pedal equivalent to flight position.
7. Drain transmission oil into a clean container and inspect for chips.
8. Inspect sump internal filter and all chip detectors.
9. If number of particles has increased, or if there are particles which can be visually identified as chip or flakes from a
gear or bearing, replace transmission, mast assembly, and transmission oil cooler. Flush oil lines. If number of particles
has decreased and only minute particles are found, continue transmission in service.
10. After five hours of service, inspect sump internal filter and three chip detectors for particles.
11. If the number of particles has increased, or if there are particles which can visually be identified as chips or flakes from
a gear or bearing, replace transmission, mast assembly, and transmission oil cooler. Flush oil lines. If the number of
particles has decreased and only minute particles are found, continue transmission in service.
63-00-01
Page 1
E-AB412-PT6T-2
3. SERVICEABILITY CHECKS - INTERMEDIATE OR TAIL GEARBOX
1. Remove, inspect, and clean appropriate chip detector.
2. Drain gearbox oil into a clean container. Inspect oil for chips.
3. Flush gearbox with clean, approved oil (Chapter 12). Inspect for chips.
4. Service gearbox with clean, approved oil.
5. Accomplish ground run in accordance with paragraph "1. Serviceability checks - transmission, tail rotor gearbox and
intermediate gearbox", step 6.
6. Repeat steps 1., 2., and 4. above.
7. If number of particles has increased, or if particles can be visually identified as chip or flakes from a gear or bearing,
replace gearbox. If number of particles has decreased and only minute particles are found, continue gearbox in service.
8. After five hours of service, repeat steps 1., 2., and 4. above.
9. If the number of particles has increased, or particles can be visually identified as chips or flakes from a gear or bearing,
replace gearbox. If the number of particles has decreased and only minute particles are found, continue gearbox in
service.
63-00-01
Page 2
E-AB412-PT6T-2
63-1 -01 ENGINE TO TRANSMISSION (MAIN) DRIVESHAFT
63-11-01
ENGINE TO TRANSMISSION (MAIN) DRIVESHAFT
1. ENGINE TO TRANSMISSION (MAIN) DRIVESHAFT - DESCRIPTION
The main driveshaft is installed between an adapter on the engine combining (reduction) gearbox and input drive quill on
transmission. The driveshaft is a steel tube with grease lubricated, spherical, splined coupling assemblies on either end to
provide flexibility.
The following paragraphs provide maintenance instructions for the main driveshaft. Vibration analysis and balancing is
contained in Chapter 18.
2. ENGINE TO TRANSMISSION (MAIN) DRIVESHAFT - REMOVAL
1. Remove left and right air inlet fairings.
2. Open left engine top cowling. Disconnect fire detector leads at firewall. Disconnect left starter generator air hose from
vent in engine cowl.
3. Remove left engine top cowling.
4. For helicopters codes [A] [B] and [C], do the steps that follow:
a. If applicable, put a mark to identify the locations of the balancing weights (2 and 8, figure 1).
b. Hold the driveshaft (6) and remove nuts (4 and 11), washers (3 and 10), bolts (1 and 7), and balancing weights
(2 and 8), if installed.
c. Put a mark on the flexible couplings for installation in the same position.
d. Push the driveshaft (6) forward until the aft end is free.
e. Remove the driveshaft (6).
5. For helicopters code [D], do the steps that follow:
a. Put marks to identify the location of the balancing weights (13 and 19).
b. Hold the driveshaft (17) and remove the nuts (12 and 18), balancing weights (13 and 19) (where applicable),
washers (15 and 20), and bolts (14 and 21).
c. Put a mark on the flexible couplings for installation in the same position.
d. Push the driveshaft (17) forward until the aft end is free.
e. Remove the driveshaft (17).
3. ENGINE TO TRANSMISSION (MAIN) DRIVESHAFT - DISASSEMBLY/ASSEMBLY
Refer to E-AB412-PT6T-3 for disassembly and assembly instructions.
63-11-01
Rev. 3 Page 1
E-AB412-PT6T-2
4. ENGINE TO TRANSMISSION (MAIN) DRIVESHAFT - INSTALLATION
The two ends of the driveshaft can be installed forward. It is recommended that the flexible coupling with the identification
plate be installed in the forward position.
1. For helicopters codes [A] [B] and [C], do the steps that follow:
a. Put the driveshaft (6, figure 1) in position in the center firewall.
NOTE
It is necessary to push the flexible couplings inboard to accomplish the step that
follows. If possible, compress the flexible couplings equally to avoid moving the
lubricant inside.
Use the marks from the removal to help put the flexible couplings in the initial
position.
b. Put the flexible couplings in the correct position on the main input quill curvic coupling adapter (9) and the
engine-to-driveshaft curvic coupling adapter (5).
NOTE
Use the marks from the removal to put the balancing weights in the initial position.
c. If necessary, install the balancing weights (2 and 8) where applicable.
d. Install bolts (1 and 7), washers (3 and 10), and nuts (4 and 11).
NOTE
Refer to figure 1 for torque sequence.
e. Torque nuts (4 and 11) 100 to 140 in-lbs (11.30 to 15.81 Nm).
2. For helicopters code [D], do the steps that follow::
a. Put the driveshaft (17) in position in the center firewall.
NOTE
It is necessary to push the flexible couplings inboard to accomplish the step that
follows. If possible, compress the flexible couplings equally to avoid moving the
lubricant inside.
Use the marks from the removal to help put the flexible couplings in the initial
position.
b. Put the flexible couplings in the correct position on the main input quill curvic coupling adapter (22) and the
engine-to-driveshaft curvic coupling adapter (16).
NOTE
Use the marks from the removal to put the balancing weights in the initial position.
c. Install bolts (14 and 21), washers (15 and 20), balancing weights (13 and 19) (where applicable), and nuts (12
and 18).
NOTE
Refer to figure 1 for torque sequence.
63-11-01
Page 2 Rev. 3
E-AB412-PT6T-2
d. Torque bolts (14 and 21) 70 to 90 in-lbs (7.91 to 10.16 Nm).
3. Connect the starter generator air hose and the fire detector leads.
4. Install the air inlet fairings and the engine top cowling.
NOTE
Ground run and leak check must be performed following installation of new,
repaired, or relubricated driveshaft flexible couplings.
5. Perform ground run of helicopter for approximately 5 minutes at 100% rotor RPM (refer to E-AB412-PT6T-1 Flight
Manual).
6. After the rotor is stopped, inspect the flexible coupling and surrounding structure for signs of grease leakage.
7. If there is evidence of leakage, remove the driveshaft (6 or 17) and inspect in accordance with E-AB412-PT6T-3
Overhaul Manual.
NOTE
For helicopters codes [A] [B] and [C], the step that follows is optional and not
necessary for component life or serviceability requirements.
For helicopters code [D] and subsequent the driveshaft must be balanced anytime it
has been removed (Chapter 18).
8. If necessary, balance the driveshaft (6 or 17) (paragraph "10. Engine to transmission (main) driveshaft - balancing").
63-11-01
Rev. 3 Page 3
E-AB412-PT6T-2
SEE VIEW
HELICOPTERS CODES [A] [B] [C]
A
HELICOPTERS CODE [D]
G6AB1061A
Figure 1. Engine-to-transmission (main) driveshaft (sheet 1 of 2)
63-11-01
Page 4 Rev. 3
E-AB412-PT6T-2
1. Bolt
2. Balancing weight
3. Washer
4. Nut
5. Engine-to-driveshaft curvic coupling adapter
6. Driveshaft
7. Bolt
8. Balancing weight
9. Main input quill curvic coupling adapter
10. Washer
11. Nut
12. Nut
13. Balancing weight
14. Bolt
15. Washer
16. Engine-to-driveshaft curvic coupling adapter
17. Driveshaft
18. Nut
19. Balancing weight
20. Washer
21. Bolt
22. Main input quill curvic coupling adapter
70 TO 90 IN-LBS
(7.91 TO 10.16 Nm)
100 TO 140 IN-LBS

(11.30 TO 15.81 Nm)
NOTE:
1 Torque bolts in three steps; 1/3 full torque, 2/3 full torque and full torque respectively.
Tighten bolts in sequence as shown in view A. Repeat sequence at each torque step.
2 Use aft flange of coupling for balance adjustment when air conditioning is installed.
Figure 1. Engine-to-transmission (main) driveshaft (sheet 2 of 2)
63-11-01
Rev. 3 Page 5
E-AB412-PT6T-2
5. ENGINE TO TRANSMISSION (MAIN) DRIVESHAFT - TROUBLESHOOTING
Table 1. Troubleshooting - engine-to-transmission (main) driveshaft
High frequency vibration Improperly assembled driveshaft. Remove, disassemble, inspect, and
assembly driveshaft (E-AB412-PT6T-3).
Loss of grease from coupling. Remove, disassembly, inspect, assembly,

and install coupling (E-AB412-PT6T-3).
Loose engine adapter or adapter bolt. Remove, inspect, and install engine
adapter.
Dirt or burr on mounting diameters of Remove, inspect, clean, and install drive-
driveshaft. shaft.
Loose coupling bolt(s). Loosen, then retighten coupling bolts in

sequence.
Driveshaft out of balance. Balance driveshaft (Chapter 18).
Improperly assembled driveshaft cou- Remove, disassemble, inspect, assembly,

pling. and install coupling (E-AB412-PT6T-3).
Grease leakage Faulty packings or seals. Replace packings or seals

(E-AB412-PT6T-3).
Over-temperature indicator Possible overheat condition and/or Refer to paragraph "7. Engine to trans-
(TEMP-PLATE) shows discolora- component degradation. mission (main) driveshaft - inspection".
tion (from white to black)
6. ENGINE TO TRANSMISSION (MAIN) DRIVESHAFT - CLEANING
MATERIALS REQUIRED
NUMBER NOMENCLATURE
1. Prior to cleaning, inspect driveshaft for lubricant leakage (figure 2).
CAUTION
DO NOT IMMERSE DRIVESHAFT IN SOLVENT OR ANY CLEANING

AGENTS.
2. Clean driveshaft parts, except boots (3 and 5), with a clean, lint-free cloth dampened with solvent (C-304).
3. Dry driveshaft with filtered, compressed air.
4. Clean boots (3 and 5) with a clean, dry, lint-free cloth.
63-11-01
Page 6 Rev. 3
E-AB412-PT6T-2
1. Retainer plate
2. Coupling
3. Boot
4. Driveshaft
5. Boot
6. Coupling
7. Visual over-temperature indicators
(“TEMP-PLATES”)
G6AB0422B
Figure 2. Main driveshaft - damage limits (sheet 1 of 2)
63-11-01
Rev. 3 Page 7
E-AB412-PT6T-2
NOTES:
1. Evidence of lubricant leakage at couplings (2) or (6) is cause for overhaul evaluation of driveshaft. Refer to E-AB412-PT6T-3
manual.
2. Mechanical and corrosion damage limits on shaft (4) are defined as follows:
MECHANICAL/CORROSION DAMAGE LIMITS
Nicks and scratches running parallel to, or Not exceeding 0.004 in (0.101 mm) in depth are acceptable without repair.
within 15° of parallel to shaft axis.
Not exceeding 0.008 in (0.203 mm) in depth or 1.5 in (38 mm) in length are
acceptable if polished out, provided the total polished area does not exceed 10%
of circumference at any point.
Nicks and scratches not running within 15° Not exceeding 0.004 in (0.101 mm) in depth are acceptable on up to 100% of the
of shaft axis. circumference of shaft if polished out.
Not exceeding 0.008 in (0.203 mm) in depth or 1.5 in (38 mm) in length are
acceptable provided the total polished area does not exceed 10% of circumfer-
ence at any point.
Corrosion pitting. Not exceeding 0.008 in (0.203 mm) in depth is acceptable provided it is polished
out. Maximum length of rework at any point must not exceed 1.5 in (38 mm) nor
cover more than 10% of the circumference at any point. The maximum accepta-
ble total reworked area is 4.0 sq-in (2580 mm²).
3. Mechanical and/or corrosion damage on plate (1) or similar plate in couplings (6) that could result in lubricant leakage is not
acceptable.
4. Mechanical and/or corrosion damage on boots (3 and 5) that could result in lubricant leakage is not acceptable.
5. Superficial mechanical damage on couplings (2 and 6) is acceptable without repair. Mechanical damage in excess of superficial
and/or corrosion damage is cause for overhaul evaluation of driveshaft. Refer to E-AB412-PT6T-3 manual.
6. Visual over-temperature indicator (“TEMP-PLATES”) for discoloration and overheat condition. A change in color of
“TEMP-PLATES” dots from to black will indicate a possible overheat condition and/or components, and cause of indicator
(“TEMP-PLATES”) dots discoloration should be determined prior to condition operation. Refer to E-AB412-PT6T-3 manual for
Inspection and Lubrication procedures.
Figure 2. Main driveshaft - damage limits (sheet 2 of 2)
63-11-01
Page 8 Rev. 3
E-AB412-PT6T-2
7. ENGINE TO TRANSMISSION (MAIN) DRIVESHAFT - INSPECTION
1. Inspect driveshaft in accordance with figure 2.
2. Refer to E-AB412-PT6T-3 manual for detailed inspection information.
3. Perform serviceability check of over-temperature indicator (TEMP-PLATE) as follows:
a. Over-temperature indicators (TEMP-PLATE) must not show evidence of over-temperature, deterioration,

debonding, or discoloration of the epoxy coating that prevents interpretation of the indicating dots. If any of
these conditions exist, proceed to step b.
b. If only one over-temperature indicator (TEMP-PLATE) of a given color is missing, and no dot on any other
over-temperature indicator (TEMP-PLATE) (on the same coupling) is discolored or shows mechanical damage
or degradation of the epoxy overcoating, the helicopter may be returned to service. The discrepant
over-temperature indicator (TEMP-PLATE) should be replaced as soon as practical.
c. If any indicator dot on either the red or yellow bordered over-temperature indicator (TEMP-PLATE) has
changed color to black, see table 2 for probable cause and required corrective action.
Table 2. Main driveshaft TEMP-PLATE condition and corrective action
ONE YELLOW OTHER YELLOW ONE RED OTHER RED PROBABLE SEE
TEMP-PLATE TEMP-PLATE TEMP-PLATE TEMP-PLATE CAUSE NOTE
Good Black Good Good Defect/Instl. 1
Black Black Good Good Elevated Temp. 2
Good Good Black Good Defect/Instl. 1
Good Good Black Black Defect/Instl. 4
Black Black Black Black Overtemp 3
Part Black Good Good Good Chem. Contamination 1
Part Black Part Black Good Good Chem. Contamination 1
Good Good Part Black Good Chem. Contamination 1
Good Good Part Black Part Black Chem. Contamination 4
Missing Good Good Good Defect/Instl. 1
Missing Missing Good Good Possible Elevated 2

Temperature
Good Good Missing Good Defect/Instl. 1
Good Good Missing Missing Defect/Instl. 4
Missing Missing Missing Missing Possible Overtemp 3
63-11-01
Rev. 3 Page 9
E-AB412-PT6T-2
(Cont.d)
ONE YELLOW OTHER YELLOW ONE RED OTHER RED PROBABLE SEE
TEMP-PLATE TEMP-PLATE TEMP-PLATE TEMP-PLATE CAUSE NOTE
NOTES:
1. Resume operation. Defective TEMP-PLATE or improper installation, replace defective TEMP-PLATE as soon as
practical in accordance with E-AB412-PT6T-3 Manual.
2. Elevated coupling temperature is indicated. Determine probable cause of elevated temperature indication and take
corrective action prior to continued operation. Accomplish checks in steps a. and b.. If probable cause is not revealed
from steps a. or b., perform steps c. and d.. It is recommended that the affected TEMP-PLATE be replaced in
accordance with E-AB412-PT6T-3 Manual prior to resuming operation.
a. Check the driveshaft coupling for any sign of grease leakage. If leakage is detected, the coupling must be
serviced prior to returning the aircraft to service.
b. Review current aircraft operating conditions to determine the probable cause of elevated coupling temperature.
For example, extended operation at CG limits, extended operation at high power, repeated heavy lift, or high
ambient temperature. Make appropriate adjustment to correct condition.
c. Inspect engine mounts and transmission pylon mounts for condition.
d. Verify engine to transmission alignment.
3. Coupling over temperature condition is very likely. Remove driveshaft and perform over temperature inspection in
accordance with E-AB412-PT6T-3 Manual.
4. Same as Note 1 except during operations before TEMP-PLATE replacement, a yellow-bordered TEMP-PLATE
indication shall be considered as an overtemperature indication and Notes 2 and 3 accomplished.
8. ENGINE TO TRANSMISSION (MAIN) DRIVESHAFT - REPAIR
MATERIALS REQUIRED
NUMBER NOMENCLATURE
C-204 PRIMER
1. Polish out acceptable defects on driveshaft (4, figure 2). Use minimum radius of 0,50 in (12,7 mm) in polishing out
surface damage. Ensure damage limits are not exceeded.
2. Refinish polished area with two coats of primer (C-204).
3. Replace over-temperature indicator (TEMP-PLATE) (7) if mutilated or discolored (E-AB412-PT6T-3).
9. ENGINE TO TRANSMISSION (MAIN) DRIVESHAFT - LUBRICATION
Refer to E-AB412-PT6T-3 for coupling lubrication instructions.
63-11-01
Page 10 Rev. 3
E-AB412-PT6T-2
10. ENGINE TO TRANSMISSION (MAIN) DRIVESHAFT - BALANCING
NOTE
Helicopters code [D] equipped with Main Driveshaft P/N 412-040-005-101/-103,
perform main driveshaft balancing whenever driveshaft is removed and reinstalled.
Refer to Chapter 18 for balancing procedures.
63-11-01
Rev. 3 Page 11
E-AB412-PT6T-2
63-11-01
Page 12 Rev. 3
E-AB412-PT6T-2
63-1 -02 ENGINE TO DRIVESHAFT CURVIC COUPLING ADAPTER
63-11-02
ENGINE TO DRIVESHAFT CURVIC COUPLING ADAPTER
1. ENGINE TO DRIVESHAFT CURVIC COUPLING ADAPTER - REMOVAL
NUMBER NOMENCLATURE
T41 WRENCH SET - CURVIC COUPLING, OR
T48-2 WRENCH SET - CURVIC COUPLING, OR
1. Remove main driveshaft (module 63-11-01 paragraph "2. Engine to transmission (main) driveshaft - removal").
2. Straighten tang of washer (3, figure 1) to permit removal of nut (4).
3. Position plate assembly (7, figure 2) on adapter (1) and install retaining nut (4).
4. Install extension bar (6). Hold plate assembly (7) and turn extension bar to loosen retaining nut (5).
5. Remove extension bar (6), plate assembly (7), and nut (5).
6. Remove engine to driveshaft curvic coupling adapter (2).
7. Discard washer (3).
2. ENGINE TO DRIVESHAFT CURVIC COUPLING ADAPTER - INSTALLATION
MATERIALS REQUIRED
NUMBER NOMENCLATURE
C-001 GREASE
NUMBER NOMENCLATURE
T41 WRENCH SET - CURVIC COUPLING OR
T48-2 WRENCH SET - CURVIC COUPLING, OR
1. Position engine-to-driveshaft curvic coupling adapter (2, figure 1) on engine (1). Lubricate threads and mating face of
nut (4) lightly with gease (C-001) or bearing grease (C-007). Keep mating faces of washer (3) and engine-to-driveshaft
curvic coupling adapter (2) dry.
63-11-02
Page 1
E-AB412-PT6T-2
2. Install washer (3) and nut (4) on engine hand tight. Using suitable marker, mark an index line on outer lock washer
tang and adapter to enable verification lock washer does not rotate during torquing.
3. Position plate assembly (7, figure 2) on adapter (1) and install nut (4). Position extension bar (6) in retaining nut (5).
4. Torque retaining nut (5) 250 to 275 ft.-lbs. (339 to 373 Nm) for initial torque. Loosen nut (5) then torque 125 to 200
ft.-lbs. (170 to 271 Nm).
5. Remove extension bar (6) and plate assembly (7).
6. Inspect washer (3, figure 1) to ensure tang indexed in step 2. has not rotated. If inspection reveals washer (3) has
rotated, replace washer and repeat steps 1. through 5. above.
7. Bend single tab of washer (3) into slot of nut (4).
3. ENGINE TO DRIVESHAFT CURVIC COUPLING ADAPTER - INSPECTION
Inspect adapter (2, figure 1) for mechanical and corrosion damage. Superficial damage is acceptable without repair. Minor
damage on curvic coupling face that contacts main driveshaft is acceptable if polished out as described in the following
paragraph.
4. ENGINE TO DRIVESHAFT CURVIC COUPLING ADAPTER - REPAIR
MATERIALS REQUIRED
NUMBER NOMENCLATURE
C-464 INDIA STONE
Repair of adapter is restricted to polishing out minor damage on face which contacts driveshaft. Polish out repairable damage
with a fine India stone (C-464).
63-11-02
Page 2
E-AB412-PT6T-2
G6AB0440A
Figure 1. Engine to driveshaft curvic coupling adapter
63-11-02
Page 3
E-AB412-PT6T-2
G6AB0441A
Figure 2. Engine to driveshaft curvic coupling wrench set - tool application
63-11-02
Page 4
E-AB412-PT6T-2
63-21-01
MAIN ROTOR MAST
1. MAIN ROTOR MAST - DESCRIPTION
The main rotor mast (2, figure 1) is a tubular steel shaft which includes a bearing and plate for attachment to top of
transmission. A bearing race is installed on lower end of mast which mates with a roller bearing located in transmission.
The following paragraphs provide maintenance information for the main rotor mast.
2. MAIN ROTOR MAST - REMOVAL
NUMBER NOMENCLATURE
T38 HOIST OR EQUIVALENT
T50 COVER PLATE
T58 MAST NUT
T59 CLEVIS
T108 SLIDE HAMMER WITH 1/4 X 20

UNC THREADED SHAFT
1. Remove main rotor hub and blade assembly (Chapter 62).
CAUTION
HELICOPTERS CODE [D] HAVE A TORQUEMETER ASSEMBLY (TORQUE

TUBE ASSEMBLY) INSTALLED INSIDE THE MAST. REMOVAL OF PLUG
AND TUBE ASSEMBLY REQUIRES REALIGNMENT. HELICOPTERS WITH
A 412-375-004-105 MONOPOLE SENSOR INSTALLED REQUIRE THE
TORQUE TUBE TO BE REALIGNED AT HELICOPTER MANUFACTURER.
HELICOPTERS WITH A 412-375-004-109 MONOPOLE SENSOR INSTALLED
MAY HAVE TORQUE TUBE ALIGNED USING 412-240-028-101 MAST
TORQUEMETER ALIGNMENT TOOL. AFTER A MAST IS INSTALLED INTO
THE TRANSMISSION, A ZERO TORQUE CALIBRATION IS REQUIRED
(CHAPTER 96).
NOTE
Hub and sleeve assembly may be removed with swashplate and support assembly as
a unit. Care must be exercised to prevent damage to mast and hub spline.
2. Remove hub sleeve assembly (Chapter 62).
63-21-01
Rev. 3 Page 1
E-AB412-PT6T-2
3. Remove swashplate and support assembly (Chapter 62).
WARNING
DO NOT LIFT MAST (2, FIGURE 1) WITH MAST CAP (412-010-160-103). USE
MAST NUT (1) (T58).
4. Install mast nut (1). Attach clevis (T59) to nut. Attach hoist to clevis.
5. For helicopters code [D], remove monopole sensor assembly (13) from bottom of transmission and mast (2) as follows:
NOTE
Some oil will be trapped behind monopole sensor assembly (13).
a. Cut and remove lockwire from four screws (16) and remove screws with washers (15).
b. Remove sealant from around base of monopole sensor assembly (13) using a sharp plastic scraper.
CAUTION
DO NOT USE JACKSCREW(S) TO PULL SENSOR FROM CASE. DO NOT

ALLOW PULLER TO BOTTOM OUT IN THREADED HOLE OF SENSOR.
c. Install slide hammer with 1/4 X 20 UNC threaded shaft in outboard holes of monopole sensor assembly (13),
pull sensor and spacer (14) from support case. Remove and discard packing (12).
6. Remove nuts (3), washers (4 and 6), temperature bulb clamp bracket (5) and wire clamp bracket (7) from mast bearing
retainer plate (8). Remove sealant from around base of retainer plate with a sharp plastic scraper.
7. Disconnect mast bearing oil hose (10) from retainer plate (8). Cap or plug oil jet and hose.
CAUTION
DO NOT TOUCH THE SECTION OF MAST INSTALLED IN TRANSMISSION

WITH BARE HANDS.
NOTE
Heating top case of transmission with a heat lamp will aid in mast removal.
8. Carefully lift mast (2) from transmission. Immediately after removal, install cover lift plate (T50).
9. Position mast (2) on padded stand to prevent damage to mast. Place protective cover on lower bearing race (9). Remove
clevis (T59). Leave mast nut (1) installed to protect threads.
63-21-01
Page 2 Rev. 3
E-AB412-PT6T-2
Torque 100 to 140 in-lbf

(11.30 to 15.82 Nm)
WARNING
DO NOT LIFT MAST (2) WITH MAST CAP

(412-010-160-103). USE MAST NUT (1)
(204-010-481-001).
NOTE:
1 Helicopters code [D].
1. Mast nut 11. Transmission

2. Mast 12. Packing
3. Nut 13. Monopole sensor assembly
4. Steel washer 14. Spacer
5. Temperature bulb clamp bracket 15. Washer
6. Aluminum washer 16. Screw
7. Wire clamp bracket 17. Bolt
8. Mast bearing retaining plate 18. Plug
9. Lower bearing race 19. Torque tube
10. Hose
G6AB0446C
Figure 1. Main rotor mast (sheet 1 of 2)
63-21-01
Rev. 3 Page 3
E-AB412-PT6T-2
G6AB0447A
Figure 1. Main rotor mast (sheet 2 of 2)
63-21-01
Page 4 Rev. 3
E-AB412-PT6T-2
3. MAIN ROTOR MAST - INSTALLATION
MATERIALS REQUIRED
NUMBER NOMENCLATURE
C-405 LOCKWIRE
C-516 CLEAN CLOTH
NUMBER NOMENCLATURE
T50 COVER PLATE
T58 MAST NUT
T59 CLEVIS
1. Remove cover plate from transmission.
2. Perform dimensional check of transmission to prevent damage to upper planetary assembly as follows:
a. Place straight edge (1, figure 2) on transmission top case (2). Measure from top of mast driving adapter (3) to
straight edge and record dimension. If dimension is less than 2.226 in (56.540 mm) comply with step b. through
d.
WARNING
HANDLE MAST DRIVING ADAPTER (3) CAREFULLY WHEN INDEXING

BEARING LINERS. INJURY TO FINGERS MAY RESULT.
b. Inspect upper and lower bearing liners (5 and 6) to determine whether tangs are disengaged. If tangs are
disengaged, a gap of approximately 0.25 in (6.35 mm) will be evident.
c. Insert hands back-to-back through mast driving adapter (3). Lift mast driving adapter slightly and rotate upper
bearing liner (5) until tabs on upper bearing liner (5) align with slots in lower bearing liner (6) and drop into
position.
d. Repeat measurements described in step a.
WARNING
DO NOT LIFT MAST (2, FIGURE 1) WITH MAST CAP (412-010-160-103). USE
ONLY MAST NUT (T58) TO LIFT MAST.
63-21-01
Rev. 3 Page 5
E-AB412-PT6T-2
3. Install mast nut (1, figure 1). Attach clevis (T59) to mast nut (1). Attach hoist to clevis.
CAUTION
HELICOPTERS CODE [D] HAVE A TORQUEMETER ASSEMBLY INSTALLED

IN MAST (2). FAILURE TO REMOVE MONOPOLE SENSOR ASSEMBLY (13)
BEFORE INSTALLING MAST (2) CAN CAUSE DAMAGE TO
TORQUEMETER ASSEMBLY.
4. Clean the mating surfaces of the mast bearing retaining plate (8) and the transmission (11) top case with a clean cloth
(C-516) moistened with aliphatic naphtha (C-305). Wipe the surfaces dry with a clean cloth before the solvent
evaporates.
NOTE
Heating transmission top case with a heat lamp will aid in installation.
5. Lower mast (2) carefully into transmission (11). Guide lower bearing race (9) of mast into lower bearing of
transmission.
6. Align mast bearing retaining plate (8) with studs in top of transmission (11).
7. Make sure that the surfaces are clean (step 4.), then apply a thin uniform coating of adhesive sealant (C-308) to mating
surfaces of mast bearing retaining plate (8) and top of transmission (11) before allowing mast bearing retaining plate
to seat.
8. Lower mast (2) until mast bearing retaining plate (8) is in contact with transmission (11) top case.
9. Install temperature bulb clamp bracket (5) next to mast bearing retaining plate (8). Install steel washer (4) and nut (3).
Install wire clamp bracket (7) with one aluminum washer (6) under L bracket and one above bracket and one steel
washer (4) under nut (3). Torque nuts (3) 100 to 140 in-lbf (11.30 to 15.82 Nm).
10. Apply a bead of adhesive sealant (C-308) around the mating edges of the mast bearing retaining plate (8) and the
transmission (11) top case. Make sure to keep the three drain holes open and free of sealant.
11. Connect oil hose (10) to mast bearing oil jet.
12. Rotate transmission input quill by hand to ensure there is no unusual noise or binding.
13. Remove clevis and mast nut (1). Use mast cap assembly for final installation.
a. For helicopters code [D] accomplish torque tube assembly alignment in accordance with paragraph "6. Main
rotor mast - torque tube assembly alignment". Alignment is only required if torque tube was removed or
disturbed during mast removal or installation.
NOTE
Replacement monopole sensor assemblies (13) will have spacer (14) temporarily
attached with hardware for shipping. Remove shipping hardware and retain spacer
for installation with monopole sensor.
14. For helicopters code [D], install monopole sensor assembly (13) in bottom of transmission (11) as follows:
a. Lubricate new packing (12) with transmission oil (Chapter 12) and install on monopole sensor assembly (13).
b. Clean transmission support case free of oil and adhesive residue using plastic scrapper and a clean cloth
dampened with drycleaning solvent (C-304).
63-21-01
Page 6 Rev. 3
E-AB412-PT6T-2
c. Apply light coat of transmission oil (Chapter 12) to bore in support case.
d. Insert monopole sensor assembly (13), with spacer (14) installed, into support case and align monopole sensor
assembly screw holes with holes in support case of transmission (arrow pointing forward).
e. Install four screws (16) with washers (15). Secure screws with lockwire (C-405).
f. Apply a bead of adhesive sealant (C-308) around mating surface of sensor.
15. Install swashplate and support assembly (Chapter 62).
16. Install hub and sleeve assembly (Chapter 62).
17. Install main rotor hub (Chapter 62).
18. For helicopters code [D], calibrate mast torque system (Chapter 96).
19. Install blade assembly (Chapter 62).
4. MAIN ROTOR MAST - CLEANING
MATERIALS REQUIRED
NUMBER NOMENCLATURE
CAUTION
DO NOT ALLOW SOLVENT TO ENTER MAST BEARINGS.
1. Clean main rotor mast (2, figure 1) with a clean, lint-free cloth damp with drycleaning solvent (C-304).
2. Dry mast with filtered, compressed air.
5. MAIN ROTOR MAST - INSPECTION AND REPAIR
Inspect and repair mast in accordance with E-AB412-PT6T-3.
6. MAIN ROTOR MAST - TORQUE TUBE ASSEMBLY ALIGNMENT
MATERIALS REQUIRED
NUMBER NOMENCLATURE
C-339 ETHYL ALCOHOL
C-405 LOCKWIRE
63-21-01
Rev. 3 Page 7
E-AB412-PT6T-2
NUMBER NOMENCLATURE
T50-3 JACKSCREWS
T62-3 MAST TORQUEMETER ALIGNMENT TOOL
NOTE
The following procedure is applicable to helicopters code [D] which have a
412-375-004-109 monopole sensor assembly (13, figure 1) and 412-040-366-111 or
-113 mast assembly. For helicopters with 412-375-004-105 monopole sensor
assembly and 412-040-366-109 mast assembly installed, torque tube alignment for
transmissions shall be accomplished at AgustaWestland only.
1. Remove monopole sensor assembly (13, figure 1) (paragraph "2. Main rotor mast - removal").
2. Remove torque tube (19) from mast (2) as follows:
a. Remove mast nut (1).
b. Using a sharp plastic scraper, remove sealant from torque tube (19) and mast (2).
c. Cut and remove lockwire from bolts (17) and remove bolts from plug (18).
d. Remove plug (18) using jackscrews (T50-3).
e. Insert a wooden rod (broom stick) inside torque tube (19) through the opening in the bottom of mast (2).
f. Using a hammer, lightly tap the wooden rod against the top of torque tube (19).
g. When torque tube (19) breaks loose, remove it from mast (2).
3. Clean surface of rotor in mast assembly which contacts with torque tube (19). Apply light coat of transmission oil to
surface. Verify surface is smooth and clean.
CAUTION
DO NOT ROTATE ANY DRIVE SYSTEM COMPONENTS WHILE TOOL IS

INSTALLED.
4. Insert alignment tool (T62-3) in bottom of transmission support case. Work top and bottom splines of tool up through
spline of rotor assembly in bottom of mast (2). Rotate tool counterclockwise (looking up at bottom of mast) until
splined teeth of tool are bottomed out against teeth of rotor in mast assembly. Hold tool in place with four screws and
washers, leave screws loose enough to allow 1/4 in movement of tool.
5. Clean outer bearing surface of torque tube (19). Verify surface is smooth. Use care to keep bearing surface clean during
installation.
6. Clean the mating surfaces of the torque tube (19) and the mast (2).
7. Apply adhesive sealant (C-308) on top of the mast (2).
8. Install torque tube (19) into mast (2) carefully. Rotate torque tube slightly, if required, to engage upper spline of
alignment tool (T-62-3). Continue installation until fully seated at top of mast.
63-21-01
Page 8 Rev. 3
E-AB412-PT6T-2
9. Ensure slots of torque tube flange are filled with adhesive sealant (C-308).
10. Remove any excess sealant from flange and top of mast.
11. Rotate torque tube counterclockwise (looking down from top of mast) as far as alignment tool will allow. Torque tube
may be rotated by gently by tapping on split flange with soft metal bar and mallet. Hold alignment tool
counterclockwise with upward pressure while tube is lowered. If alignment tool is pushed down while lowering torque
tube, this is an indication of misalignment. Rotate torque tube gently until alignment tool rises. This indicates the
alignment tool has engaged both the signals and reference gears.
12. Install plug (18) into torque tube (19). Install bolts (17) and torque to 50 to 70 in-lbs (5.65 to 7.91 Nm) in symmetrical
manner.
13. Loosen bolts on alignment tool. Verify tool can be rotated slightly and fits loosely in splines of mast (2) and torque
tube (19). If tool cannot be rotated, repeat steps 11. and 12.
14. Remove alignment tool by pulling tool past torque tube spline, rotating tool a few degrees, and pulling tool out past
mast spline.
15. Install monopole sensor assembly (13) (paragraph "3. Main rotor mast - installation").
16. Secure torque tube plug (18) with lockwire (C-405). Apply ethyl alcohol (C-339) to mating surfaces of torque tube
(19).
17. Install mast nut (1) (Chapter 62).
18. Perform mast torque system zero torque calibration (module 96-24-36 paragraph "2-4. Mast torque measurement
system [D] - zero torque calibration").
19. Perform mast torque system flight check (module 96-24-36 paragraph "2-5. Mast torque measurement system [D] -
mast torque system flight check").
63-21-01
Rev. 3 Page 9
E-AB412-PT6T-2
1. Straight edge
2. Transmission top case
3. Mast driving adapter
4. Mast driving adapter extension
5. Upper bearing liner
6. Lower bearing liner
7. Bearing
8. Bearing
G6AB0448B
Figure 2. Mast driving adapter to transmission top case dimension requirements
63-21-01
Page 10 Rev. 3
E-AB412-PT6T-2
63-2 -01 TRANSMISSION
63-22-01
TRANSMISSION
1. TRANSMISSION - DESCRIPTION
The transmission (figure 1) is a mechanical reduction gearbox attached to fuselage structure by four isolation mounts at
corners of transmission support case and by lift link which is the main load bearing component. The two aft isolation mounts
attach to helicopter structure and also to friction dampers. The lift link is attached to transmission support case and helicopter
lift beam.
2. TRANSMISSION - REMOVAL
MATERIALS REQUIRED
NUMBER NOMENCLATURE
NUMBER NOMENCLATURE
T13 STAND
T38 HOIST
T48-1 DEHYDRATOR ASSEMBLY
T58 MAST NUT
T59 CLEVIS
T60-1 COVER AND LIFT PLATE
T88 ADAPTER
T89 COVER
1. If transmission is not to be reinstalled, accomplish transmission preservation by one of the following methods:
a. If helicopter and transmission are operational, perform a ten minute ground run in accordance with
E-AB412-PT6T-1 Flight Manual prior to removal of transmission. Prior to engine run-up, add corrosion
preventive compound (C-124) to transmission and gearbox oil system as follows:
63-22-01
Page 1
E-AB412-PT6T-2
(1) If the transmission is serviced with lubricating oil MIL-PRF-23699 (C-011), add corrosion preventive
compound (C-124) in the proportion of 150cc of concentrate to each liter of the oil system capacity (15%
concentration).
(2) If the transmission is serviced with lubricating oil DOD-PRF-85734 (C-030), add corrosion preventive
compound (C-124) in the proportion of 45cc of concentrate to each liter of the oil system capacity (5%
concentration).
(3) Use of corrosion preventive compound (C-124) in lubricating oil MIL-PRF-7808 (C-010) is not
recommended.
b. If transmission and engine cannot be ground run, accomplish preservation after transmission is removed as
follows:
(1) Remove mast assembly (module 63-21-01 paragraph "2. Main rotor mast - removal").
(2) Spray inside of transmission through top opening, with approximately four liters of applicable lubricating
oil mixed with corrosion preventive compound (C-124). Use 150cc of corrosion preventive compound
(C-124) per liter of lubricating oil if the transmission is serviced with lubricating oil MIL-PRF-23699
(C-011) (15% concentration). Use 45cc of corrosion preventive compound (C-124) per liter of lubricating
oil if the transmission is serviced with lubricating oil DOD-PRF-85734 (C-030) (5% concentration). While
spraying manually rotate internal gears and bearings with input drive quill. Ensure all gears, bearings and
surfaces are coated. Drain the transmission.
(3) Install cover and lift plate (T60-1) or install mast assembly.
(4) Cut and remove lockwire from plug and remove plug (AN814-6DL) from top case and install dehydrator
assembly (T48-1).
2. Remove hub and blade assembly (Chapter 62).
NOTE
Hub and sleeve assembly may be removed with swashplate and support assembly as
a unit. Care must be exercised to prevent damage to mast and hub splines.
3. Remove hub and sleeve assembly (Chapter 62).
4. Remove swashplate and support assembly (Chapter 62).
CAUTION
WHEN REMOVING THE TAIL ROTOR DRIVESHAFT (10, FIGURE 2) ON

HELICOPTERS CODES [A] [B] [C], BOTH CLAMP ASSEMBLIES (9 AND 11)
MUST BE REMOVED PRIOR TO REMOVING DRIVESHAFT (10). FAILURE
TO COMPLY MAY RESULT IN DAMAGE TO FLEXIBLE COUPLINGS.
NOTE
Tail rotor driveshaft clamps (9 and 11) are a matched set; keep in sets to maintain
balance. To replace one clamp half, or if clamp halves are intermixed, each clamp
half shall be re-matched with one of equal weight (within one gram).
63-22-01
Page 2
E-AB412-PT6T-2
SEE NOTE
NOTE
For helicopters codes B C refer to module 63-25-09
G6AB0453A
Figure 1. Transmission
63-22-01
Page 3
E-AB412-PT6T-2
6. Remove clamp assemblies (9 and 11) and remove tail rotor driveshaft (10).
7. For helicopters code [D], remove tail rotor driveshaft (10) connected to transmission (Chapter 65).
8. Drain oil from transmission sump (Chapter 12).
9. Disconnect oil inlet hose (7).
10. Disconnect oil outlet hose (23).
11. Disconnect oil sump drain line (22).
12. If installed, disconnect rotor brake hydraulic hoses and wiring.
14. Remove system 1 hydraulic pump (Chapter 29). Install cover (AN100036) (6) on pump drive quill.
15. Remove fluid from hydraulic system 2 using a suction gun. Disconnect all hoses from hydraulic system 2 pump. Do
not remove pump at this time. Cap all open ports and hoses.
16. Install mast nut (T58) (3) and clevis (T59) (1) with pin (18). Secure pin (18) with quick release pin (2).
NOTE
If mast is not installed, cover and lift plate (T60-1) shall be installed on transmission
for lifting.
CAUTION
BEFORE USING HOIST (T38) TO REMOVE OR INSTALL TRANSMISSION,

PLACE A SUPPORT UNDER TAILBOOM TO STEADY FUSELAGE.
17. If a suitable stationary or portable hoist is not available, install hoist assembly (T38).
18. Attach hoist to clevis (T59) (1).
19. Remove bolts (19), washers (20), and shouldered washers (21) from isolation mounts (24).
20. Tie forward isolation mounts (24) into position to prevent mounts from disengaging from support case.
21. Remove bolt (26) from lift link (31).
22. Install adapter (T88) on stand (T13) if not previously accomplished.
CAUTION
VERIFY HYDRAULIC PUMP FOR SYSTEM 1 AND ALL ELECTRICAL

WIRING, HOSES, LINES, AND ATTACHING HARDWARE IS REMOVED
BEFORE ATTEMPTING TO LIFT TRANSMISSION FROM HELICOPTER.
23. Hoist transmission clear of airframe. Place transmission in support stand and secure to stand with bolts.
24. If transmission is not to be reinstalled, remove bolt assembly (30) and lift link (31).
63-22-01
Page 4
E-AB412-PT6T-2
3. TRANSMISSION - INSTALLATION
MATERIALS REQUIRED
NUMBER NOMENCLATURE
C-405 LOCKWIRE
NUMBER NOMENCLATURE
T38 HOIST ASSEMBLY
T48-1 DEHYDRATOR ASSEMBLY
T58 MAST NUT
T59 CLEVIS
T60-1 COVER, LIFT PLATE
CAUTION
IF REPLACING TRANSMISSION FOR INTERNAL FAILURE OR METAL

PARTICLES IN OIL, CLEAN ALL OIL LINES AND REPLACE OIL COOLER,
EXTERNAL OIL FILTER, AND MAST ASSEMBLY.
1. Inspect condition of pylon structure and repair or replace any unserviceable isolation mounts (24, figure 2) and/or
dampers (25) (module 63-31-01).
2. Install mast assembly (module 63-21-01 paragraph "3. Main rotor mast - installation") and replace dehydrator
assembly (T48-1) in top case with plug (AN814-6DL). Torque plug or breather 80 to 120 in.-lbs. (9,04 to 13,56 Nm).
Secure plug with lockwire (C-405).
3. If not previously accomplished, position lift link (31) and washer (32) between lugs of fitting (36). Install bolt (30),
washer (33), and nut (34). Torque nut (34) 60 to 80 ft.-lbs. (81 to 108 Nm).
Install cotter pin (35).
4. Erect hoist assembly (T38 or equivalent). Install clevis (1) on mast nut (3). Attach hoist to clevis.
NOTE
If mast is not installed, cover and lift plate (T60-1) must be installed on transmission
for lifting.
5. Lift transmission from stand and lower into position on isolation mounts (24) while guiding lift link (31) into position
on lift beam.
63-22-01
Page 5
E-AB412-PT6T-2
(T59)
(T58)
G6AB0454A
Figure 2. Transmission removal and installation (sheet 1 of 2)
63-22-01
Page 6
E-AB412-PT6T-2
G6AB0455A
Figure 2. Transmission removal and installation (sheet 2 of 2)
63-22-01
Page 7
E-AB412-PT6T-2
6. Align lift link (31) with lift beam and install bolt (26), washer (27), and nut (29). Torque nut (29) 108 to 125 ft.-lbs.
(146,8 to 170 Nm). Install cotter pin (28).
NOTE
Ensure countersunk side of washer (20) is toward head of bolt (19). Washer (21) is
installed with beveled side down.
7. Install bolts (19), washers (20), and washers (21) on isolation mounts (24). Torque bolts (19) 90 to 105 ft.-lbs. (122 to
142 Nm). Remove ties holding forward isolation mounts (24) in position.
8. For helicopters code [C], install tail rotor driveshaft (10) as follows:
NOTE
Clamp assemblies (9 and 11) are a matched set. To replace one clamp half, or if
clamp halves are inadvertently mixed, each clamp half shall be rematched with one
of equal weight (within one gram) to maintain balance.
a. Position tail rotor driveshaft (10) between tail rotor drive quill (12) and tail rotor hanger coupling (8).
NOTE
All nuts used on a clamp shall be the same type and style. Nuts are self-locking and
shall not be used unless nut drag torque is 3,5 in.-lbs. (0,50 Nm) minimum and 30
in.-lbs. (3,39 Nm) maximum.
b. Install clamp assembly (9) with bolt heads in direction of rotation. Tighten clamp assembly bolts evenly. Torque
nuts 30 to 35 in.-lbs. (3,39 to 3,95 Nm) above nut friction. Tap lightly around outer surface of clamp assembly
with plastic mallet to seat clamp. Repeat torquing procedure.
c. Install clamp assembly (11) with bolt heads in direction of rotation and with clamp joints 90 to clamp assembly
(9). Torque clamp assembly bolts in same manner as described in step b. above.
9. For helicopters code [D], install forward tail rotor driveshaft (Chapter 65).
10. Install engine-to-transmission driveshaft (13) (module 63-11-01 paragraph "4. Engine to transmission (main)
driveshaft - installation").
11. Install hydraulic system 1 pump (Chapter 29).
12. Connect electrical connector (5) on right side of transmission.
13. Connect transmission oil inlet hose (7) to oil filter.
14. Connect transmission oil outlet hose (23) to manifold line.
15. Connect oil sump drain line (22).
16. If equipped, connect rotor brake hydraulic hose and electrical wiring.
17. Connect hydraulic system 2 inlet and pressure hoses, case drain hose, and seal drain hose to pump fittings.
18. Service transmission (Chapter 12). Verify actual presence of oil in sight gauge.
19. If transmission has not been previously qualified on run-in test stand, accomplish alternate run-in procedures in the
following module.
63-22-01
Page 8
E-AB412-PT6T-2
SEE NOTE
A D
NOTE
G6AB0456A
Figure 3. Transmission assembly
63-22-01
Page 9
E-AB412-PT6T-2
4. TRANSMISSION - INSPECTION
1. Inspect three electric chip detectors as follows:
a. Remove, inspect, and install mast bearing electric chip detector (3, figure 3) (module 63-41-01
"TRANSMISSION OIL SYSTEM COMPONENTS - MAST BEARING ELECTRIC CHIP DETECTOR").
b. Remove, inspect, and install main input gear quill chip detector (4) (module 63-41-02 "TRANSMISSION OIL
SYSTEM COMPONENTS - MAIN INPUT GEAR QUILL ELECTRIC CHIP DETECTOR").
c. Remove, inspect, and install sump electric chip detector (8) (module 63-41-03 "TRANSMISSION OIL
SYSTEM COMPONENTS - SUMP CASE ELECTRICAL CHIP DETECTOR [A] [B] [C]").
2. Inspect main driveshaft couplings and tail rotor drive quill couplings over-temperature indicator (TEMP-PLATE) for
discoloration. A change in color indicates a possible overheat condition and/or component degradation. Determine and
correct cause of discoloration prior to continued operation.
3. Remove, inspect, and install external oil filter (9) (module 63-24-01 paragraph "2. Transmission oil cooling system -
external oil filter").
4. Remove, inspect, and install sump internal oil filter (10) (module 63-23-17 "TRANSMISSION OIL SYSTEM
COMPONENTS - SUMP INTERNAL FILTER [A] [B] [C]").
5. Remove, inspect, and install oil pump inlet screen (7) (module 63-23-16 "TRANSMISSION OIL SYSTEM
COMPONENTS - OIL PUMP INLET SCREEN").
6. Inspect oil level sight glass (6) for crazing, cracks, or staining (module 63-23-19 "TRANSMISSION OIL SYSTEM
COMPONENTS - SIGHT GLASSES").
7. Inspect transmission for loose, missing, or damaged bolts and studs.
NOTE
Pay special attention to attaching bolts (26 and 30, figure 2) for lift link (31) and four
bolts (19) securing transmission support case to structure.
8. Inspect isolation mounts (24) and dampers (25) for secure installation and distortion.
9. Inspect transmission and attached oil lines for leaks. If main input quill is leaking, replace magnetic seal
(module 63-25-02).
10. Inspect transmission for mechanical and corrosion damage (E-AB412-PT6T-3).
11. Inspect transmission electrical wiring for secure installation and damaged wires.
12. Inspect main rotor mast (module 63-21-01 paragraph "5. Main rotor mast - inspection and repair").
NOTE
Additional detailed inspections of the transmission and component parts are found in
E-AB412-PT6T-3.
63-22-01
Page 10
E-AB412-PT6T-2
5. TRANSMISSION - TROUBLESHOOTING
NOTE
In analysis of transmission oil system troubles, consider the following characteristics
of the system.
1. Low oil level will not cause low oil pressure indications provided sump contains sufficient oil to cover pump inlet. Oil
temperature however, may rise.
2. Effects of an oil leak will depend on location of leak within system and rate of fluid loss. Do not exceed 10 drops per
minute from any single source. Do not exceed 15 drops per minute from all sources on the transmission. An external
leak can allow sump to be pumped dry, causing internal failure of transmission. While any oil remains in sump, the
pressure relief valve will tend to maintain normal system pressure. This applies especially to leaks between pump and
relief valve. Leaks occurring beyond the relief valve could cause indications of low oil pressure. Leaks in the interior
of transmission will not affect oil level but may starve downstream lubrication areas and also may affect indicated oil
pressure and temperature.
3. Cumulative clogging of oil filters will not show as a gradual drop in oil pressure because the pressure relief valve
maintains normal system pressure. The external filter has a visual indicator which will extend when filter bypass
conditions are impending. This indicator should be checked during all normal inspections.
63-22-01
Page 11
E-AB412-PT6T-2
63-22-01
Page 12
E-AB412-PT6T-2
63-2 -02 TRANSMISSION - BUILD-UP
63-22-02
TRANSMISSION - BUILD-UP
1. BUILD-UP - DESCRIPTION
MATERIALS REQUIRED
NUMBER NOMENCLATURE
C-405 LOCKWIRE
NUMBER NOMENCLATURE
T13 STAND
T15 ADAPTER
T38 HOIST
T60-1 COVER AND LIFT PANEL
1. Install adapter (T15) on stand (T13).
2. Install cover and lift plate (3, figure 1) on transmission using steel washers (2) and nuts (1).
3. Remove transmission from shipping container and position on stand (T13). Secure transmission to stand with bolts.
4. If transmission is to be installed in helicopter immediately, open drain valve (8) and allow all preservative oil to drain.
Close valve (8).
CAUTION
IF ANY OIL LINES FROM A TRANSMISSION WHICH WAS REMOVED DUE

TO INTERNAL FAILURE OR METAL CONTAMINATION ARE TO BE
INSTALLED ON REPLACEMENT TRANSMISSION, ENSURE ALL FOREIGN
PARTICLES ARE CLEANED FROM HOSES. MAST ASSEMBLIES FROM
TRANSMISSIONS DESCRIBED ABOVE SHALL BE OVERHAULED PRIOR
TO FURTHER USE.
NOTE
If components from transmission removed from helicopter are to be used for buildup
of replacement transmission, position transmissions near each other to facilitate
transfer of components.
5. Install mast in transmission (module 63-21-01 paragraph "3. Main rotor mast - installation").
63-22-02
Page 1
E-AB412-PT6T-2
6. Remove cover (14, figure 1) and install system 2 hydraulic pump (Chapter 29). Cap or plug open ports on hydraulic
line.
NOTE
System 1 hydraulic pump will be installed after transmission is installed in
helicopter. Leave hydraulic pump (system 1) drive quill cover (26) installed at this
time.
7. Remove cover (10) and install rotor tachometer generator (19) (module 63-25-06 paragraph "3. Rotor tachometer
generator - installation").
8. Remove plug (24) and packing (23). Install oil pressure transmitter (40) and packing (39) (module 63-23-11 paragraph
"2. Oil pressure transmitter - installation").
9. Remove cap (22). Install oil pressure switch (36) and packing (38) (module 63-23-12 paragraph "2. Oil pressure switch
- installation").
NOTE
Refer to Chapter 98 for electrical wiring diagrams to confirm wire numbers.
10. Install electrical harness (32) as follows:
a. Connect electrical connector (42) to pressure switch (36).
b. Connect electrical connector (41) to pressure transmitter (40).
c. Connect ground wire to connector (33).
d. Install six clamps (30) (remaining four are installed in step h. below).
e. Remove cover (21). Install electrical terminal and nipple (35) on thermo switch (25).
f. Connect terminal and nipple (37) to main input gear quill chip detector (7) (module 63-41-02 paragraph "3. Main
input gear quill electric chip detector - installation").
g. Connect terminal and nipple (34) to mast bearing chip detector (4) (module 63-41-01 paragraph "3. Mast bearing
electric chip detector - installation").
h. Install four clamps (30).
i. Install terminal and nipple (29) on sump chip detector (27) or connect electrical harness to full flow debris
monitor.
j. Install connector (28) on tachometer generator (19) and secure with lockwire (C-405).
k. If transmission is to be installed in a helicopter equipped with a rotor brake, remove cover (6) and install rotor
brake quill (refer to module 63-25-08 paragraph "3. Rotor brake quill - installation" on code [A] and refer to
module 63-25-09 paragraph "3. Utility hydraulic pump and rotor brake drive quill [B][C] - installation" on codes
[B] [C]).
l. Install caps, covers, and plugs removed in preceding steps on transmission removed from helicopter.
63-22-02
Page 2
E-AB412-PT6T-2
A D
SEE NOTE
NOTE
G6AB0449A
Figure 1. Transmission build-up (sheet 1 of 4)
63-22-02
Page 3
E-AB412-PT6T-2
G6AB0450A
63-22-02
Page 4
E-AB412-PT6T-2
G6AB0451A
63-22-02
Page 5
E-AB412-PT6T-2
G6AB0452A
63-22-02
Page 6
E-AB412-PT6T-2
63-2 -03 TRANSMISSION - ALTERNATE RUN-IN PROCEDURES
63-22-03
TRANSMISSION - ALTERNATE RUN-IN PROCEDURES
1. ALTERNATE RUN-IN PROCEDURES - DESCRIPTION
NOTE
After overhaul, it is desirable transmission be test run and inspected in accordance
with publication furnished with run-in test stand. In the event a test stand is not
available, the following functional test may be accomplished as the minimum
acceptable alternate test.
1. Install sufficient ballast in cabin to obtain maximum gross weight (E-AB412-PT6T-1).
2. Verify helicopter is properly serviced and lubricated (Chapter 12). Visually inspect the following:
a. Oil system for security and leakage.
b. Fuel system for security and leakage.
c. Hydraulic system for security and leakage.
d. Flight controls for security.
3. Inspect engine accessories and controls for security, loose connections, and proper operation.
NOTE
Throughout the entire procedure which follows, carefully check for evidence of
leakage and abnormal noises.
4. Start engines (E-AB412-PT6T-1) and run at 60% RPM for five minutes. Verify temperatures and pressures are within
limits.
5. Gradually increase RPM from 60 to 88% at the rate of 7% each six minutes of operation.
6. Hold 88% for two minutes with collective applied to the maximum which can be attained without becoming airborne
or exceeding 100% torque.
7. Shut down engines. Remove, inspect, clean, and install the following components:
a. Three electric chip detectors (module 63-41-01 "TRANSMISSION OIL SYSTEM COMPONENTS - MAST
BEARING ELECTRIC CHIP DETECTOR", module 63-41-02 "TRANSMISSION OIL SYSTEM
COMPONENTS - MAIN INPUT GEAR QUILL ELECTRIC CHIP DETECTOR", module 63-41-03
"TRANSMISSION OIL SYSTEM COMPONENTS - SUMP CASE ELECTRICAL CHIP DETECTOR [A] [B]
[C]").
b. Oil pump inlet screen (module 63-23-16 "TRANSMISSION OIL SYSTEM COMPONENTS - OIL PUMP
INLET SCREEN").
c. Sump case internal filter (module 63-23-17 "TRANSMISSION OIL SYSTEM COMPONENTS - SUMP
INTERNAL FILTER [A] [B] [C]").
d. External oil filter (module 63-24-01 paragraph "2. Transmission oil cooling system - external oil filter").
63-22-03
Page 1
E-AB412-PT6T-2
e. Planetary oil jets (two) (module 63-23-01 "TRANSMISSION OIL SYSTEM COMPONENTS - PLANETARY
OIL JETS").
f. Oil jet no. 1 (module 63-23-02 "TRANSMISSION OIL SYSTEM COMPONENTS - OIL JET NO. 1")
g. Oil jet no. 2 (module 63-23-03 "TRANSMISSION OIL SYSTEM COMPONENTS - OIL JET NO. 2").
h. Oil jet no. 3 (module 63-23-04 "TRANSMISSION OIL SYSTEM COMPONENTS - OIL JET NO. 3").
i. Oil jet no. 4 (module 63-23-05 "TRANSMISSION OIL SYSTEM COMPONENTS - OIL JET NO. 4").
j. Oil jet no. 5 (module 63-23-06 "TRANSMISSION OIL SYSTEM COMPONENTS - OIL JET NO. 5").
k. Oil jet no. 6 (module 63-23-07 "TRANSMISSION OIL SYSTEM COMPONENTS - OIL JET NO. 6").
l. Oil jet no. 7 (module 63-23-08 "TRANSMISSION OIL SYSTEM COMPONENTS - OIL JET NO. 7").
8. Restart engines (E-AB412-PT6T-1) and gradually increase RPM to 88% RPM. Operate at 88% for six minutes. Move
collective to the maximum position which can be attained without becoming airborne. At the rate of 3% each six
minutes, gradually increase RPM to 100% without exceeding 100% torque.
9. At 100% RPM, check transmission oil pressure. Pressure should be between 52 and 58 psig when oil temperature is
90 to 100C. If pressure is not within these limits, adjust pressure relief valve as follows:
a. Shut down helicopter.
b. Loosen jam nut on adjustment screw.
c. Turn adjustment screw clockwise to increase, or counterclockwise to decrease, pressure as required.
d. Tighten jam nut.
e. Start engines and gradually increase RPM to 100% and recheck pressure.
f. Repeat steps a. through e. above, as required, to obtain proper oil pressure.
10. Operate at 100% RPM for 30 minutes with collective applied to maximum attainable without becoming airborne or
exceeding 100% torque.
11. Shut down helicopter and repeat inspections listed in step 7. above.
12. Inspect main driveshaft couplings, tail rotor drive quill couplings, and surrounding area for evidence of grease leakage.
If there is evidence of leakage, replace or repair defective components. Repeat leak test run in step 10. above.
13. Inspect main and tail rotor driveshaft couplings over-temperature indicator (TEMP-PLATE) for possible overheat
condition. A change in color (from white to black) indicates possible overheating and/or component degradation. If
overheating is indicated, cause shall be determined and corrected prior to helicopter being released for flight. Refer to
E-AB412-PT6T-3 for inspection and lubrication of main driveshaft couplings and for tail rotor driveshaft couplings.
14. Check transmission oil level. Service as required (Chapter 12).
15. Install engine and transmission cowling.
16. Check for leaks at next helicopter ground run.
63-22-03
Page 2
E-AB412-PT6T-2
63-23-01
TRANSMISSION OIL SYSTEM COMPONENTS - PLANETARY OIL JETS
1. PLANETARY OIL JETS - DESCRIPTION
Two planetary oil jets (8, figure 1) are installed in the planetary gear case of the transmission to provide positive lubrication
to planetary gearing.
2. PLANETARY OIL JETS - REMOVAL
NOTE
The planetary oil jet on the forward side of transmission is shown in figure 1.
Maintenance procedures for the planetary oil jet on left side of transmission are
similar.
1. Disconnect tube (2, figure) from fitting (4).
2. Cut and remove lockwire from screw (7) and remove screw.
3. Remove planetary oil jet (8).
4. Disassemble planetary oil jet (8) as follows:
a. Loosen nut (5) and remove fitting (4) with packings (6).
b. Remove and discard packings (1 and 6).
3. PLANETARY OIL JETS - INSTALLATION
MATERIALS REQUIRED
NUMBER NOMENCLATURE
C-405 LOCKWIRE
1. Lubricate new packing (1, figure 1) with transmission oil (Chapter 12). Install packing on planetary oil jet (8).
2. Lubricate new packing (6) with transmission oil and install on fitting (4).
3. Install nut (5) on fitting (4), and install fitting on planetary oil jet (8).
4. Insert planetary oil jet (8) into transmission housing and install screw (7). Secure screw (7) on planetary oil jet (8) with
lockwire (C-405).
5. Connect tube (2) and tighten nut (3).
6. Check for oil leaks at next helicopter ground run.
63-23-01
Page 1
E-AB412-PT6T-2
4. PLANETARY OIL JETS - CLEANING
MATERIALS REQUIRED
NUMBER NOMENCLATURE
1. Clean oil jets using drycleaning solvent (C-304).
5. PLANETARY OIL JETS - INSPECTION
1. Inspect planetary oil jet for clogging. If passages are clogged, determine source(s) of material (module 63-00-00
paragraph "2-1. Metal particle contamination - inspection").
2. Inspect for corrosion. Superficial corrosion damage on plate on exterior of transmission is acceptable if removed.
3. Inspect for mechanical damage. Cracks and distortion are not acceptable.
6. PLANETARY OIL JETS - REPAIR
Repair of planetary (8, figure 1) jets is limited to removal of corrosion products from plate at base of jet on exterior of
transmission.
63-23-01
Page 2
E-AB412-PT6T-2
G6AB0459A
Figure 1. Planetary oil jet
63-23-01
Page 3
E-AB412-PT6T-2
63-23-01
Page 4
E-AB412-PT6T-2
63-23-02
TRANSMISSION OIL SYSTEM COMPONENTS - OIL JET NO. 1
1. OIL JET NO. 1 - REMOVAL
1. Cut and remove lockwire from screw (9, figure 1) and screw (3), and remove screw (9).
2. Remove oil jet No. 1 (6) from housing in top case (2) on transmission (1).
3. Remove screw (3) and washers (4 and 5).
2. OIL JET NO. 1 - INSTALLATION
MATERIALS REQUIRED
NUMBER NOMENCLATURE
C-405 LOCKWIRE
1. Install screw (3, figure 1) with washers (4 and 5) on oil jet No. 1 (6).
2. Lubricate new packings (7 and 8) with transmission oil (Chapter 12) and install in grooves of oil jet No. 1 (6).
3. Carefully insert oil jet No. 1 (6) into housing in top case (2).
4. Install screw (9). Secure screw (9) to screw (3) using lockwire (C-405).
3. OIL JET NO. 1 - CLEANING
Refer to module 63-23-01 paragraph "4. Planetary oil jets - cleaning".
4. OIL JET NO. 1 - INSPECTION
Refer to module 63-23-01 paragraph "5. Planetary oil jets - inspection".
5. OIL JET NO. 1 - REPAIR
Refer to module 63-23-01 paragraph "6. Planetary oil jets - repair".
63-23-02
Page 1
E-AB412-PT6T-2
G6AB0460A
Figure 1. Oil jet No. 1
63-23-02
Page 2
E-AB412-PT6T-2
63-23-03
1. Cut and remove lockwire from screw (1, figure 1), and remove screw (1) from oil jet No. 2 (4).
2. Remove oil jet No. 2 (4) from housing (8) on transmission.
MATERIALS REQUIRED
NUMBER NOMENCLATURE
C-405 LOCKWIRE
2. Lubricate new packings (2 and 3) with transmission oil (Chapter 12) and install in grooves of jet, No. 2.
3. Carefully insert oil jet No. 2 (4) into housing (8) on transmission.
4. Install screw (1). Secure screw (1) to screw (7) using lockwire (C-405).
63-23-03
Page 1
E-AB412-PT6T-2
G6AB0461A
63-23-03
Page 2
E-AB412-PT6T-2
63-23-04
1. Cut and remove lockwire from bolt (1, figure 1) and screw (10).
2. Remove bolt (1), washer (2), and bracket (3) from oil jet No. 3 (7).
3. Remove oil jet No. 3 (7) with packing (4, 5, and 6).
5. Remove and discard packings (4, 5, and 6).
MATERIALS REQUIRED
NUMBER NOMENCLATURE
C-405 LOCKWIRE
1. Carefully install screw (10, figure 1) with washers (8 and 9) on oil jet No. 3 (7).
2. Lubricate new packings (4, 5, and 6) with transmission oil (Chapter 12) and install in grooves of oil jet No. 3 (7).
3. Carefully insert oil jet No. 3 (7) into manifold (11).
4. Install bolt (1), washer (2), and bracket (3). Torque bolt (1) 50 to 70 in.-lbs. (5,7 to 7,9 Nm).
5. Secure bolt (1) to screw (10) using lockwire (C-405).
63-23-04
Page 1
E-AB412-PT6T-2
G6AB0462A
63-23-04
Page 2
E-AB412-PT6T-2
63-23-05
1. Remove access door on left side of pylon support in cabin.
2. Cut and remove lockwire from screw (8, figure 1) and screw (7). Remove screw (8).
NOTE
When removing oil jet No. 4 (4) from sump case, make sure packings (2 and 3) are
extracted with the oil jet.
3. Remove oil jet No. 4 (4) with packings (2 and 3) from sump case (1).
4. Remove screw (7) and washers (5 and 6) from oil jet No. 4 (4).
MATERIALS REQUIRED
NUMBER NOMENCLATURE
C-405 LOCKWIRE
3. Carefully insert oil jet (4) into sump case (1).
4. Install screw (8) to secure oil jet No. 4 (4) into sump case (1). Secure screw (8) to screw (7) using lockwire (C-405).
63-23-05
Page 1
E-AB412-PT6T-2
G6AB0463A
63-23-05
Page 2
E-AB412-PT6T-2
63-23-06
1. Cut and remove lockwire from screw (4, figure 1) and screw (5). Remove screw (4).
2. Carefully remove oil jet No. 5 (3) with packing (1 and 2).
3. Remove screw (5) and washers (6 and 7) from oil jet No. 5 (3).
MATERIALS REQUIRED
NUMBER NOMENCLATURE
C-405 LOCKWIRE
3. Carefully insert oil jet No. 5 (3) into transmission case.
4. Install screw (4), and secure screw (5) to screw (4) using lockwire (C-405).
63-23-06
Page 1
E-AB412-PT6T-2
G6AB0464A
63-23-06
Page 2
E-AB412-PT6T-2
63-23-07
1. Cut and remove lockwire from screw (7, figure 1) and screw (6), and remove screw (7).
2. Remove oil jet No. 6 (8) with packings (1, 2, and 3).
4. Remove and discard packings (1, 2, and 3).
MATERIALS REQUIRED
NUMBER NOMENCLATURE
C-405 LOCKWIRE
4. Install screw (7). Secure screw (7) to screw (6) with lockwire (C-405).
63-23-07
Page 1
E-AB412-PT6T-2
G6AB0465A
63-23-07
Page 2
E-AB412-PT6T-2
63-23-08
1. Cut and remove lockwire from oil pressure regulating valve (1, figure 1) and thermo switch (11) and thermo bulb (12).
2. Remove oil pressure regulating valve (1, figure 1) with packing (2). Discard packing (2).
3. Cut and remove lockwire from screw (8) and screw (9), and remove screw (8) and washer (7).
4. Remove oil jet No. 7 (6) with packings (3, 4, and 5).
5. Remove screw (9) and seal (10). Discard seal (10).
6. Discard packings (3, 4, and 5).
MATERIALS REQUIRED
NUMBER NOMENCLATURE
C-405 LOCKWIRE
1. Install screw (9, figure figure 1) with new seal (10).
4. Install screw (8) and washer (7). Secure screw (8) to screw (9) with lockwire (C-405).
5. Lubricate new packing (2) with transmission oil (Chapter 12) and install on oil pressure regulating valve (1).
6. Install oil pressure regulating valve (1) in manifold.
7. Secure oil pressure regulating valve (1) to thermo switch (11) and thermo bulb (12) with lockwire (C-405).
63-23-08
Page 1
E-AB412-PT6T-2
G6AB0466A
63-23-08
Page 2
E-AB412-PT6T-2
63-23-09
TRANSMISSION OIL SYSTEM COMPONENTS - OIL PRESSURE
REGULATING VALVE
1. OIL PRESSURE REGULATING VALVE - REMOVAL
1. Cut and remove lockwire from oil pressure regulating valve (1, figure 1) and thermo switch (3) and thermobulb (4).
2. Remove oil pressure regulating valve (1) and packing (2). Discard packing (2).
2. OIL PRESSURE REGULATING VALVE - INSTALLATION
MATERIALS REQUIRED
NUMBER NOMENCLATURE
C-405 LOCKWIRE
1. Lubricate new packing (2, figure 1) with transmission oil (Chapter 12), and install packing on oil pressure regulating
valve (1).
2. Install oil pressure regulating valve (1) in manifold (Detail A).
3. Secure oil pressure regulating valve (1) to thermo switch (3) and thermobulb (4) with lockwire (C-405).
3. OIL PRESSURE REGULATING VALVE - CLEANING
MATERIALS REQUIRED
NUMBER NOMENCLATURE
CAUTION
DO NOT IMMERSE VALVE IN SOLVENT
1. Wipe oil pressure regulating valve (1, figure 1) with clean cloth damp with drycleaning solvent (C-304).
2. Dry using filtered, compressed air.
63-23-09
Page 1
E-AB412-PT6T-2
4. OIL PRESSURE REGULATING VALVE - INSPECTION
Inspect oil pressure regulating valve (1, figure 1) for damaged threads and for mechanical or corrosion damage. Damage in
excess of superficial is unacceptable. Corrosion damage shall be removed.
5. OIL PRESSURE REGULATING VALVE - REPAIR
Repair of oil pressure regulating valve (1, figure 1) is limited to removal of superficial corrosion from areas exposed on
exterior of transmission.
G6AB0467A
Figure 1. Oil pressure regulator valve
63-23-09
Page 2
E-AB412-PT6T-2
63-23-10
TRANSMISSION OIL SYSTEM COMPONENTS - OIL TEMPERATURE
MANIFOLD
1. OIL TEMPERATURE MANIFOLD - REMOVAL
1. Cut and remove lockwire from bolt (16, figure 1) and screw (15).
2. Remove bolt (16), thin steel washer (17), and bracket (18).
3. Remove oil jet No. 3 (14) and packings (11, 12, and 13). Discard packings (11, 12, and 13).
4. Cut and remove lockwire from electrical connector and disconnect electrical connector from thermobulb (6).
5. Disconnect hose (9) from elbow (8).
6. Identify and tag electrical wire installed on thermo switch (23), and disconnect electrical wire from thermo switch (23).
7. Identify and tag electrical wires installed on bracket (21). Remove electrical wires from bracket (21).
8. Remove bolt (19), thin steel washer (20), and bracket (21).
9. Cut sealant from around tube (2) using a sharp plastic scraper.
10. Carefully work manifold (24) loose and remove manifold with tube (2), packings (1, 3, 4, and 5), and gasket (25).
Discard packings (1, 3, 4, and 5) and gasket (25).
2. OIL TEMPERATURE MANIFOLD - INSTALLATION
MATERIALS REQUIRED
NUMBER NOMENCLATURE
C-405 LOCKWIRE
C-508 LOCKWIRE
1. If removed, install nut (7, figure 1) on elbow (8), coat new packing (10) with transmission oil (Chapter 12) and install
in manifold (24). Install elbow (8) and nut (7) on manifold. Do not tighten nut (7) at this time.
2. Lubricate new packings (1 and 3) with transmission oil and install on tube (2). Install tube (2) in oil manifold assembly
(24).
3. Lubricate new packings (4 and 5) with transmission oil and install in oil manifold assembly (24). Lubricate new gasket
(25) with transmission oil and install on oil manifold (24).
63-23-10
Page 1
E-AB412-PT6T-2
4. Carefully work oil manifold (24) into position on transmission case. Ensure tube (2) is seated in manifold. Ensure
bushings on oil manifold are seated on transmission case.
5. Install bolt (19) with washer (20) and bracket (21). Do not torque bolt (19) at this time.
6. Lubricated new packings (11, 12, and 13) and install packings on oil jet No. 3 (14).
7. Carefully install oil jet No. 3 (14) in oil manifold (24) and install bolt (16) with washer (17) and bracket (18).
8. Torque bolt (16) 50 to 70 in.-lbs. (5,6 to 7,9 Nm). Secure bolt (16) to screw (15) with lockwire (C-405).
9. Torque bolt (19) 50 to 70 in.-lbs. (5,6 to 7,9 Nm). Secure bolt (19) to thermo switch (23) and thermobulb (6) with
lockwire (C-405).
10. Install hose (9) on elbow (8). Tighten nut (7).
11. Connect electrical plug to thermobulb (6) and secure with lockwire (C-508).
12. Connect electrical wire to thermo switch (23).
13. Install electrical wires on bracket (21). Remove identification tag.
14. Apply a bead of adhesive (C-308) around each end of tube (2) at mating joint.
63-23-10
Page 2
E-AB412-PT6T-2
G6AB0468A
Figure 1. Oil temperature manifold
63-23-10
Page 3
E-AB412-PT6T-2
63-23-10
Page 4
E-AB412-PT6T-2
63-23-11
TRANSMISSION OIL SYSTEM COMPONENTS - OIL PRESSURE
TRANSMITTER
1. OIL PRESSURE TRANSMITTER - REMOVAL
1. Cut and remove lockwire from electrical connector (5, figure 1), and disconnect electrical connector.
2. Cut and remove lockwire securing oil pressure transmitter (4).
3. Remove oil pressure transmitter (4) with packing (3). Discard packing.
4. Cap or plug exposed cavity in oil pressure manifold (2).
2. OIL PRESSURE TRANSMITTER - INSTALLATION
MATERIALS REQUIRED
NUMBER NOMENCLATURE
C-405 LOCKWIRE
C-508 LOCKWIRE
1. Lubricate packing (3, figure 1) with transmission oil (Chapter 12).
2. Install packing (3) on oil pressure transmitter (4).
3. Install oil pressure transmitter (4) in oil pressure manifold (2). Secure oil pressure transmitter with lockwire (C-405).
4. Install electrical connector (5) and secure electrical connector with lockwire (C-508).
5. Perform functional check of pressure transmitter (4) (Chapter 96) and check for oil leaks at next helicopter ground run.
3. OIL PRESSURE TRANSMITTER - INSPECTION
Inspect oil pressure transmitter (4, figure 1) and electrical connector for bent pins, damaged threads, dents, or other
mechanical damage rendering transmitter unserviceable.
63-23-11
Page 1
E-AB412-PT6T-2
G6AB0469A
Figure 1. Oil pressure transmitter
63-23-11
Page 2
E-AB412-PT6T-2
63-23-12
TRANSMISSION OIL SYSTEM COMPONENTS - OIL PRESSURE SWITCH
1. OIL PRESSURE SWITCH - REMOVAL
1. Cut and remove lockwire from electrical connector (5, figure 1), and disconnect electrical connector (5).
2. Cut and remove lockwire from pressure switch (4), and remove pressure switch (4) with packing (3). Discard packing
(3).
3. Cap or plug cavity in oil pressure manifold (2).
2. OIL PRESSURE SWITCH - INSTALLATION
MATERIALS REQUIRED
NUMBER NOMENCLATURE
C-405 LOCKWIRE
C-508 LOCKWIRE
1. Lubricate packing (3, figure 1) with transmission oil (Chapter 12), and install packing (3) on pressure switch (4).
2. Install pressure switch (4) in manifold (2), and secure pressure switch (4) with lockwire (C-405).
3. Install electrical connector (5). Secure connector with lockwire (C-508).
4. Perform functional check of pressure switch (Chapter 96) and check for oil leaks at next helicopter ground run.
3. OIL PRESSURE SWITCH - INSPECTION
Inspect pressure switch (4, figure 1) and electrical connector for bent pins, damaged threads, dents, or other mechanical
damage which would render switch unserviceable.
63-23-12
Page 1
E-AB412-PT6T-2
G6AB0470A
Figure 1. Oil pressure switch
63-23-12
Page 2
E-AB412-PT6T-2
63-23-13
TRANSMISSION OIL SYSTEM COMPONENTS - OIL PRESSURE MANIFOLD
1. OIL PRESSURE MANIFOLD - REMOVAL
1. Remove oil pressure switch (module 63-23-12 paragraph "1. Oil pressure switch - removal").
2. Remove oil pressure transmitter (module 63-23-11 paragraph "1. Oil pressure transmitter - removal").
3. Remove tube assembly (2, figure 1).
4. Remove nuts (7) and washers (5 and 6) securing oil manifold (4). Remove manifold (4) and spacer (3) from
transmission (1).
2. OIL PRESSURE MANIFOLD - INSTALLATION
1. Position spacer (3, figure 1) and oil manifold (4) on transmission (1).
2. Install aluminum washers (5) next to manifold then steel washers (6) and install nuts (7).
3. Install tube assembly (2).
4. Install oil pressure transmitter (module 63-23-11 paragraph "2. Oil pressure transmitter - installation") and pressure oil
switch (module 63-23-12 paragraph "2. Oil pressure switch - installation").
5. Perform functional check of pressure switch and transmitter (Chapter 96) and check for oil leaks at next helicopter
ground run.
3. OIL PRESSURE MANIFOLD - CLEANING
MATERIALS REQUIRED
NUMBER NOMENCLATURE
1. Wipe oil manifold (4, figure 1) with clean cloth damp with drycleaning solvent (C-304).
4. OIL PRESSURE MANIFOLD - INSPECTION
Inspect oil manifold (4, figure 1) for damaged threads and for mechanical or corrosion damage. Damage in excess of
superficial is unacceptable. Corrosion damage shall be removed.
63-23-13
Page 1
E-AB412-PT6T-2
5. OIL PRESSURE MANIFOLD - REPAIR
Repair of oil manifold (4, figure 1) is limited to removal of superficial corrosion from areas exposed on exterior of
transmission.
G6AB0471A
Figure 1. Oil pressure manifold
63-23-13
Page 2
E-AB412-PT6T-2
63-23-14 TRANSMISSION OIL SYSTEM COMPONENTS - FILLER NECK, SCUPPER, AND MOUNTING BRACKET
63-23-14
TRANSMISSION OIL SYSTEM COMPONENTS - FILLER NECK, SCUPPER,
AND MOUNTING BRACKET
1. FILLER NECK, SCUPPER, AND MOUNTING BRACKET - REMOVAL
1. Disconnect hose assembly (16, figure 1) from elbow (18).
2. Remove nut (24), washer (25), and screw (17).
3. Disconnect tube assembly (19).
4. Loosen and remove nut (14) from extension cap (15), and loosen nut (12) from elbow (11) and nut (14) from extension
cap (15). Remove tube (13).
5. Loosen nut (10) and remove elbow (11) with packing (9). Discard packing.
6. Remove nuts (20) and washers (21). Remove scupper assembly (1) from bracket (5) and remove aluminium washers
(22) from bracket (5).
7. Remove nuts (8) and washers (6 and 7) from bolts (2), and remove bracket (5).
8. Remove bolts (2) and washers (3 and 4) from bracket (5).
2. FILLER NECK, SCUPPER, AND MOUNTING BRACKET - INSTALLATION
1. Install aluminum washers (22, figure 1) on scupper assembly (1). Position scupper assembly (1) on bracket (5).
2. Install aluminum washers (21) and nuts (20). Torque nuts (20) 50 to 70 in.-lbs. (5,6 to 7,9 Nm).
3. Install nut (10) on elbow (11).
4. Lubricate packing (9) with transmission oil (Chapter 12). Install packing (9) on elbow (11).
5. Install elbow (11) on scupper assembly (1). Do not tighten nut (10) at this time.
6. Position bracket (5) on transmission and install bolts (2) with steel washers (3) under bolt heads and aluminum washers
(4) next to bracket (15).
7. Install aluminum washers (6) next to bracket (15) with steel washer (7) next to nuts (8). Torque nuts (8) 230 to 250
in.-lbs. (25,9 to 28,2 Nm).
8. Install tube (13) on elbow (11). Tighten nuts (12 and 14) and tighten nut (10).
9. Connect tube assembly (19) to fitting (23).
10. Install screw (17), washer, and nut.
11. Connect hose assembly (16) to elbow (18).
63-23-14
Page 1
E-AB412-PT6T-2
NOTE
Extension cap (15) may be installed by inserting cap on transmission, pressing down
on cap and twisting clockwise to engage lock.
12. Check for leaks at next helicopter ground run.
3. FILLER NECK, SCUPPER, AND MOUNTING BRACKET - CLEANING
MATERIALS REQUIRED
NUMBER NOMENCLATURE
C-304 DRY CLEANING SOLVENT
1. Wipe all parts with clean cloth damp with drycleaning solvent (C-304).
4. FILLER NECK, SCUPPER, AND MOUNTING BRACKET - INSPECTION
1. Inspect scupper (1, figure 1) and oil filler cap for cracks and distortion or other damage rendering either component
unserviceable. A loose fitting cap and/or cracked or distorted scupper is not acceptable. Unserviceable components
shall be replaced. Superficial damage such as dents, nicks, or scratches not affecting serviceability are acceptable
without repair. Light surface corrosion is acceptable provided it is removed and original surface finish restored.
2. Inspect bracket (5) and tube (13) for damage such as distortion and cracks. Loose fitting, cracked, and/or severely
distorted parts are unacceptable and shall be replaced. Superficial dents, nicks, and scratches not affecting
serviceability are acceptable without repair.
63-23-14
Page 2
E-AB412-PT6T-2
G6AB0472A
Figure 1. Filler neck, scupper, and mounting bracket
63-23-14
Page 3
E-AB412-PT6T-2
63-23-14
Page 4
E-AB412-PT6T-2
63-23-15
TRANSMISSION OIL SYSTEM COMPONENTS - OIL PUMP
1. OIL PUMP - REMOVAL
NUMBER NOMENCLATURE
T109 SLIDE HAMMER WITH 1/4 X 28

UNF THREADED SHAFT
1. Remove access door in front of pylon support in cabin area.
2. Drain transmission oil (Chapter 12) from transmission sump assembly (1, figure 1).
3. Cut and remove lockwire securing oil pump screen (18) and remove oil pump screen with packing (17). Discard
packing.
4. Remove tubes (11 and 16).
5. Remove nut (9) and steel washer (8). Remove bracket (10), tee connection (15), nut (12), and washer (13) together as
an assembly.
6. Clean sealant from puller hole in bottom center of pump using a sharp plastic scraper.
CAUTION
DO NOT USE JACKSCREWS TO REMOVE PUMP. DO NOT ALLOW PULLER

BOLT TO BOTTOM OUT IN THREADED HOLE OF PUMP.
7. Install slide hammer type puller equipped with 1/4 X 28 UNF threads into center of pump base.
8. Loosen jam nut on drain valve (14) and rotate counterclockwise.
9. Remove remaining nuts (7) with washers (5 and 6) and remove pump (4) with packings (2 and 3).
63-23-15
Page 1
E-AB412-PT6T-2
2. OIL PUMP - INSTALLATION
MATERIALS REQUIRED
NUMBER NOMENCLATURE
C-405 LOCKWIRE
1. Lubricate packings (2 and 3, figure 1) and mating surfaces of pump (4) and transmission sump assembly (1) with
transmission oil (Chapter 12). Install packings (2 and 3) on pump (4).
NOTE
The main rotor can be manually rotated, as necessary, to obtain alignment of oil
pump shaft.
2. Warm sump case port with a heat lamp and insert pump into mounting port. Align pump shaft with internal splines of
transmission shaft (18). Use a flashlight to verify engagement of pump and shaft (18) through open port of oil pump
screen (17).
3. Install bracket (10), tee connection (14), washer (13), and nut (12) on pump mounting stud.
4. Install steel washer (8) and nut (9). Position drain valve (19), as required, and tighten jam nut.
5. Install washers (5), steel washers (6), and nuts (7). Torque nuts (7) and nut (9) 50 to 70 in.-lbs. (5,6 to 7,0 Nm).
6. Connect drain tubes (11 and 15).
7. Lubricate packing (16) with transmission oil (Chapter 12). Install packing (16) on oil pump screen (17).
8. Install oil pump screen (17) and torque oil pump screen 300 to 400 in.-lbs. (33,9 to 45,1 Nm).
9. Secure oil pump screen (17) to electric chip detector base with lockwire (C-405).
10. Service transmission (Chapter 12).
11. Install access door.
63-23-15
Page 2
E-AB412-PT6T-2
G6AB0488A
Figure 1. Transmission oil pump
63-23-15
Page 3
E-AB412-PT6T-2
63-23-15
Page 4
E-AB412-PT6T-2
63-23-16
TRANSMISSION OIL SYSTEM COMPONENTS - OIL PUMP INLET SCREEN
1. OIL PUMP INLET SCREEN - REMOVAL
1. Drain transmission oil sump (Chapter 12).
2. Cut and remove lockwire from oil pump inlet screen (1, figure 1).
3. Remove oil pump inlet screen (1) from transmission sump assembly (3).
4. Remove and discard gasket (2).
2. OIL PUMP INLET SCREEN - INSTALLATION
MATERIALS REQUIRED
NUMBER NOMENCLATURE
C-405 LOCKWIRE
1. Lubricate new gasket (2, figure 1) with transmission oil (Chapter 12). Install gasket (2) on inlet oil pump screen (1).
2. Install inlet oil pump screen (1) on transmission sump assembly (3).
3. Torque inlet oil pump screen (1) 300 to 400 in-lbs (33.9 to 45.2 Nm).
4. Secure inlet oil pump screen (1) to transmission sump assembly (3) with lockwire (C-405).
3. OIL PUMP INLET SCREEN - CLEANING
MATERIALS REQUIRED
NUMBER NOMENCLATURE
1. Rinse inlet oil pump screen (1, figure 1) with drycleaning solvent (C-304).
63-23-16
Rev. 3 Page 1
E-AB412-PT6T-2
4. OIL PUMP INLET SCREEN - INSPECTION
1. Inspect oil pump inlet screen (figure 2) for metal particles. If metal particles are present, refer to module 63-00-00
paragraph "2. Main rotor drive - metal particle contamination".
2. Inspect inlet oil pump screen (1, figure 1) for damage in accordance with figure 2.
63-23-16
Page 2 Rev. 3
E-AB412-PT6T-2
300 TO 400 IN-LBS

T (39.9 TO 45.2 Nm)
1. Screen
2. Gasket
3. Transmission sump assembly
G6AB0494C
Figure 1. Oil pump screen
63-23-16
Rev. 3 Page 3
E-AB412-PT6T-2
AREA LIMITS
All No cracks allowed
A Maximum depth of pitting is 0.030 in (0.762 mm ) with no more than 40% of any 1.0 sq-in (645.16 mm²) or
20% of any total area of any pitted surface.
B Maximum depth of pitting is 0.020 in (0.508 mm) with no more than 40% of any 1.0 sq-in (645.16 mm²) or
20% of any total area of any pitted surface. Corrosion is not permitted on screen. Thread damage is not per-
mitted.
G6AB0495C
Figure 2. Oil pump inlet screen - damage limits
63-23-16
Page 4 Rev. 3
E-AB412-PT6T-2
63-23-17
TRANSMISSION OIL SYSTEM COMPONENTS - SUMP INTERNAL FILTER
[A] [B] [C]
1. SUMP INTERNAL FILTER [A] [B] [C] - REMOVAL
1. Remove access door on right side of pylon support in cabin area.
2. Remove nuts (1, 11, and 13, figure 1) with washers (2, 10, and 12). Remove bracket (3).
3. Remove nut (9) with washers (7 and 8).
4. Remove filter assembly (4).
5. Remove and discard packing (5) from filter assembly (4).
6. Cap or cover filter mounting port in sump case (6).
2. SUMP INTERNAL FILTER [A] [B] [C] - INSTALLATION
1. Lubricate new packing (5, figure 1) with transmission oil (Chapter 12). Install packing (5) on filter (4).
2. Insert filter assembly (4) in mounting port of sump (6).
3. Position bracket (3) over filter (4) and studs on sump case (6).
4. Install washers (2, 10, and 12) and nuts (1, 11, and 13).
5. Install aluminum washer (7) next to filter housing and steel washer (8) adjacent to nut (9).
6. Install nut (9). Torque nuts (1, 9, 11, and 13) 50 to 70 in.-lbs. (5,6 to 7,0 Nm).
3. SUMP INTERNAL FILTER [A] [B] [C] - INSPECTION
NOTE
If the sump internal filter must be disassembled for inspection, refer to paragraph
paragraph "1. Sump internal filter [A] [B] [C] - removal" and perform steps 1.a. and
1.b.
1. Inspect filter for metal particles and/or other material. If metal particles are found, refer to module 63-00-00 paragraph
"2-1. Metal particle contamination - inspection".
2. Inspect wafer screens (4, figure 2) for distortion or tears. Damage that can be detected visually is not acceptable.
3. Inspect spacers (3) for corrosion and deformation. Damage in excess of superficial is not acceptable.
63-23-17
Page 1
E-AB412-PT6T-2
4. Inspect nut (1) for corrosion and thread damage. Damage in excess of superficial is not acceptable.
5. Inspect filter body (5) for mechanical and corrosion damage (figure 3).
4. SUMP INTERNAL FILTER [A] [B] [C] - CLEANING
MATERIALS REQUIRED
NUMBER NOMENCLATURE
NOTE
Perform steps 1. and 2, if it is not possible to sufficiently clean the filters while
assembled.
Perform steps 3. and 4., if it is possible to sufficiently clean the filters while
assembled.
1. To disassemble filter, proceed as follows:
a. Straighten tangs on washer (2, figure 2) and remove nut (1).
b. Remove washer (2), spacer (3), and wafer screens (4).
c. Wash wafer screens (4) with drycleaning solvent (C-304). Dry wafer screens (4) with filtered, compressed air.
2. To assemble filter, proceed as follows:
a. Install 10 spacers (3) and 10 wafer screens (4). Starting with spacer, alternately install spacers and wafer screens.
b. Install eleventh spacer (3), washer (2) and nut (1).
c. Tighten nut (1) until wafer screens (4) will not rotate when turned by hand.
d. Bend one tang of washer (2) over a flat side of nut.
3. Wash filter assembly (4, figure 1) with drycleaning solvent (C-304).
63-23-17
Page 2
E-AB412-PT6T-2
G6AB0490A
Figure 1. Sump internal filter (helicopters codes [A] [B] [C])
63-23-17
Page 3
E-AB412-PT6T-2
G6AB0491A
Figure 2. Sump internal filter assembly (helicopters codes [A] [B] [C])
63-23-17
Page 4
E-AB412-PT6T-2
G6AB0492A
Figure 3. Sump internal filter - damage limits (helicopters codes [A] [B] [C])
63-23-17
Page 5
E-AB412-PT6T-2
63-23-17
Page 6
E-AB412-PT6T-2
63-23-18
TRANSMISSION OIL SYSTEM COMPONENTS - FULL FLOW DEBRIS
MONITOR [D]
1. FULL FLOW DEBRIS MONITOR - REMOVAL
2. Disconnect electrical harness (2, figure 1).
3. Remove nuts (5), washers (4), and brackets (1 and 3).
4. Remove debris monitor from sump case.
5. Remove cup (8), scupper (7), and screen tube (10).
2. FULL FLOW DEBRIS MONITOR - INSTALLATION
1. Lubricate new packings (6 and 11, figure 1) with transmission oil (Chapter 12).
2. Install packings (6 and 11) on debris monitor.
3. Install screen tube (10), scupper (7), and cap (8) on debris monitor.
4. Torque cap (8) 22 to 30 in.-lbs. (2,5 to 3,5 Nm).
6. Install debris monitor in transmission sump case with connector at bottom.
7. Install brackets (1 and 3) using washers (4) and nuts (5).
8. Torque nuts (5) 50 to 70 in.-lbs. (5,6 to 7,0 Nm).
9. Install electrical harness (2).
10. Install access door on right side of pylon support in cabin area.
63-23-18
Page 1
E-AB412-PT6T-2
3. FULL FLOW DEBRIS MONITOR - INSPECTION
1. Inspect chip detectors and screen tube (9 and 10, figure 1) for metal particles and/or other material. If metal particles
are found, refer to module 63-00-00 paragraph "2. Main rotor drive - metal particle contamination".
2. Inspect chip detectors (9) and screen tube (10) for distortion or tears. Damage which can be detected visually is not
acceptable.
3. Inspect nuts (5) for corrosion and thread damage. In excess of superficial is not acceptable.
4. FULL FLOW DEBRIS MONITOR - CLEANING
MATERIALS REQUIRED
NUMBER NOMENCLATURE
1. Wash chip detectors (9, figure 1) and screen tube (10) with drycleaning solvent (C-304).
63-23-18
Page 2
E-AB412-PT6T-2
G6AB0498A
Figure 1. Full flow debris monitor (helicopters code [D])
63-23-18
Page 3
E-AB412-PT6T-2
63-23-18
Page 4
E-AB412-PT6T-2
63-23-19
TRANSMISSION OIL SYSTEM COMPONENTS - SIGHT GLASSES
1. SIGHT GLASSES - DESCRIPTION
NOTE
The following maintenance procedures are detailed for indicator (4, figure 1).
Maintenance procedures for indicator (6) are similar.
2. SIGHT GLASSES - REMOVAL
1. Drain transmission oil as necessary (Chapter 12) to a level below sight gauge.
2. Remove retainer ring (1, figure 1).
3. Carefully remove glass (3) with packing (2) and discard packing.
4. Remove indicator (4).
6. Cover opening in transmission sump case (5).
3. SIGHT GLASSES - INSTALLATION
1. Lubricate new packing (2, figure 1) with transmission oil (Chapter 12). Install indicator (4) in sump.
2. Install new packing (2) on sight glass (3) and insert glass in sump over indicator.
3. Install retainer ring (1).
4. SIGHT GLASSES - CLEANING
MATERIALS REQUIRED
NUMBER NOMENCLATURE
1. Wipe components with a clean cloth damp with drycleaning solvent (C-304).
63-23-19
Page 1
E-AB412-PT6T-2
5. SIGHT GLASSES - INSPECTION
1. Inspect glass (3, figure 1) for cracks, crazing, and stains which would prevent an accurate determination of oil level.
If any of these conditions are present, replace glass.
2. Inspect indicator (4) for stains that might present a false oil level reading. If such condition exists, replace indicator.
3. Inspect retainer ring (1) for distortion, cracks, tool marks, and insufficient tension. If any of these conditions exist,
replace retainer.
G6AB0493A
Figure 1. Sight glasses
63-23-19
Page 2
E-AB412-PT6T-2
63-24-01
TRANSMISSION OIL COOLING SYSTEM
1. TRANSMISSION OIL COOLING SYSTEM - DESCRIPTION
The transmission oil cooling system (figure 1) detailed in this Chapter consists of an external oil filter, thermal oil bypass
valve, two drain valves, and connecting tubes and hoses. Maintenance procedures applicable to the oil cooler and blower is
described in Chapter 79.
2. TRANSMISSION OIL COOLING SYSTEM - EXTERNAL OIL FILTER
2-1. EXTERNAL OIL FILTER - DESCRIPTION
The external oil filter (figure 2) is located inside the right pylon support below the sump case and is connected to an oil cooler
outlet line. The filter element is replaceable and is made of pleated paper. The filter head includes a bypass valve to assure
oil flow in the event of filter clogging. If a bypass condition is impending, a red indicator button extends to provide a positive
visual indication.
2-2. EXTERNAL OIL FILTER - REMOVAL
1. Remove access door on front of pylon support in cabin area. Place container under external oil filter body (19,
figure 2) to catch oil spillage.
2. Cut and remove lockwire from v-band clamp (14) and open v-band clamp (14). Remove external oil filter body (19).
3. Remove filter element (17) and make a visual check for evidence of contamination of metal particles.
4. Remove packing (16) from center boss under filter head (13). Remove packing (18) from boss inside bottom of
external oil filter body (19). Discard packings (16) and (18).
6. If it is necessary to remove the filter head (13), perform the following:
a. Disconnect inlet tube (20) and outlet hose (5).
b. Cut and remove lockwire from bolts (3).
c. Remove bolts (3), aluminium washers (4), and spacers (24) from bracket (25). Remove filter head (13).
7. Cap or plug all open lines and hoses to prevent contamination.
63-24-01
Page 1
E-AB412-PT6T-2
2-3. EXTERNAL OIL FILTER - INSTALLATION
MATERIALS REQUIRED
NUMBER NOMENCLATURE
C-405 LOCKWIRE
1. If removed, install filter head (13, figure 2) with outlet port aft. Install spacers (24) between filter bracket (25) and filter
head (13). Install bolts (3), washers (4), and secure with lockwire (C-405).
2. Remove plugs or caps and install inlet tube (20) from thermal bypass valve to reducer (21) in filter inlet.
3. Install hose (5) to fitting (6) in filter outlet.
4. Lubricate packings (15, 16, and 18) with transmission oil (Chapter 12).
5. Place packing (18) on boss inside bottom of external oil filter body (19). Insert new filter element (17) and seat firmly
on boss. Place large packing (15) around upper lip of external oil filter body (19) next to flange.
6. Install packing (16) around center boss under filter head (13). Insert external oil filter body (19) into filter head (13)
while pressing upward until seated.
7. Install v-band clamp (14) around mating flanges of head and body. While tapping v-band clamp (14) lightly to aid in
seating, torque nut on clamp to 50 in.-lbs. (5,7 Nm). Secure v-band clamp (14) with lockwire (C-405).
2-4. EXTERNAL OIL FILTER - CLEANING
MATERIALS REQUIRED
NUMBER NOMENCLATURE
NOTE
Inspect oil filter components both before and after cleaning.
63-24-01
Page 2
E-AB412-PT6T-2
Chapter 79
G6AB0824A
Figure 1. Transmission oil cooling system
63-24-01
Page 3
E-AB412-PT6T-2
G6AB0506A
Figure 2. Transmission external oil filter
63-24-01
Page 4
E-AB412-PT6T-2
2-5. EXTERNAL OIL FILTER - INSPECTION
NOTE
Inspect oil filter components both before and after cleaning.
1. Inspect oil filter element (17, figure 2) for contamination. If metal particles are present, refer to module 63-00-00
paragraph "2-1. Metal particle contamination - inspection". Do not reuse element.
2. Inspect flange areas of filter body (19) and filter head (13) for cracks. If cracks are found, replace part.
3. Inspect area contacted by packing (15) for damage such as distortion and sharp edges. Minor surface irregularities may
be removed. Distortion or sharp edges necessitates replacement.
63-24-01
Page 5
E-AB412-PT6T-2
63-24-01
Page 6
E-AB412-PT6T-2
63-24-02
TRANSMISSION OIL COOLING SYSTEM - THERMAL BYPASS VALVE
1. THERMAL BYPASS VALVE - DESCRIPTION
The thermal oil bypass valve (figure 1) is installed on the rear bulkhead of cargo hook compartment. The valve is located in
oil lines between transmission and oil cooler. The assembly consists of a valve body and a thermostat. The thermostat will
be completely open when transmission oil temperature is 130F (55C) or below causing oil to bypass cooler and flow
directly to transmission. The thermostat partially closes at temperatures between 130 and 175F (55 and 79C) passing
some oil through oil cooler while allowing remainder to bypass directly to transmission. At higher temperatures, all oil flow
is directed through oil cooler before being routed to transmission.
2. THERMAL BYPASS VALVE - REMOVAL
NOTE
Thermostat (1, figure 1) may be removed without removing valve body (3).
1. Disconnect tubes (7, 10, 11, and 16) from valve body (3).
2. Remove screws and washers (4) and remove valve body (3) from bulkhead.
3. Remove unions (6, 9, 12, and 15) with packings (5, 8, 13, and 14) and discard packings.
4. Cut and remove lockwire from thermostat (1). Remove thermostat (1) and gasket (2) from valve body (3) and discard
gasket.
3. THERMAL BYPASS VALVE - INSTALLATION
MATERIALS REQUIRED
NUMBER NOMENCLATURE
C-405 LOCKWIRE
1. Lubricate new gasket (2, figure 1) and new packings (5, 8, 13, 14) with transmission oil (Chapter 12).
2. Install thermostat (1) with gasket (2) in valve body (3). Tighten thermostat (1) sufficiently to prevent leakage. Secure
thermostat (1) with lockwire (C-405).
3. Install unions (6, 9, 12, and 15) with new packings (5, 8, 13, and 14).
4. Install valve body (4) on bulkhead bracket with screws and washers (4).
6. Check for oil leaks and proper operation at next helicopter ground run.
63-24-02
Page 1
E-AB412-PT6T-2
4. THERMAL BYPASS VALVE - CLEANING
MATERIALS REQUIRED
NUMBER NOMENCLATURE
G6AB0507A
Figure 1. Thermal oil bypass valve
63-24-02
Page 2
E-AB412-PT6T-2
63-24-03
TRANSMISSION OIL COOLING SYSTEM - OIL DRAIN VALVES
1. OIL DRAIN VALVES - DESCRIPTION
Two ball type drain valves (one for inlet and one for outlet oil) are installed in lowest part of oil system (figure 1) between
thermal oil bypass valve and transmission oil cooler. The valves are provided to drain oil trapped in lines of oil cooler to
transmission system.
NOTE
Maintenance procedures for drain valves are identical. The procedures for inlet drain
valve are provided.
2. OIL DRAIN VALVES - REMOVAL
1. Place a container beneath drain valves (3, figure 1) to catch oil spillage.
2. Open drain valve (3) and drain oil.
3. Disconnect tubes (2, 9, and 15). Cap or plug tubes to prevent contamination.
4. Remove tee (12) with drain valve (3) as an assembly.
5. Complete disassembly by loosening nut (4) and removing valve (3) and packing (5). If required, remove bushing (6)
with packing (7), union (10) with packing (11), and union (14) with packing (13).
6. Discard packings (5, 7, 11, and 13).
3. OIL DRAIN VALVES - INSTALLATION
1. Lubricate new packings (5, 7, 11, and 13, figure 1) with transmission oil (Chapter 12).
2. Install unions (10 and 14) with new packings (11 and 13) into side ports of tee (12).
3. Install packing (7) on bushing (6) and install bushing in lower port of tee (12).
4. Install valve (3) with packing (5) and nut (4) in bushing (6). Tighten nut (4) sufficiently to prevent leakage.
5. Place tee and drain valve assembly in position in helicopter after removing protective cover/caps from lines, hoses,
and ports.
6. Install tubes (9 and 15) and install drain valve tube (2) with new grommet (1) (if required) on lower portion of valve.
8. Check for oil leaks and proper operation at next helicopter ground run.
63-24-03
Page 1
E-AB412-PT6T-2
4. OIL DRAIN VALVES - CLEANING
MATERIALS REQUIRED
NUMBER NOMENCLATURE
5. OIL DRAIN VALVES - INSPECTION
1. Inspect components for cracks and thread damage. No cracks or thread damage is permissible.
2. Inspect valve for proper operation.
3. Discard components that are not serviceable.
63-24-03
Page 2
E-AB412-PT6T-2
G6AB0508A
Figure 1. Oil drain valve
63-24-03
Page 3
E-AB412-PT6T-2
63-24-03
Page 4
E-AB412-PT6T-2
63-24-04 TRANSMISSION OIL COOLING SYSTEM - TRANSMISSION OIL COOLER AND BLOWER
63-24-04
TRANSMISSION OIL COOLING SYSTEM - TRANSMISSION OIL COOLER
AND BLOWER
1. TRANSMISSION OIL COOLER AND BLOWERS - DESCRIPTION
Refer to Chapter 79 for maintenance procedures applicable to the combination reduction gearbox oil and transmission oil
cooler and combination engine oil and transmission oil cooler blower assemblies.
63-24-04
Page 1
E-AB412-PT6T-2
63-24-04
Page 2
E-AB412-PT6T-2
63-25-01
TRANSMISSION QUILLS - MAIN INPUT QUILL
1. MAIN INPUT QUILL - DESCRIPTION
The transmission quills consists of main input quill, hydraulic system 2 drive quill, hydraulic system 1 and tachometer drive
quill, rotor brake quill, and tail rotor drive quill.
The main input quill provides the means for engine to provide power to transmission through the main driveshaft.
2. MAIN INPUT QUILL - REMOVAL
NUMBER NOMENCLATURE
T27 JACKSCREW SET
1. Open engine and transmission cowling.
3. Disconnect drain tube (24, figure 1).
4. Remove nut (11) with clip (10) from lower right stud on transmission (1).
5. Remove nuts (12).
6. Using a sharp plastic scraper, cut sealant around edge of quill.
7. Cut and remove lockwire from screw (8) and remove screws.
8. Using a heat lamp or a 250 watt light bulb, heat case of the transmission (1) in area of quill. Heat case until area near
quill is hot to the touch with bare hands. Install three jackscrews (T27) in holes where screws (8) were removed.
Tighten jackscrews evenly and carefully to separate main input quill (6) from transmission (1).
9. After main input quill (6) has completely separated from case, remove jackscrews and install three screws (8) with
aluminum washers (7) to secure cap to quill sleeve.
10. Position main input quill (6) at right angle, for clearance, and remove from transmission pylon cavity.
12. Remove oil transfer tube (17) with packings (16 and 18). Discard packings.
13. Install cover (module 63-26-01 paragraph "3. Transmission quill port covers - installation") over main input quill port
of transmission (1).
63-25-01
Rev. 3 Page 1
E-AB412-PT6T-2
3. MAIN INPUT QUILL - INSTALLATION
MATERIALS REQUIRED
NUMBER NOMENCLATURE
C-405 LOCKWIRE
C-452 ANTISEIZE COMPOUND
NUMBER NOMENCLATURE
T40 PUSHER SET
1. Remove setscrews (15, figure 1) from studs in transmission (1).
NOTE
If rotor brake quill is installed, remove cover from port on opposite side of
transmission (module 63-26-01 paragraph "2. Transmission quill port covers -
removal"). If this port is removed, it will be necessary to remove oil jet no. 6
(module 63-23-07 paragraph "1. Oil jet No. 6 - removal") to allow clearance for
work and plug.
NOTE
For helicopters codes [B] [C] refer to module 63-25-09 "TRANSMISSION QUILLS
- UTILITY HYDRAULIC PUMP AND ROTOR BRAKE DRIVE QUILL [B] [C]".
2. Remove cover (20) (module 63-26-01 paragraph "2. Transmission quill port covers - removal").
3. Reach through port where cover was removed and position work aid (3, figure 1 and 2, figure 2) to hold rollers of
bearing (2, figure 1) against outer race of bearing.
4. Using a heat lamp or a 250 watt light bulb, heat case of the transmission (1) in area of quill port. Heat case until area
near quill port is hot to the touch with bare hands.
5. Lubricate new packings (16 and 18) with transmission oil (Chapter 12) and install on oil transfer tube (17). Position
tube in transmission case.
6. Lubricate new packings (4 and 5) with transmission oil (Chapter 12). Install packing (5) in groove of main input quill
(6) nearest flange and packing (4) in groove nearest pinion. Leave center groove open.
CAUTION
THE CENTER GROOVE IS AN OIL PASSAGE. IT MUST STAY OPEN.
7. Position main input quill (6) into port with drain tube union (15, figure 2) for drain tube at bottom.
8. Install the three pusher set studs (13) in holes where setscrews (15, figure 1) were removed in step 1. above.
63-25-01
Page 2 Rev. 3
E-AB412-PT6T-2
9. Carefully slide input quill pinion (6, figure 2) into transmission (1) case. Align input quill pinion (6) teeth with input
gear quill (5) teeth. Align front of input quill pinion (6) with bearing rollers (3).
10. Slide spacers (11) over studs and install nuts (12) on studs.
11. Tighten nuts (12) evenly to keep quill aligned. When quill is started into bearing, remove work aid plug (2) to prevent
pushing work aid into oil jet no. 6 (if installed).
12. Continue tightening nuts (12) to fully seat quill. When quill is fully seated, loosen nuts (12) and remove studs (13) and
spacers (11).
NOTE
In the following steps, for aluminum washers (7 and 14, figure 1) use only
AN960JD616 (aluminum) washer next to transmission case. Do not substitute any
other type (including NAS1197).
13. Install aluminium washer (9), clip (10), and nut (11) on lower right stud. Install six aluminum washers (14) (next to
transmission case), six thin steel washers (13) (under nut), and six nuts (12) on remaining studs. Torque nuts (11 and
12) 160 to 190 in-lbs (18,1 to 21.5 Nm).
14. Rotate main driveshaft curvic coupling adapter (4, figure 3) on outboard end of main input quill (6, figure 1) by hand.
Check for binding and verify presence of backlash. Any binding or roughness is not acceptable.
15. Place a small amount of antiseize compound (C-452) on threads of union (27).
16. If removed, lubricate a new packing (26) with transmission oil (Chapter 12), and install on union (25). Install union in
main input quill (6) and install tube (24) in union.
17. Install three aluminium washers (7) (AN960JD616 only) on screws (8) and install screws. Secure screws (8) to main
input quill (6) with lockwire (C-405).
18. Install three setscrews (15) into studs on transmission case.
NOTE
If port cover opposite cover (20) was removed, install oil jet no. 6 (module 63-23-07
paragraph "2. Oil jet No. 6 - installation") and cover (module 63-26-01 paragraph "3.
Transmission quill port covers - installation").
19. Lubricate new packing (19) with transmission oil (Chapter 12), and install packing (19) on cover (20).
NOTE
Aluminum washers (21) are installed next to transmission case and steel washers
(22) are installed directly under heads of bolt (23).
20. Install steel washers (22) and then aluminum washers (21) under heads of bolt (23).
21. Install bolts (23) on cover (20). Torque bolts 160 to 190 in-lbs (18,1 to 21.5 Nm).
22. Apply a bead of adhesive (C-308) around flange of quill and cover which was removed where there is contact with
case.
23. Install main driveshaft (module 63-11-01 paragraph "4. Engine to transmission (main) driveshaft - installation").
24. Close engine and transmission cowling.
63-25-01
Rev. 3 Page 3
E-AB412-PT6T-2
25. Perform engine ground run (E-AB412-PT6T-1) and check for proper operation and leakage.
4. MAIN INPUT QUILL - CLEANING
MATERIALS REQUIRED
NUMBER NOMENCLATURE
NOTE
Inspect main input quill for evidence of leakage prior to cleaning. The cause of any
leakage shall be corrected prior to further use. For a definition of acceptable leakage,
refer to paragraph "5. Main input quill - inspection" below.
1. Wipe external surfaces of main input quill (6, figure 1) with a clean cloth dampened with drycleaning solvent (C-304).
5. MAIN INPUT QUILL - INSPECTION
1. Inspect main input quill (6, figure 1) for evidence of leakage. External leakage around seals is not acceptable. A small
amount of seepage, however, is acceptable. A continuous flow of droplets is considered leakage.
CAUTION
THIS COMPONENT IS DYNAMICALLY BALANCED. SIGNIFICANTLY

REWORKED DAMAGED AREAS MAY CAUSE HIGH FREQUENCY
VIBRATIONS AFTER INSTALLATION.
2. Inspect visible portion of main driveshaft curvic coupling adapter (4, figure 3). Superficial damage is permissible
without rework.
3. Inspect visible portions of input quill cap assembly (3). Maximum depth of pitting is 0.030 in (0.76 mm), provided no
more than 40% of any 1.0 sq-in (645,15 sq-mm) or 20% of total area of any surface is affected. Repair acceptable
damage in accordance with paragraph "6. Main input quill - repair".
4. Inspect visible portion of input sleeve (2). Light oxidation is permitted provided no more than 40% of any 1.0 sq-in
(645,15 sq-mm) or 20% of total area of any surface is affected. Remove acceptable oxidation as described in paragraph
"6. Main input quill - repair".
5. Inspect teeth on quill pinion (1) for abnormal gear wear pattern (E-AB412-PT6T-3). Abnormal gear wear pattern is not
acceptable and is cause to inspect mating gear in transmission.
6. Inspect bearings inside quill by rotating main driveshaft curvic coupling adapter (4) while holding input sleeve (2).
Bearing roughness which can be detected by feel is not acceptable. If bearings exhibit roughness, refer to
E-AB412-PT6T-3 for overhaul procedures.
63-25-01
Page 4 Rev. 3
E-AB412-PT6T-2
6. MAIN INPUT QUILL - REPAIR
MATERIALS REQUIRED
NUMBER NOMENCLATURE
C-464 INDIA STONE
1. Repair quills that have leakage by installing a new seal (module 63-25-02 paragraph "7. Main input quill magnetic seal
- repair" or module 63-25-03 paragraph "5. Main input quill seal - repair", as applicable).
2. Polish out acceptable corrosion and mechanical damage (as defined in paragraph "5. Main input quill - inspection")
using a fine India stone (C-464) and 600 grit abrasive cloth or paper (C-423).
3. Touch-up repaired areas that were previously painted using polyamide primer (C-204).
63-25-01
Rev. 3 Page 5
E-AB412-PT6T-2
TORQUE NUTS (11 AND 12)

160 TO 190 IN-LBS
(18.1 TO 21.4 Nm)
TORQUE
160 TO 190 IN-LBS
(18.1 TO 21.4 Nm)
1. Transmission 14. Aluminum washer

2. Bearing 15. Setscrew
3. Workaid (rubber plug) 16. Packing
4. Packing 17. Oil transfer tube
5. Packing 18. Packing
6. Main input quill 19. Packing
7. Aluminum washer 20. Cover
8. Screw 21. Aluminum washer
10. Clip 23. Bolt
11. Nut 24. Tube (seal drain)
12. Nut 25. Union
13. Thin steel washer 26. Packing
G6AB0479B
Figure 1. Main input quill
63-25-01
Page 6 Rev. 3
E-AB412-PT6T-2
1. Main rotor mast

2. Work aid plug
3. Bearing (roller)
4. Bearing outer race
5. Input gear quill (driven gear)
6. Input quill pinion
7. Packing
8. Transmission main bevel gear case
9. Packing
10. Main input quill sleeve
11. Spacer
12. Nut
13. Pusher set stud (T40)
14. Curvic coupling adapter
15. Drain tube union
G6AB0480B
Figure 2. Pusher set, T40, application
63-25-01
Rev. 3 Page 7
E-AB412-PT6T-2
1. Pinion
2. Input sleeve
3. Input quill cap assembly
4. Main driveshaft curvic coupling adapter
G6AB0481B
Figure 3. Main input quill assembly
63-25-01
Page 8 Rev. 3
E-AB412-PT6T-2
63-25-02 TRANSMISSION QUILLS - MAIN INPUT QUILL MAGNETIC SEAL (412-040-1 1)
63-25-02
TRANSMISSION QUILLS - MAIN INPUT QUILL MAGNETIC SEAL
(412-040-111)
1. MAIN INPUT QUILL MAGNETIC SEAL - REMOVAL (HELICOPTERS CODES [A] [B]
[C])
NUMBER NOMENCLATURE
T25 WRENCH
T41 WRENCH SET
3. Remove retainer ring (1, figure 1), plate (2), and packing (3). Discard packing (3).
4. Remove lock spring (4).
5. Insert splined wrench (9, figure 2) (T25) in nut (5). Install wrench (3) (T41) on main driveshaft curvic coupling adapter
(1) so splines on wrench (3) engage splines of wrench (9). Tighten wing nuts (2) to lock wrench (3) to main driveshaft
curvic coupling adapter (1).
6. Insert extension bar (4) through wrench (3) and engage wrench (9).
7. Hold wrench (3) and loosen nut (5) so it can be removed by hand. Leave nut (5) installed. Remove extension bar (4),
wrench (3), and wrench (9).
8. Remove retainer ring (7, figure 1).
9. Remove nut (5, figure 2).
10. Use two screwdrivers to remove adapter and magnetic seal assembly (12, figure 1) as an assembly. Position two
screwdrivers 180° apart and engage groove in seal retainer (8). Try against input quill cap assembly (9) to remove
adapter and magnetic seal assembly (12). Carefully place assembly on bench with main driveshaft curvic coupling
adapter (8, figure 3) facing down.
CAUTION
MAGNETIC RING (3) AND CARBON SEAL (2) MUST BE KEPT CLEAN IF
THEY ARE TO BE REINSTALLED. STORE THESE PARTS IN A CLEAN
PLASTIC BAG IMMEDIATELY AFTER REMOVAL TO PREVENT METAL
PARTICLES OR OTHER MATERIAL FROM ADHERING TO MAGNETIC
AND/OR CARBON SEAL.
63-25-02
Rev. 3 Page 1
E-AB412-PT6T-2
11. Remove carbon seal (2) and seal retainer (6) and magnetic ring (3) from main driveshaft curvic coupling adapter (8)
as an assembly. Refer to detail B.
CAUTION
MAGNETIC RING (3) AND CARBON SEAL (2) SHALL BE SEPARATED BY

PULLING HALVES STRAIGHT AWAY FROM EACH OTHER. ALLOWING
HALVES TO SLIDE AGAINST EACH OTHER MAY DAMAGE MATING
SURFACES.
12. Remove carbon seal (2) from seal retainer (6).
13. Remove packing (1) from carbon seal (2). Discard packing.
14. Remove magnetic ring (3) from seal retainer (6). Refer to detail C.
15. Remove packings (4 and 5) from seal retainer (6). Discard packings.
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E-AB412-PT6T-2
HELICOPTERS CODES A B C
T 350 TO 400 FT-LBS

(474.5 TO 542.3 Nm)
1. Retainer ring
2. Plate
3. Packing
4. Lock-spring
5. Nut
6. Main driveshaft curvic coupling
7. Retainer ring
8. Seal retainer
10. Transmission
12. Adapter and magnetic seal assembly
G6AB0482C
Figure 1. Main input quill magnetic seal (sheet 1 of 2)
63-25-02
Rev. 3 Page 3
E-AB412-PT6T-2
HELICOPTERS CODES D
T 450 TO 500 FT-LBS

(610.12 TO 677.91 Nm)
13. Retainer ring

14. Plate
15. Packing
16. Retainer ring
17. Lockwasher
18. Nut
19. Main driveshaft adapter
20. Retainer ring
21. Seal retainer
23. Transmission
25. Packing
26. Packing
27. Packing
28. Magnetic seal
29. Packing
G6AB0483C
Figure 1. Main input quill magnetic seal (sheet 2 of 2)
63-25-02
Page 4 Rev. 3
E-AB412-PT6T-2
HELICOPTERS CODES A B C

2. Wing nut
3. Wrench set (T41)
4. Extension bar (L-122)
5. Nut
6. Seal retainer
9. Tool (T25)
10. Triplex bearings
G6AB0484B
Figure 2. Tool application (sheet 1 of 2)
63-25-02
Rev. 3 Page 5
E-AB412-PT6T-2
HELICOPTERS CODES D
10. Triplex bearings

11. Main driveshaft adapter
12. Wrench set (T113)
13. Wrench (T62-4)
14. Nut
15. Seal retainer
18. Retainer ring
G6AB0485B
Figure 2. Tool application (sheet 2 of 2)
63-25-02
Page 6 Rev. 3
E-AB412-PT6T-2
1. Packing
2. Carbon seal
3. Magnetic ring
4. Packing
5. Packing
6. Seal retainer
7. Retaining ring
G6AB0486B
Figure 3. Main input quill curvic coupling adapter and magnetic seal assembly
63-25-02
Rev. 3 Page 7
E-AB412-PT6T-2
2. MAIN INPUT QUILL MAGNETIC SEAL - REMOVAL (HELICOPTERS CODE [D])
NUMBER NOMENCLATURE
T62-4 WRENCH
T113 WRENCH SET
3. Remove retainer ring (13, figure 1) and the plate (14).
4. Remove and discard the packing (15).
5. Remove the retainer ring (16) and the lock-washer (17).
6. Install the wrench set (12, figure 2) (T113).
7. Install the wrench (13) (T62-4) on the nut (18, figure 1).
8. Loosen the nut but leave it installed.
9. Remove the wrench (13, figure 2) (T62-4) and the wrench set (12) (T113).
10. Remove the retainer ring (20, figure 1).
11. Remove the nut (18).
NOTE
Adapter and magnetic seal assembly consists of all parts shown in figure 1. These
parts may be removed as an assembly.
12. Use two screwdrivers to remove the main driveshaft adapter (19) and the magnetic seal (28) as an assembly.
13. Position two screwdrivers 180° apart and engage them in the grooves of the seal retainer (21).
14. Apply a force against the input quill cap assembly (22) to remove the main driveshaft adapter (19) and the magnetic
seal (28).
15. Put the assembly on a bench with the main driveshaft adapter (19) face down.
16. Remove and discard the packing (29) from the input quill pinion (24).
CAUTION
MAGNETIC RING (3, figure 3) AND CARBON SEAL (2) MUST BE KEPT
CLEAN IF THEY ARE TO BE REINSTALLED. STORE THESE PARTS IN A
CLEAN PLASTIC BAG IMMEDIATELY AFTER REMOVAL TO PREVENT
METAL PARTICLES OR OTHER MATERIAL FROM ADHERING TO
MAGNETIC AND/OR CARBON SEAL.
63-25-02
Page 8 Rev. 3
E-AB412-PT6T-2
17. Remove carbon seal (2, figure 3) seal retainer (6) and magnetic ring (3) from main driveshaft curvic coupling adapter
(8) as an assembly. Refer to detail B.
CAUTION
MAGNETIC RING (3) AND CARBON SEAL (2) SHALL BE SEPARATED BY

PULLING HALVES STRAIGHT AWAY FROM EACH OTHER. ALLOWING
HALVES TO SLIDE AGAINST EACH OTHER MAY DAMAGE MATING
SURFACES.
18. Remove the carbon seal (2) from seal retainer (6).
19. Remove packing (1) from carbon seal (2). Discard packing.
20. Remove magnetic ring (3) from seal retainer (6). Refer to detail C.
21. Remove the packing (4 and 5) from seal retainer (6). Discard packing.
3. MAIN INPUT QUILL MAGNETIC SEAL - INSTALLATION (HELICOPTERS CODES

[A] [B] [C])
NUMBER NOMENCLATURE
T25 WRENCH
T41 WRENCH SET
MATERIALS REQUIRED
NUMBER NOMENCLATURE
C-001 GREASE
1. Assemble adapter and magnetic seal assembly (12, figure 1) as follows:
CAUTION
LEAVE THE SEAL IN PACKAGING UNTIL READY FOR INSTALLATION.

THE SEAL CAVITY MUST BE CLEAN AND FREE OF BURRS ON PACKING
CONTACT DIAMETERS. WHEN THE SEAL PACKAGE IS OPENED, THE
SEAL MUST BE SEPARATED BY PULLING HALVES AWAY FROM EACH
OTHER TO PREVENT DAMAGE TO MATING SURFACES. INSTALL THE
SEAL BY HAND PRESSURE ONLY.
a. Coat packings (4 and 5, figure 3) and seal retainer (6) contact diameters with assembly fluid (C-024).
b. Install packing (5) in inner groove of seal retainer (6). Install magnetic ring (3) in seal retainer (6).
63-25-02
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E-AB412-PT6T-2
c. Install packing (4) on outer groove of seal retainer (6).
d. Coat packing (1) sparingly with assembly fluid (C-024) and install in inner groove of carbon seal (2) as shown
in detail B.
CAUTION
DO NOT SLIDE SEAL HALVES ON EACH OTHER DURING ASSEMBLY.
e. Place, very carefully, carbon seal (2) on magnetic ring (3). Align so magnetic seal assembly may be installed on
main driveshaft curvic coupling adapter (8). Refer to detail A.
2. Position retaining ring (7) on main driveshaft curvic coupling adapter (8). Refer to detail A.
3. Position seal retainer (6), and parts assembled in step 1. above, on main driveshaft curvic coupling adapter (8). Refer
to detail A
4. Coat outer diameter of packing (4) and contact area of seal retainer (6) with assembly fluid (C-024).
CAUTION
DO NOT PUSH ON SEAL RETAINER (6) WHILE INSTALLING MAGNETIC

SEAL AND ADAPTER ASSEMBLY. CARBON SEAL (2) MAY BE PUSHED
OFF EDGE OF ADAPTER.
5. Align splines of main driveshaft curvic coupling (6, figure 1) with splines of input quill pinion (11). Using hand
pressure only, push main driveshaft curvic coupling (6) inward to obtain contact with splines of pinion.
6. Locate groove in edge of seal retainer (8). Rotate seal retainer (8) to align groove with pin at upper side of input quill
cap assembly (9), then push main driveshaft curvic coupling (6) in against triplex bearings. Refer to figure 2 for a
sectional view of installed adapter and magnetic seal assembly.
CAUTION
DO NOT SEAT SEAL RETAINER (6, FIGURE 2) INTO INPUT QUILL CAP
ASSEMBLY (7) AT THIS TIME.
7. Install nut (5, figure 1) finger tight to hold adapter and magnetic seal assembly (12) in place.
8. Install wrench set (T25) and (T41) as described in paragraph "1. Main input quill magnetic seal - removal (helicopters
codes [A] [B] [C])". Torque nut (5) 350 to 400 ft-lbs (474.5 to 542.3 Nm).
9. Install lock-spring (4). Ensure tang on lock-spring fully engages nut (5) and input quill pinion (11).
10. Using hand pressure only, seat seal retainer (6, figure 2) in groove on input quill cap assembly (7). Ensure seal retainer
is fully seated.
11. Install retainer ring (7, figure 1) in groove on input quill cap assembly (9). Ensure seal retainer (6, figure 2) is fully
seated.
12. Install packing (3, figure 1) on plate (2). Install plate (2) on main driveshaft curvic coupling (6).
13. Install retainer ring (1). Ensure retainer ring is fully seated.
63-25-02
Page 10 Rev. 3
E-AB412-PT6T-2
15. Close and secure engine and transmission cowling.
16. Perform engine ground run (E-AB412-PT6T-1) to check for operation and leaks.
4. MAIN INPUT QUILL MAGNETIC SEAL - INSTALLATION (HELICOPTERS CODE [D])
NUMBER NOMENCLATURE
T62-4 WRENCH
T113 WRENCH SET
MATERIALS REQUIRED
NUMBER NOMENCLATURE
C-001 GREASE
1. Assemble the magnetic seal (28, figure 1) and the main driveshaft adapter (19) as follows:
CAUTION
LEAVE THE SEAL IN PACKAGING UNTIL READY FOR INSTALLATION.

THE SEAL CAVITY MUST BE CLEAN AND FREE OF BURRS ON PACKING
CONTACT DIAMETERS. WHEN THE SEAL PACKAGE IS OPENED, THE
SEAL MUST BE SEPARATED BY PULLING HALVES AWAY FROM EACH
OTHER TO PREVENT DAMAGE TO MATING SURFACES. INSTALL THE
SEAL BY HAND PRESSURE ONLY.
a. Apply assembly fluid (C-024) to the packings (4 and 5, figure 3) and the seal retainer (6) contact diameter.
b. Install the packing (5) in the inner groove of the seal retainer (6).
c. Install the magnetic ring (3) in the seal retainer (6).
d. Install the packing (4) on the outer groove of the seal retainer (6).
e. Lightly apply assembly fluid (C-024) to the packing (1).
f. Install the packing (1) in the inner groove of the carbon seal (2). Refer to detail B.
CAUTION
DO NOT SLIDE SEAL HALVES ON EACH OTHER DURING ASSEMBLY.
g. Very carefully, put the carbon seal (2) in position on the magnetic ring (3).
63-25-02
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E-AB412-PT6T-2
h. Align to make sure that the magnetic seal assembly can be installed on the main driveshaft curvic coupling
adapter (8). Refer to detail A.
2. Put the retainer ring (7) in position on main driveshaft curvic coupling adapter (8). Refer to detail A.
3. Put the seal retainer (6) and the assembly from step 1. in position on the main driveshaft curvic coupling adapter (8).
Refer to detail A.
4. Apply assembly fluid (C-024) to the outside diameter of the packing (4) and to the contact area of the seal retainer (6).
5. Install a new packing (29, figure 1) on the input quill pinion (24).
CAUTION
DO NOT PUSH ON SEAL RETAINER (6, figure 3) WHILE INSTALLING THE

ADAPTER AND MAGNETIC SEAL. CARBON SEAL (2) CAN BE PUSHED
OFF THE EDGE OF THE ADAPTER.
6. Align the splines of main driveshaft adapter (19, figure 1) with the splines of the input quill pinion (24).
7. With your hands, push on the main driveshaft adapter (19) to get in contact with the splines of the input quill pinion
(24).
8. Find the groove in the edge of the seal retainer (21).
9. Rotate the seal retainer (21) to align the groove with the pin at the upper side of the input quill cap assembly (22).
10. Push the main driveshaft adapter (19) against triplex bearings. Refer to figure 2 for a sectional view of the assembly.
11. Apply a thin layer of grease (C-001) to the threads of the nut (18) and transmission oil to the flange face (Chapter 12).
12. Install the wrench set (T113) (figure 2).
13. With the wrench (T62-4) install nut (18, figure 1)
14. Torque the nut (18) 450 to 500 ft-lbs (610.12 to 677.91 Nm).
15. Remove and clean the nut (18)
16. Repeat steps 11., 13., and 14.
17. Clean all excess grease from the threads and around the flange of the nut (18).
18. Remove the wrench (T62-4) (figure 2) and the wrench set (T113).
19. Install the lockwasher (17, figure 1) and the retainer ring (16).
20. With hand pressure only, push the seal retainer (21) in the groove of the input quill cap assembly (22).
21. Make sure that the seal retainer (21) is installed against the input quill cap assembly (22).
22. Install the retainer ring (20) in the groove of the input quill cap assembly (22).
23. Make sure that the seal retainer (15, figure 2) continues to be in the correct position.
24. Install the packing (15, figure 1) on the plate (14).
63-25-02
Page 12 Rev. 3
E-AB412-PT6T-2
25. Install the plate (14) on the main driveshaft adapter (19).
26. Install the retainer ring (13).
27. Make sure that the retainer ring (13) is in the correct position.
28. Install the main driveshaft (module 63-11-01 paragraph "4. Engine to transmission (main) driveshaft - installation").
29. Close and safety the engine and transmission cowling.
30. Perform an engine ground run (E-AB412-PT6T-1) to examine for leaks and operation.
5. MAIN INPUT QUILL MAGNETIC SEAL - CLEANING
MATERIALS REQUIRED
NUMBER NOMENCLATURE
1. Clean seal retainer (6, figure 3) and main driveshaft curvic coupling adapter (8) with drycleaning solvent (C-304).
6. MAIN INPUT QUILL MAGNETIC SEAL - INSPECTION
1. Inspect main driveshaft curvic coupling adapter (8, figure 3) (module 63-11-02 paragraph "3. Engine to driveshaft
curvic coupling adapter - inspection").
2. Inspect seal retainer (6) (E-AB412-PT6T-3).
7. MAIN INPUT QUILL MAGNETIC SEAL - REPAIR
Polish out nicks and burrs on seal retainer (6, figure 3) which could damage packings.
63-25-02
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E-AB412-PT6T-2
63-25-02
Page 14 Rev. 3
E-AB412-PT6T-2
63-25-03
TRANSMISSION QUILLS - MAIN INPUT QUILL SEAL (2820-3655)
1. MAIN INPUT QUILL SEAL - REMOVAL
NUMBER NOMENCLATURE
T25 WRENCH
T41 WRENCH SET
COMMERCIAL GRINDER, HANDHELD
1. Remove retaining ring (12, figure 1) and plate (11) with packing (10). Discard packing.
2. Remove lock spring (9). Remove nut (8) using wrench (T25) and wrench set (T41) (module 63-25-02 paragraph "1.
Main input quill magnetic seal - removal (helicopters codes [A] [B] [C])").
CAUTION
WHEN CUTTING THROUGH OLD WEAR SLEEVE IN THE FOLLOWING

STEP, USE EXTREME CARE TO AVOID DAMAGING ADAPTER (7).
3. Remove adapter (7). Using a handheld grinder, cut a groove almost through wear sleeve (6). Strike wear sleeve (6)
with a rubber mallet to break uncut portion of wear sleeve. Remove and discard wear sleeve (6).
4. Remove retaining ring (5) and sleeve (4) from cap (3). Remove and discard packing (1).
5. Remove seal (2) from sleeve (4) by pressing inboard.
2. MAIN INPUT QUILL SEAL - INSTALLATION
MATERIALS REQUIRED
NUMBER NOMENCLATURE
C-028 DRY LUBRICANT
C-317 ADHESIVE
C-327 ADHESION PROMOTER
63-25-03
Page 1
E-AB412-PT6T-2
(Continued)
NUMBER NOMENCLATURE
C-345 PRIMER
C-407 ABRASIVE PAD
NUMBER NOMENCLATURE
T25 WRENCH
T41 WRENCH SET
COMMERCIAL BRUSH, HOG BRISTLE, UNPAINTED HANDLE
CAUTION
BONDING SHALL BE ACCOMPLISHED WITHOUT DELAY BETWEEN

STEPS. FOUR HOURS IS THE MAXIMUM TIME INTERVAL BETWEEN
SANDBLASTING AND THE NEXT STEP.
NOTE
Precautions shall be taken when accomplishing the following steps to keep wear
sleeve and adapter clean. Wear clean white gloves when handling parts and change
gloves when soiled. Cover work bench with clean white paper. Avoid any contact
with mold release agents such as silicone, oil, waxes, grease, etc. Area where work is
performed shall be maintained at 64 to 82F (18 to 28C) with relative humidity
below 75%. Area shall be dust-free to the extent that bonding operations are not
affected.
1. Mask outer diameter of new wear sleeve (6, figure 1).
2. Mask all surfaces of adapter (7) except those surfaces which mate with wear sleeve (6).
3. Sandblast unmasked surfaces of wear sleeve (6) and adapter with 60 grit garnet at 5 to 10 psi and remove residue. If
there is to be any delay before accomplishing the next step, wrap parts in clean barrier material (C-427) after
sandblasting.
4. Stir primer (C-345) thoroughly in its container and apply to unmasked portion of adapter (7) only. Scrub primer into
surface of adapter with abrasive pad (C-407). Repeat scrubbing as required to ensure adapter is clean.
5. Allow degreaser residue to dry to a white powder. Remove residue from adapter with a clean, dry cheesecloth.
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E-AB412-PT6T-2
G6AB0487A
Figure 1. Main input quill seal (2820-3655)
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Page 3
E-AB412-PT6T-2
CAUTION
KEEP ADHESION PROMOTER (C-327) IN A COVERED, NON-ABSORPTIVE

CONTAINER AND KEEP LID TIGHTLY CLOSED WHEN NOT IN USE.
EXPOSURE TO ATMOSPHERE WILL CAUSE DECOMPOSITION. SEDIMENT
OR BROWN RESIDUE IN BOTTOM OF CONTAINER INDICATES
DECOMPOSITION OF PROMOTER TO THE EXTENT IT SHALL BE
DISCARDED. PROMOTER PH RANGE SHALL BE MAINTAINED BETWEEN
7,0 AND 8,0.
NOTE
If the next step is not to be accomplished immediately, wrap adapter (7) with clean
barrier material (C-427).
6. Apply adhesion promoter (C-327) to unmasked portion of wear sleeve (6) and adapter (7) with a pure hog bristle brush
with an unpainted handle. Apply only enough promoter to wet the surfaces.
7. Allow promoter to dry for a minimum of 30 minutes at 65 to 85F (18 to 29C) or for 15 minutes at 150 to 160F
(66 to 71C).
NOTE
If the next step is not to be accomplished immediately, wrap parts with clean barrier
material (C-427).
8. Mix adhesive (C-317) 33 parts B to 100 parts A. The pot life of mixed adhesive is 30 to 50 minutes.
9. Coat inside diameter of wear sleeve (6) and mating surface on adapter (7) with mixed adhesive (C-317).
10. Press wear sleeve (6) on adapter (7) until inner shoulder of wear sleeve (6) contacts adapter.
11. Clean excess adhesive from wear sleeve (6) thoroughly and remove all protective masking material. Allow adhesive
to cure at 65 to 85F (18 to 29C) for 24 hours.
CAUTION
ENSURE NO EXCESSIVE BONDING MATERIAL REMAINS BETWEEN

WEAR SLEEVE (6) AND COUPLING RACE. BONDING MATERIAL WILL
BECOME HARD AND FLAKE OFF. THIS FLAKING BETWEEN SEAL LIP
AND WEAR RING WILL CAUSE LEAKAGE.
12. Apply a film of sealing compound (C-328) to outside diameter of new seal (2). Press seal into sleeve (4) until bottomed
out. Remove excess sealant.
13. Lubricate packing (1) with transmission oil (Chapter 12). Install packing (1) on sleeve (4). Align cutout in sleeve (4)
with pin in cap (3) and install sleeve (4) in cap (3) by pressing with hand pressure. Install retaining ring (5).
14. Spray wear sleeve (6) with dry lubricant (C-028). Position adapter (7) on quill pinion.
15. Install wrench (T25) and wrench set (T41) as described in module 63-25-02 paragraph "1. Main input quill magnetic
seal - removal (helicopters codes [A] [B] [C])". Torque nut (8) 350 to 400 ft.-lbs. (475 to 542 Nm).
16. Install lock spring (9) in hole of nut that is in line with slot in pinion.
63-25-03
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E-AB412-PT6T-2
17. Lubricate new packing (10) with transmission oil (Chapter 12). Install packing on plate (11). Install plate in adapter (7).
18. Install retaining ring (12) in adapter (7).
20. Close engine and transmission cowling.
21. Perform engine ground run (E-AB412-PT6T-1) and check for proper operation and leakage.
3. MAIN INPUT QUILL SEAL - CLEANING
MATERIALS REQUIRED
NUMBER NOMENCLATURE
C-407 ABRASIVE PAD
1. Clean disassembled components with an abrasive pad (C-407).
2. Clean adapter (7, figure 1) and sleeve (4) with a plastic scraper and an abrasive pad (C-407) to remove foreign matter.
3. Rinse adapter (7) and sleeve (4) with drycleaning solvent (C-304).
4. Dry parts using filtered, compressed air.
4. MAIN INPUT QUILL SEAL - INSPECTION
1. Inspect parts for excessive wear and corrosion.
2. Inspect parts for cracks. No cracks are allowed.
3. Inspect packing grooves in cap (3, figure 1) and plate (11) for sharp nicks and distortion.
4. Inspect threaded components for thread damage. No thread damage is allowed.
5. Inspect retaining rings (5 and 12) for distortion. No distortion is allowed.
5. MAIN INPUT QUILL SEAL - REPAIR

MATERIALS REQUIRED
NUMBER NOMENCLATURE
C-407 ABRASIVE PAD
Remove light surface corrosion from adapter (7, figure 1) and sleeve (4) with a plastic scraper and abrasive pad (C-407).
63-25-03
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E-AB412-PT6T-2
63-25-03
Page 6
E-AB412-PT6T-2
63-25-04
TRANSMISSION QUILLS - NO. 1 HYDRAULIC PUMP DRIVE QUILL
1. NO. 1 HYDRAULIC PUMP DRIVE QUILL - DESCRIPTION
The No. 1 hydraulic system pump and tachometer drive quill is located on the forward right side of the transmission sump
assembly. It drives the no. 1 hydraulic system pump. A chain-and-sprocket offset drive inside the quill rotor-tachometer
generator.
2. NO. 1 HYDRAULIC PUMP DRIVE QUILL - REMOVAL
NUMBER NOMENCLATURE
T27 JACKSCREW SET
2. Using a sharp plastic scraper, cut sealant at mating flanges of tachometer generator (13, figure 1), hydraulic pump (3),
and quill (8). Remove sealant from jackscrew holes.
3. Remove tachometer generator (13) (module 63-25-06 paragraph "2. Rotor tachometer generator - removal").
4. Remove hydraulic pump (3) (Chapter 29).
5. Install jackscrews (T27) on quill (8).
CAUTION
TIGHTEN JACKSCREWS CAREFULLY AND EVENLY TO KEEP QUILL

ALIGNED DURING REMOVAL.
6. Using a heat lamp or a 250 watt light bulb to heat sump (10) in area of quill (8). Heat area until hot to the touch with
bare hands. Remove quill (8) by tightening jackscrews evenly. Cover open mounting port.
7. Remove and discard packing (9) from quill (8).
3. NO. 1 HYDRAULIC PUMP DRIVE QUILL - INSTALLATION
MATERIALS REQUIRED
NUMBER NOMENCLATURE
1. Lubricate new packing (9, figure 1) with transmission oil (Chapter 12). Install packing (9) in groove around quill
sleeve (8).
63-25-04
Rev. 2 Page 1
E-AB412-PT6T-2
2. Using a standard heating lamp (or 250 watt light bulb) to heat sump mounting port until unit is hot to the touch.
3. Coat mating surfaces of quill (8) and sump (10) with transmission oil (Chapter 12).
4. Position quill (8) on mounting port with tachometer generator pad forward.
5. Insert quill (8) into sump. Mesh gears carefully and guide sleeve flange over mounting studs.
6. Install aluminum washers (7), steel washers (6), and nuts (5) on two studs (11). Torque nuts 100 to 140 in-lbs (11.3 to
11.7 Nm).
7. Check quill (8) to verify presence of backlash.
8. Install hydraulic system 1 pump (Chapter 29).
9. Install rotor tachometer generator (module 63-25-06 paragraph "3. Rotor tachometer generator - installation").
10. Apply a bead of adhesive (C-308) around mating surfaces of quill (8), pump (3), and tachometer generator (13).
11. Install access door on right side of pylon support in cabin area.
12. Perform engine ground run (E-AB412-PT6T-1) and check for proper operation of hydraulic system 1 and leakage.
4. NO. 1 HYDRAULIC PUMP DRIVE QUILL - CLEANING
MATERIALS REQUIRED
NUMBER NOMENCLATURE
1. Clean sealant residue from both quill (8) and transmission mounting port using a sharp plastic scraper.
2. Clean external surfaces of parts using drycleaning solvent (C-304).
5. NO. 1 HYDRAULIC PUMP DRIVE QUILL - INSPECTION
1. Visually inspect all accessible parts for damage.
2. Rotate quill gear and check bearings for smooth operation. Roughness that can be detected by feel is unacceptable.
3. Inspect gear teeth for nicks, dents, cracks and abnormal wear pattern. Any such damage that can be detected visually
is unacceptable.
4. Inspect seals for evidence of leakage, damage, and abnormal wear. Leaking, damaged, or worn seals are unacceptable.
5. For additional, detailed inspection criteria, refer to E-AB412-PT6T-3.
63-25-04
Page 2 Rev. 2
E-AB412-PT6T-2
1. Nut
2. Steel washer
3. Hydraulic pump
4. Gasket
5. Nut
6. Steel washer
7. Aluminum washer
8. Quill
9. Packing
10. Sump
11. Drive quill mounting studs
12. Gasket
13. Tachometer generator
14. Steel washer
15. Nut
G6AB0500B
Figure 1. No. 1 Hydraulic pump drive quill
63-25-04
Rev. 2 Page 3
E-AB412-PT6T-2
6. NO. 1 HYDRAULIC PUMP DRIVE QUILL - REPAIR
MATERIALS REQUIRED
NUMBER NOMENCLATURE
NUMBER NOMENCLATURE
T27 JACKSCREW SET
1. Quill (8, figure 1) shall be replaced as an assembly when inspection requirements are not met, however, seals may be
replaced as required.
2. Replace seals (2 and 9, figure 2) as follows:
a. Remove nuts (12), washers (11 and 10), and bolt (5) with washers (6 and 8) and bracket (7).
NOTE
As sleeve (4) and cover (1) separate, tap splined end of gear shafts (not shown)
where they protrude through seals (2 and 9) to prevent binding of shaft bearing in
sleeve assembly.
b. Using jackscrew (T27) carefully and evenly remove cover (1) from sleeve assembly (4).
c. Remove and discard gasket (3) from sleeve assembly (4) studs.
d. Press seals (2 and 9) from cover (1).
e. Clean seal housing in cover (1) with drycleaning solvent (C-304) and dry using filtered, compressed air.
f. Install seals (2 and 9) on cover (1) with numbered side of seals outboard.
g. Coat lip of seals (2 and 9) with transmission oil (Chapter 12).
h. Position new gasket (3) on sleeve assembly (4) studs.
i. Install cover assembly (1) on sleeve assembly (4).
NOTE
Bracket (7) replaces washer (6) at 12 o'clock position only.
j. Install bolt (5) with aluminum washers (8) next to quill housing and steel washers (6), or bracket (7), next to bolt
head.
k. Install nuts (12) with aluminum washers (10) next to cover (1) and steel washers (11) next to nut.
63-25-04
Page 4 Rev. 2
E-AB412-PT6T-2
1. Cover
2. Seal
3. Gasket
4. Sleeve assembly
5. Bolt
6. Steel washer
7. Bracket
8. Aluminum washer
9. Seal
10. Aluminum washer
11. Steel washer
12. Nut
G6AB0501B
Figure 2. No. 1 Hydraulic pump drive quill assembly
63-25-04
Rev. 2 Page 5
E-AB412-PT6T-2
63-25-04
Page 6 Rev. 2
E-AB412-PT6T-2
63-25-05
TRANSMISSION QUILLS - NO. 2 HYDRAULIC PUMP DRIVE QUILL
1. NO. 2 HYDRAULIC PUMP DRIVE QUILL - DESCRIPTION
The No. 2 hydraulic system pump is driven by a quill located on forward side of transmission.
2. NO. 2 HYDRAULIC PUMP DRIVE QUILL - REMOVAL
NUMBER NOMENCLATURE
T29 JACKSCREW SET
1. Open transmission forward cowling.
2. Remove hydraulic system No. 2 pump (Chapter 29).
3. Using a sharp plastic scraper, cut sealant from around flange of quill assembly (1, figure 1). Clean sealant from
jackscrew holes (5).
4. Remove bolts (8) and washers (6 and 7).
5. Install jackscrews (T29) in holes on quill (1). Tighten jackscrews carefully and evenly to remove quill (1) from
transmission (4) case.
7. Cover open mounting port to prevent foreign objects from entering transmission case.
3. NO. 2 HYDRAULIC PUMP DRIVE QUILL - INSTALLATION
MATERIALS REQUIRED
NUMBER NOMENCLATURE
1. Lubricate packing (3, figure 1) with transmission oil (Chapter 29) and install on quill (1).
2. Lubricate mating surfaces of quill (1) and transmission mounting port with transmission oil.
3. Using a heat lamp (or 250 watt light bulb), heat sump mounting port until unit is hot to the touch.
4. Position quill assembly (1) with oil hole (2) straight up. Insert quill (1) into transmission while rotating pinion
simultaneously to permit gear meshing.
63-25-05
Page 1
E-AB412-PT6T-2
NOTE
Install AN960JD616 aluminum washers (6) next to quill sleeve. Do not substitute
any other type washer (including NAS1197).
5. Install bolts (8) with steel washers (7) under bolt heads and aluminum washers adjacent to quill flange. Torque bolts
160 to 190 in.-lbs. (18,1 to 21,5 Nm).
6. Check quill pinion for freedom of rotation and existence of backlash.
7. Fill gap between flange on quill (1) and flange on transmission with adhesive (C-308). Also fill jackscrew holes with
same sealant. Allow to cure.
8. Install hydraulic system no. 2 pump (Chapter 29).
9. Perform engine ground run (E-AB412-PT6T-1) and check for proper operation of hydraulic system 2 and leakage.
4. NO. 2 HYDRAULIC PUMP DRIVE QUILL - CLEANING
MATERIALS REQUIRED
NUMBER NOMENCLATURE
1. Clean sealant residue from both quill and transmission mounting port using a sharp plastic scraper.
5. NO. 2 HYDRAULIC PUMP DRIVE QUILL - INSPECTION
1. Inspect quill and pinion gear (1, figure 1) for obvious mechanical and corrosion damage (E-AB412-PT6T-3).
2. Rotate pinion in sleeve and check for rough bearings. Bearing roughness that can be detected by feel is not acceptable.
6. NO. 2 HYDRAULIC PUMP DRIVE QUILL - REPAIR
For repair and overhaul instructions, refer to E-AB412-PT6T-3.
63-25-05
Page 2
E-AB412-PT6T-2
G6AB0478A
Figure 1. Hydraulic pump drive quill
63-25-05
Page 3
E-AB412-PT6T-2
63-25-05
Page 4
E-AB412-PT6T-2
63-25-06
TRANSMISSION QUILLS - ROTOR TACHOMETER GENERATOR
1. ROTOR TACHOMETER GENERATOR - DESCRIPTION
The rotor tachometer generator (5, figure 1) is driven by a chain-and-sprocket offset drive from the hydraulic pump and
tachometer generator drive quill (2) which also drives the system 1 hydraulic pump (1). The hydraulic pump (1) and
tachometer generator drive quill (2) is located on the transmission sump case (3).
2. ROTOR TACHOMETER GENERATOR - REMOVAL
1. Disconnect electrical connector from rotor tachometer generator (5, figure 1).
2. Remove nuts (7) and steel washers (6).
3. Using a sharp plastic scraper, cut sealant from flange of rotor tachometer generator (5).
4. Remove rotor tachometer generator (5) and gasket (4). Discard gasket (4).
3. ROTOR TACHOMETER GENERATOR - INSTALLATION
MATERIALS REQUIRED
NUMBER NOMENCLATURE
C-308 ADHESIVE
1. Clean mating surfaces of rotor tachometer generator (5, figure 1) and drive quill (2) with drycleaning solvent (C-304).
2. Lubricate rotor tachometer generator (5) shaft splines with bearing grease (C-007).
3. Position gasket (4) on hydraulic pump and tachometer generator drive quill (2).
4. Position rotor tachometer generator (5) on quill (2) with electrical connector positioned for attachment of wiring.
Install steel washers (6) and nuts (7).
5. Apply a bead of adhesive (C-308) around mating flange of rotor tachometer generator (5) and quill (2). Allow sealant
to cure.
6. Perform helicopter ground run (E-AB412-PT6T-1). Check for oil leaks and perform operational check of triple
tachometer indicating system (Chapter 95).
63-25-06
Page 1
E-AB412-PT6T-2
4. ROTOR TACHOMETER GENERATOR - CLEANING
MATERIALS REQUIRED
NUMBER NOMENCLATURE
1. Clean sealant residue from both quill and mating surface of offset drive using a sharp plastic scraper.
5. ROTOR TACHOMETER GENERATOR - INSPECTION
1. Inspect rotor tachometer generator (5, figure 1) for mechanical and corrosion damage. Superficial damage is
acceptable providing all corrosion is removed.
2. Inspect electrical connector for damaged threads and distorted or missing pins.
6. ROTOR TACHOMETER GENERATOR - REPAIR
MATERIALS REQUIRED
NUMBER NOMENCLATURE
C-407 ABRASIVE PAD
1. Remove any surface corrosion using abrasive pad (C-407).
2. Remove residue by wiping area with a clean cloth damp with drycleaning solvent (C-304).
63-25-06
Page 2
E-AB412-PT6T-2
G6AB0499A
Figure 1. Rotor tachometer generator
63-25-06
Page 3
E-AB412-PT6T-2
63-25-06
Page 4
E-AB412-PT6T-2
63-25-07
TRANSMISSION QUILLS - TAIL ROTOR DRIVE QUILL
1. TAIL ROTOR DRIVE QUILL - DESCRIPTION
Helicopters codes [A] [B] [C] have a tail rotor drive quill equipped with a flexible coupling and located on aft side of
transmission sump case. The tail rotor driveshaft is connected to the drive quill by a V-band clamp set.
Helicopters code [D] and sub. have a tail rotor drive quill equipped with a rigid adapter rather than the flexible coupling
noted previously and is also located on aft side of transmission sump case. The tail rotor driveshaft is bolted to an
independent flex coupling which is attached to the rigid adapter.
2. TAIL ROTOR DRIVE QUILL - REMOVAL
NUMBER NOMENCLATURE
T27 JACKSCREW SET
1. Remove access doors from left and right side of pylon support in cabin area.
2. Disconnect and remove forward section of tail rotor driveshaft (Chapter 65).
3. Drain transmission oil (Chapter 12) as necessary to a level below quill mounting port.
4. Remove nuts (1, figure 1), steel washers (2), spacers (3), steel washers (4), and washers (5).
5. Using a sharp plastic scraper, cut sealant between quill mounting flange and transmission case. Remove sealant from
jackscrew holes (6).
6. Using a heat lamp, heat sump mounting port until it is hot to the touch.
7. Install jackscrews (T27) in holes on quill. Tighten jackscrews carefully and evenly to remove tail rotor drive quill (7)
from transmission sump assembly (11).
9. Cover open mounting port to prevent foreign objects from entering transmission case.
63-25-07
Page 1
E-AB412-PT6T-2
G6AB0489A
Figure 1. Tail rotor drive quill
63-25-07
Page 2
E-AB412-PT6T-2
3. TAIL ROTOR DRIVE QUILL - INSTALLATION
MATERIALS REQUIRED
NUMBER NOMENCLATURE
C-308 ADHESIVE
1. Lubricate new packing (8, figure 1) with transmission oil (Chapter 12). Install packing in groove around tail rotor drive
quill (7) sleeve.
2. Verify mating surfaces of quill (7) sleeve and transmission case are free of all foreign material.
3. Lubricate mating surfaces of quill (7) and transmission mounting port with transmission oil (Chapter 12).
4. Using a heating lamp (or 250 watt light bulb), heat sump mounting port until unit it is hot to the touch.
5. Insert quill (7) into transmission while rotating pinion simultaneously to permit gear meshing. Position mounting holes
in sleeve over transmission studs.
NOTE
Install AN960JD616 aluminum washers (5) next to quill sleeve. Do not substitute
any other type washer (including NAS1197).
6. Install aluminum washers (5), thin steel washers (4), spacers (3), thin steel washers (2), and nuts (1). Torque nuts 50
to 70 in.-lbs. (5,45 to 7,91 Nm).
8. Fill gap between flange on quill (7) and flange on transmission sump assembly (11) with adhesive (C-308). Also fill
jackscrew holes with same sealant. Allow to cure.
9. Install forward section of tail rotor driveshaft (Chapter 65).
10. Ground run helicopter (E-AB412-PT6T-1) and check for leaks at quill flange and loss of lubricant at coupling. If
lubricant loss is evident, refer to Chapter 65.
11. Install access doors on both sides of pylon support in cabin area.
4. TAIL ROTOR DRIVE QUILL - CLEANING
MATERIALS REQUIRED
NUMBER NOMENCLATURE
CAUTION
DO NOT IMMERSE TAIL ROTOR DRIVE QUILL IN SOLVENT OR SPRAY

SOLVENT ON QUILL. USE ONLY CLEAN CLOTHS DAMP WITH SOLVENT
(C-304) TO EXTERIOR OF QUILL.
63-25-07
Page 3
E-AB412-PT6T-2
1. Clean sealant residue from both quill and transmission mounting port using a sharp plastic scraper.
3. Dry with filtered, compressed air or clean, dry, lint-free cloths.
5. TAIL ROTOR DRIVE QUILL - INSPECTION
MATERIALS REQUIRED
NUMBER NOMENCLATURE
NOTE
The following inspection procedures shall be accomplished when tail rotor drive
quill is removed for normal maintenance.
1. Inspect coupling (10, figure 1) for grease leakage. Wetting of adjacent areas by grease is cause for replacement of
defective parts with the following exception: A small amount of grease expelled from around lip of seal (9) and/or
other quill parts provided the following evaluation of grease leakage is accomplished.
CAUTION
DO NOT CLEAN OR SPRAY COUPLING WITH ANY TYPE OF SOLVENT

DURING INSPECTION. USE ONLY CLEAN CLOTH DAMP WITH SOLVENT
(C-304) TO CLEAN EXTERIOR OF QUILL.
a. Wipe grease from coupling (10) and adjacent parts with clean cloths.
b. Inspect coupling (10) over-temperature indicator (TEMP-PLATE) for discoloration and overheat condition. A
change in color of over-temperature indicator (TEMP-PLATE) (from white to black) indicates a possible
overheat condition and/or component degradation. Cause of discoloration shall be determined and corrected
prior to continued operation. Refer to E-AB412-PT6T-3 for inspection procedures.
c. Inspect coupling (10) for grease leakage and for discoloration due to overheating at frequent intervals during the
next ten flight hours. If grease leakage and/or overheating occurs, replace quill.
2. Inspect seal (9) for protrusion and other evidence of damage. Protruding and/or damaged seals are not acceptable.
3. Inspect tail rotor drive quill (7) in accordance with E-AB412-PT6T-3.
63-25-07
Page 4
E-AB412-PT6T-2
6. TAIL ROTOR DRIVE QUILL - REPAIR
1. Repair mechanical and corrosion damage in accordance with E-AB412-PT6T-3.
2. Replace seal (9, figure 1) in accordance with E-AB412-PT6T-3.
3. Lubricate coupling (10).
4. Replace over-temperature indicator (TEMP-PLATE) if required (E-AB412-PT6T-3).
63-25-07
Page 5
E-AB412-PT6T-2
63-25-07
Page 6
E-AB412-PT6T-2
63-25-08
TRANSMISSION QUILLS - ROTOR BRAKE QUILL
1. ROTOR BRAKE QUILL - DESCRIPTION
For helicopters so equipped, the rotor brake quill is installed on left side of transmission main case (figure 1).
2. ROTOR BRAKE QUILL - REMOVAL
NUMBER NOMENCLATURE
T27 JACKSCREW SET
1. Open transmission cowling to gain access to transmission.
2. Remove outboard brake assembly half (module 63-27-03 paragraph "2. Brake assembly - removal (P/N 9450103)").
3. If required, remove brake disc (module 63-27-04 paragraph "1. Disc - removal").
4. Using a sharp plastic scraper, cut sealant from between quill mounting flange and transmission case. Clean sealant
from jackscrew holes.
5. Remove bolts (5, figure 1), steel washers (4), and aluminum washers (3).
6. Use a heat lamp or 250 watt light bulb to heat sump mounting port until it is hot to the touch.
7. Install jackscrews (T17) and tighten carefully and evenly to remove rotor brake drive quill (2) with packing (1) from
transmission. Discard packing.
8. Cover mounting port in transmission to prevent entry of foreign material.
63-25-08
Rev. 3 Page 1
E-AB412-PT6T-2
1. Packing
2. Rotor brake quill
3. Aluminum washer
4. Steel washer
5. Bolt
6. Brake disk
7. Nut
8. Packing
9. Flange
T 1
160 TO 190 IN-LBS
(18.1 TO 21.47 Nm)
125 TO 150 FT-LBS
(169.5 TO 203.4 Nm)
T 1
T 2
NOTES:
1 The 412-040-123-101 quill assembly contains a look alike gear. Ensure pinion has six holes before installation in
412-040-002-ALL transmission and mast assembly (helicopters codes [A] [B] [C]).
2 The 412-040-123-103 quill assembly contains a look alike gear. Ensure pinion has four holes before installation in
412-040-004-ALL transmission and mast assembly (helicopters codes [D]).
G6AB0476C
Figure 1. Rotor brake quill
63-25-08
Page 2 Rev. 3
E-AB412-PT6T-2
3. ROTOR BRAKE QUILL - INSTALLATION
MATERIALS REQUIRED
NUMBER NOMENCLATURE
C-405 LOCKWIRE
1. Remove cover from mounting port in transmission.
2. Ensure mating surfaces of quill and transmission are free of all sealant and other foreign matter. Clean as required.
3. Lubricate new packing (1, figure 1) with transmission oil (Chapter 12). Install packing in groove on quill (2).
4. Apply a light coat of transmission oil to bore of transmission quill port and to mating diameter of quill assembly.
5. Using a heating lamp (or 250 watt light bulb) to heat sump mounting port until unit is hot to the touch.
CAUTION
ROTOR BRAKE QUILL ASSEMBLIES HAVE A LOOK ALIKE GEAR.

ENSURE SIX-HOLE PINION IS ONLY INSTALLED IN 412-040-002-ALL
TRANSMISSION AND MAST ASSEMBLY. ENSURE FOUR-HOLE PINION IS
ONLY INSTALLED IN 412-040-004-ALL TRANSMISSION AND MAST
ASSEMBLY (HELICOPTERS CODE [D]). INSTALLATION OF INCORRECT
QUILL ASSEMBLY WILL RESULT IN INTERNAL TRANSMISSION
DAMAGE.
NOTE
During installation of quill assembly, lightly tap quill inward uniformly around face
of quill flange near outer edge with a plastic mallet. Do not strike end of quill shaft.
6. Insert rotor brake quill (2) into transmission while rotating pinion simultaneously to permit gear meshing.
7. Install aluminium washers (3) against flange of quill, steel washers (4) under head of bolts (5) and install bolts. Torque
bolts 160 to 190 in-lbs (18.1 to 21.47 Nm).
9. Secure bolts (5) with lockwire (C-405).
10. Fill gap between flange on rotor brake quill (2) and flange on transmission sump with adhesive (C-308). Also fill
jackscrew holes with same sealant. Allow to cure.
11. Apply a light coat of transmission oil (Chapter 12) to splines in quill and mating splines on disc and flange assembly
(9).
12. Install disc and flange assembly (9) on quill.
13. Lubricate new packing (8) and install on nut (7).
14. Install nut (7) in center of disc and flange assembly. Tighten nut 169.5 to 203.4 Nm (125 to 150 ft-lbs). Secure nut with
lock wire (C-405).
63-25-08
Rev. 3 Page 3
E-AB412-PT6T-2
4. ROTOR BRAKE QUILL - CLEANING
MATERIALS REQUIRED
NUMBER NOMENCLATURE
1. Clean sealant residue from both quill and mating surface of transmission using a sharp plastic scraper and drycleaning
solvent (C-304).
5. ROTOR BRAKE QUILL - INSPECTION
1. Inspect quill for signs of leakage.
2. Inspect quill and pinion gear for obvious mechanical and corrosion damage (E-AB412-PT6T-3).
3. Rotate pinion and check for rough bearings. Bearing roughness which can be detected by feel is not acceptable.
6. ROTOR BRAKE QUILL - REPAIR
For complete repair procedures, refer to E-AB412-PT6T-3.
63-25-08
Page 4 Rev. 3
E-AB412-PT6T-2
63-25-09 TRANSMISSION QUILLS - UTILITY HYDRAULIC PUMP AND ROTOR BRAKE DRIVE QUILL [B] [C]
63-25-09
TRANSMISSION QUILLS - UTILITY HYDRAULIC PUMP AND ROTOR
BRAKE DRIVE QUILL [B] [C]
1. UTILITY HYDRAULIC PUMP AND ROTOR BRAKE DRIVE QUILL [B][C] -

DESCRIPTION
The utility hydraulic pump and rotor brake disc drive quill (figure 1) is installed on the left-hand side of the transmission.
the drive quill shaft drives the rotor brake disc directly and utility hydraulic pump through a gear train.
2. UTILITY HYDRAULIC PUMP AND ROTOR BRAKE DRIVE QUILL [B][C] - REMOVAL
MATERIALS REQUIRED.
NUMBER NOMENCLATURE
1. Remove left-hand air intake and transmission fairings to gain access to the drive quill.
2. Remove utility hydraulic pump according to the procedures given in Chapter 29.
3. Remove rotor brake disc and caliper according to the procedures given in Chapter 29.
4. Cut sealant around edge of quill with a sharp plastic scraper.
5. Remove hardware securing drive quill to transmission.
6. Draw quill out of transmission and remove from the helicopter.
NOTE
To facilitate drive quill removal, heat transmission case with a heat lamp. Do not use
open flame heater unit and avoid use of tools.
7. Remove remaining sealant from case by using a cloth soaked with MEK (C-309).
8. Cover transmission case opening.
63-25-09
Page 1
E-AB412-PT6T-2

INSTALLATION
MATERIALS REQUIRED.
NUMBER NOMENCLATURE
C-305 ALIPHATIC NAPHTA
C-308 SEALANT
C-405 LOCKWIRE
1. Remove cover from transmission case opening.
2. Check that mating surfaces of quill sleeve and case are clean.
3. Install a new packing (4, figure 1) in groove of quill (2).
4. Apply heat to mounting port in transmission main case. Insert quill into transmission.
NOTE
Exercise caution to avoid damage to gear teeth.
5. Secure drive quill to transmission with relative hardware and check backlash between gear teeth by lightly turning
drive quill gear back and forth. Presence of backlash indicates proper matching.
6. Apply sealant in gap around edge of quill where quill contacts transmission case as follows:
NOTE
Apply sealant prior to painting transmission.
a. Clean area where sealant is to be applied with naphta (C-305) and wipe dry with a clean cloth before solvent
evaporates.
b. Mix the two part sealant (C-308), in accordance with directions on container. The sealant must be used before
pot life time expires.
c. Run a small bead of sealant in area to be sealed off. Use an extrusion gun. If necessary smooth sealant before it
cures with a wooden tongue depressor wetted with MEK (C-309) or with finger wetted with water.
7. Install utility hydraulic pump according to the procedure given in Chapter 29.
8. Installation of rotor brake disc as follows:

Bring rotor brake disc in its position on the rotor brake quill. Tap rotor brake disc with rubber hammer until it abuts.
Install bolts and washers and torque 50 to 70 in-lbs (5.52 to 7.8 Nm). Secure with lockwire (C-405). Retorque after 50
flight hours.
9. Installation caliper as follows:

Install rotor brake assy with inboard mounts onto the rotor brake quill. Install bolts and washers and torque 80 to 100
in-lbs (9.04 to 11.30 Nm.). Secure with lockwire (C-405).
10. Install transmission and LH air intake fairings.
63-25-09
Page 2
E-AB412-PT6T-2
11. Check for leaks at next run-up.

INSPECTION
1. Inspect drive quill case for damage.
2. Inspect drive quill for wear and corrosion.
3. Check bearings for freedom of movement.
4. Check gear teeth for burrs, wear and abrasions.
5. For additional, detailed inspection criteria, refer to E-AB412-PT6T-3 Overhaul Manual.
5. UTILITY HYDRAULIC PUMP AND ROTOR BRAKE DRIVE QUILL [B][C] - REPAIR
For repair and overhaul instructions, refer to E-AB412-PT6T-3 Overhaul Manual.
63-25-09
Page 3
E-AB412-PT6T-2
G6AB0825A
Figure 1. Utility hydraulic pump and rotor brake disc drive quill [B] [C]
63-25-09
Page 4
E-AB412-PT6T-2
63-26-01
TRANSMISSION QUILL PORT COVERS
1. TRANSMISSION QUILL PORT COVERS - DESCRIPTION
NOTE
Removal and installation procedures for both left and right quill port covers are
identical. The following procedures detail removal and installation of rotor brake
quill port cover which is used when there is no rotor brake quill installed.
2. TRANSMISSION QUILL PORT COVERS - REMOVAL
NUMBER NOMENCLATURE
T17 SCREW SET
1. Remove bolts (4, figure 1), steel washers (3), and aluminum washers (2).
2. Cut sealant from around edge of cover (5) using a sharp plastic scraper. Clean sealant from jackscrew holes.
3. Clean sealant from tapped holes (6).
4. Install jackscrew set (T17) in three tapped holes (6).
5. Carefully and evenly, tighten all three jackscrews and remove cover (5).
3. TRANSMISSION QUILL PORT COVERS - INSTALLATION

MATERIALS REQUIRED
NUMBER NOMENCLATURE
1. Lubricate new packing (1, figure 1) with transmission oil (Chapter 12).
2. Install packing (1) on cover (5).
3. Place cover (5) over transmission quill port and install bolts (4) with steel washers (3) under bolt heads and aluminium
washers (2) next to cover (5). Torque bolts (4) 160 to 190 in-lbs (18.1 to 21.4 Nm).
4. Apply a bead of adhesive (C-308) around perimeter of cover (5) where it meets transmission case (7).
63-26-01
Rev. 2 Page 1
E-AB412-PT6T-2
SEE NOTE
1. Packing
2. Aluminum washer
3. Steel washer
4. Bolt
5. Cover [A] [D]
6. Tapped hole
7. Transmission case
NOTE:
For helicopters codes [B] [C] refer to module 63-25-09.
G6AB0475B
Figure 1. Quill port covers
63-26-01
Page 2 Rev. 2
E-AB412-PT6T-2
63-27-01
ROTOR BRAKE SYSTEM
1. ROTOR BRAKE SYSTEM - DESCRIPTION
The rotor brake system (figure 1) is composed of a master cylinder, located on the cabin roof console to the left of the pilot,
and a brake assembly. The brake assembly consists of a disc connected to a drive quill on the LH side of the transmission
and of a brake unit which, when the master cylinder is actuated by pulling the handle, rapidly stops the disc and consequently
the rotor.
CAUTION
DO NOT APPLY ROTOR BRAKE IF ROTOR EXCEED 4090 OF MAXIMUM

RPM.
NOTE
Refer to Chapter 98 for rotor brake wiring diagram.
2. ROTOR BRAKE SYSTEM - OPERATIONAL CHECK
1. Pull down on the actuator handle, moving handle toward vertical position (do not pass center for maximum braking
effort).
2. Verify that the ROTOR BRAKE indicator light on the master caution panel comes on.
3. To release brake, return handle to OFF (horizontal position).
4. Verify that the ROTOR BRAKE indicator light extinguishes.
3. ROTOR BRAKE SYSTEM - TROUBLESHOOTING
The table 1 lists probable causes, isolation procedures and remedies, and it’s intended to aid in rotor brake system
troubleshooting.
Table 1. Troubleshooting - rotor brake system
No braking action. Insufficient fluid in system. Fill and bleed system.
Foreign substance in fluid. Purge system.
Primary valve open. Replace master cylinder.
Relief valve open. Replace master cylinder.
Excessive brake lining wear. Replace lining.
63-27-01
Rev. 3 Page 1
E-AB412-PT6T-2
(Cont.d)
Spongy action of control. Air in system. Fill and bleed system.
Loss of braking action. Worn seal in master cylinder. Replace master cylinder.
Worn seal in brake assembly. Replace brake assembly.
Excessive brake lining wear. Replace lining.
Leaks at master cylinder. Worn or damaged seal in cylinder. Replace master cylinder seals.
Leaks at brake assembly. Worn or damaged seals in brake Replace brake assembly seals.
assembly.
Indicator light inoperative. Burned out bulbs. Replace bulbs.
Loose electrical connection. Tighten connections.
Broken or disconnected wire. Replace or connect wire.
Improper microswitch adjustment. Adjust microswitches.
Indicator light illuminates when mas- Faulty microswitch. Replace switch.

ter cylinder not applied.
Improper microswitch adjustment. Adjust microswitches.
Lining binding. Clean brake cylinder.
4. ROTOR BRAKE SYSTEM - INSPECTION
MATERIALS REQUIRED.
NUMBER NOMENCLATURE
Inspect rotor brake installation at the interval specified in the E-AB412-PT6T-6 Inspection Requirements Manual.
Perform special inspection of master cylinder as follows:
1. Gain access to rotor brake located on left side of transmission.
2. Flush rotor brake hydraulic system with hydraulic fluid (C-002) to eliminate water and/or other foreign matter.
3. Bleed minimum 0.500 liters (1 pint) of hydraulic oil through system. Refer to paragraph "5-1. Bleeding - brake
assembly P/N 9450103" or paragraph "5-2. Bleeding - brake assembly P/N 9450103-1".
4. Disconnect hose at rotor brake caliper. Connect 0 to 35.15 kg/cm2 (0 to 500 psi) pressure gage to hose.
Bleed hose at gage to expel air. Actuate master cylinder handle several times. System must be bled properly to obtain
accurate pressure readings.
63-27-01
Page 2 Rev. 3
E-AB412-PT6T-2
CAUTION
PARTIAL MASTER CYLINDER HANDLE ACTUATION IS RECOMMENDED

UNTIL MAXIMUM PRESSURE READING IS ESTABLISHED. IF PRESSURE
EXCEEDS 35.15 KG/CM2 (500 PSI) DAMAGE TO GAGE MAY RESULT.
MAXIMUM PRESSURE OCCURS JUST PRIOR TO HANDLE ENGAGING
FULL DOWN (PARK DETENT).
5. Reconnect hose to gage and carefully check pressure. Slowly (about 2 second cycle) actuate master cylinder handle
through complete operative arc and record maximum pressure.
NOTE
Pressure gage reading should not be lower than 14 kg/cm² (199 psi) or higher than
19 kg/cm² (270 psi).
6. If pressure gage reads lower than 14 kg/cm² (199 psi) or higher than 19 kg/cm² (270 psi), but does not exceed 28 kg/
cm² (398 psi), proceed to step 7. If pressure gage reading exceeds 28 kg/cm² (398 psi), proceed to step 8.
7. Remove master cylinder from helicopter. Refer to module 63-27-02 paragraph "1. Master cylinder - removal". Adjust
master cylinder poppet valve or replace with serviceable master cylinder previously pressure checked.
8. If pressure exceeds 28 kg/cm² (398 psi), inspect spiral bevel gear in transmission. Refer to E-AB412-PT6T-6, Section
IX for instructions.
NOTE
Pressure exceeding 28 kg/cm² (398 psi) due to improperly adjusted poppet valve
may cause contact damage to spiral bevel gear (204-040-701) by rotor brake pinion
(205-040-301).
9. Return damaged gears to AgustaWestland for evaluation.
10. Reassemble transmission with serviceable parts.
11. After proper pressure gage reading of 14 to 19 kg/cm² (199 to 270 psi) is retained, remove hose from gage. Reinstall
hose on rotor brake caliper.
12. Bleed system until air is expelled. Refer to Refer to paragraph "5-1. Bleeding - brake assembly P/N 9450103" or
paragraph "5-2. Bleeding - brake assembly P/N 9450103-1".
13. Reinstall components removed and return helicopter to service.
5. ROTOR BRAKE SYSTEM - BLEEDING
NOTE
Bleeding is invalid if hydraulic quick disconnect is removed.
63-27-01
Rev. 3 Page 3
E-AB412-PT6T-2
5-1. BLEEDING - BRAKE ASSEMBLY P/N 9450103
NUMBER NOMENCLATURE
COMMERCIAL RUBBER HOSE
NOTE
Drain a minimum of one-half pint (236,6 ml) of fluid from each valve before starting
bleeding operation.
1. Check master cylinder (4, figure 1) for proper fluid level (Chapter 12).
NOTE
Ensure rubber hose used in following step 2. is clean.
2. Place one end of a length of clean rubber hose on bleed valve (2) extension.
3. Route other end of hose to a suitable container in order to capture brake fluid discharged during bleeding operation.
4. Open one bleed valve (2).
NOTE
Do not allow handle to pass center into fully deployed position.
5. Slowly pull handle (3) down and hold before the fully deployed position.
6. Close bleed valve (2).
7. Service fluid in master cylinder (4) (Chapter 12).
8. Repeat step 2. through step 6. until discharged fluid is free of air.
5-2. BLEEDING - BRAKE ASSEMBLY P/N 9450103-1
MATERIALS REQUIRED
NUMBER NOMENCLATURE
NOTE
Drain a minimum of one-half pint (236,6 ml) of fluid from each valve before starting
bleeding operation.
1. Check master cylinder (4, figure 1) for proper fluid level (Chapter 12).
2. Place rags under bleed valves (2) to catch fluid during bleeding.
3. Slowly open one bleed valve.
63-27-01
Page 4 Rev. 3
E-AB412-PT6T-2
NOTE
Do not allow handle to pass center into fully deployed position.
4. Slowly pull handle (3) down and hold before the fully deployed position.
5. Close bleed valve (2).
6. Service fluid in master cylinder (4) (Chapter 12).
7. Return handle (3) to stowed position.
8. Repeat step 2. through step 7. until discharged fluid is free of air.
9. Repeat step 2. through step 8. for other bleed valve (2).
10. Clean area of any spilled fluid with dry-cleaning solvent (C-304).
63-27-01
Rev. 3 Page 5
E-AB412-PT6T-2
A
A
2
1. Rotor brake assembly

2. Bleed valve
3. Handle
3 4. Master cylinder
G6AB1062A
Figure 1. Rotor brake system
63-27-01
Page 6 Rev. 3
E-AB412-PT6T-2
63-27-02
ROTOR BRAKE SYSTEM - MASTER CYLINDER
1. MASTER CYLINDER - REMOVAL
MATERIALS REQUIRED
NUMBER NOMENCLATURE
C-304 DRYCLENANING SOLVENT
CAUTION
CLEANING HYDRAULIC COMPONENTS SHALL BE ACCOMPLISHED

1. Open transmission fairing (Chapter 52).
2. On cabin roof, remove sealing compound from around top of master cylinder reservoir (3, figure 1).
3. Gain access to master cylinder (3) located inside cabin above pilot seat.
CAUTION
USE SUITABLE PRECAUTIONS TO PROTECT PILOT SEAT AND CABIN

INTERIOR FROM HYDRAULIC FLUID WHEN LOOSENING HYDRAULIC
LINE.
NOTE
Drain hydraulic fluid into suitable container.
4. Loosen hydraulic line (2) from end of master cylinder (3) and allow fluid to drain into suitable container.
5. Disconnect hydraulic line (2) from master cylinder (3).
6. Plug openings to prevent entry of foreign materials.
7. Remove bolts (5), nuts (6) and washers (4) attaching master cylinders (3) to roof structure.
8. Remove master cylinder (3).
63-27-02
Rev. 3 Page 1
E-AB412-PT6T-2
2. MASTER CYLINDER - INSTALLATION
MATERIALS REQUIRED.
NUMBER NOMENCLATURE
C-308 SEALANT
1. Place master cylinder (3, figure 1) to the right of overhead console inside cabin and attach to roof structure with four
bolts (5), four nuts (6) and eight washers (4).
2. Apply bead of sealant (C-308) to top of cabin roof surface around master cylinder (3) fill port.
3. Attach hydraulic line (2) to forward end of master cylinder (3).
4. Bleed rotor brake system in accordance with module 63-27-01 paragraph "5. Rotor brake system - bleeding".
3. MASTER CYLINDER - INSPECTION
NOTE
For checking and inspection of master cylinder refer to E-AB412-PT6T-3 Overhaul
Manual.
4. MASTER CYLINDER - REPAIR AND REPLACEMENT
NOTE
Replace or repair master cylinder if leaking or otherwise unserviceable. Refer to
E-AB412-PT6T-3 Overhaul Manual.
63-27-02
Page 2 Rev. 3
E-AB412-PT6T-2
A 2 A
4
5 6
3

2. Hydraulic line
3. Master cylinder
4. Washer
5. Bolt
6. Nut
G6AB1063A
Figure 1. Rotor brake system - master cylinder arrangement
63-27-02
Rev. 3 Page 3
E-AB412-PT6T-2
63-27-02
Page 4 Rev. 3
E-AB412-PT6T-2
63-27-03
ROTOR BRAKE SYSTEM - BRAKE ASSEMBLY
1. BRAKE ASSEMBLY - DESCRIPTION
NOTE
Maintenance practices are the same for brake assembly P/N 9450103 and
9450103-1, unless otherwise noted.
2. BRAKE ASSEMBLY - REMOVAL (P/N 9450103)
1. Remove microswitches (4, figure 1) from rotor brake assembly (1).
2. Disconnect hydraulic line (2) from rotor brake assembly (1).
3. Remove bolts (12, figure 2), washers (13) and outboard brake assembly half (11).
4. Remove brake assembly spacer (23) from oil transfer tube (14) in inboard brake assembly half (5).
5. Remove brake oil transfer tube (14) from inboard brake assembly half (5).
6. Remove and discard packings (22) from counterbored cavities in mating surfaces of inboard brake assembly (5) and
outboard brake assembly (11).
7. Remove rotor brake disc (module 63-27-04 paragraph "1. Disc - removal")
8. Cut lockwire (4), remove bolts (2), washers (3), and inboard brake assembly half (5) from quill assembly (1).
3. BRAKE ASSEMBLY - REMOVAL (P/N 9450103-1)
1. Disconnect hydraulic line (2, figure 1) from rotor brake assembly (1).
NOTE
Access to bolts (2, figure 2) can be achieved by turning rotor brake disc until holes in
disc align with bolts.
2. Remove lockwire (4), bolts (2), and washers (3).
CAUTION
USE CARE SO AS NOT TO DAMAGE MICROSWITCH WIRING WHEN

REMOVING BRAKE ASSEMBLY.
3. Remove rotor brake assembly (1, figure 1) as a unit.
4. Remove lockwire (11), screws (9), and washers (10).
63-27-03
Rev. 3 Page 1
E-AB412-PT6T-2
5. Remove microswitches (8).
6. Remove bolts (12, figure 2), washers (13), and outboard brake assembly half (11).
7. Remove brake assembly spacer (23) from oil transfer tube (14) in inboard brake assembly half (5).
8. Remove brake oil transfer tube (14) from inboard brake assembly half (5).
9. Remove and discard packings (22) from counterbored cavities in mating surfaces of inboard brake assembly half (5)
and outboard brake assembly half (11).
10. Remove rotor brake disc (module 63-27-04 paragraph "1. Disc - removal").
4. BRAKE ASSEMBLY - INSTALLATION (P/N 9450103)
MATERIALS REQUIRED
NUMBER NOMENCLATURE
C-405 LOCKWIRE
NOTE
Ensure that microswitch is adjusted so that ROTOR BRAKE light illuminates when
brake piston has moved 0.030 in (0.762 mm) from the original position.
1. Install microswitch (8, figure 1) on inboard brake assembly half (5, figure 2) using screws (9, figure 1) and washers
(10).
2. Secure with lockwire (11) (C-405).
3. Install inboard brake assembly half (5, figure 2) on rotor brake quill assembly (1) using bolts (2) and washers (3).
4. Torque bolts (2) to 80 to 100 in-lbs (9.04 to 11.30 Nm) and secure with lockwire (4) (C-405).
5. Install rotor brake disc (7) (module 63-27-04 paragraph "2. Disc - installation").
6. Install packings (22) in counterbored cavities in mating surfaces of inboard brake assembly half (5) and outboard brake
assembly half (11).
7. Insert brake oil transfer tube (14) through packing (22) in inboard brake assembly half (5) until it bottoms out in hole
in inboard brake assembly half (5).
NOTE
8. Install microswitch (8, figure 1) on outboard brake assembly half (11, figure 2) using screws (9, figure 1) and washers
(10).
10. Place brake assembly spacer (23, figure 2) over protruding oil transfer tube (14) in inboard brake assembly half (5).
63-27-03
Page 2 Rev. 3
E-AB412-PT6T-2
11. Ensure holes for bolts (12) in brake assembly spacer (23) align with corresponding holes in inboard brake assembly
half (5).
12. Install outboard brake assembly half (11) on inboard brake assembly half (5) using bolts (12) and washers (13).
13. Torque bolts (12) to 120 to 130 in-lbs (13,56 to 14,69 Nm) and secure with lockwire (C-405).
14. Install hydraulic hose (2, figure 1) on rotor brake assembly (1).
15. Bleed system module 63-27-01 paragraph "5-1. Bleeding - brake assembly P/N 9450103".
16. Check for proper system operation including illumination of ROTOR BRAKE light.
5. BRAKE ASSEMBLY - INSTALLATION (P/N 9450103-1)
MATERIALS REQUIRED
NUMBER NOMENCLATURE
C-405 LOCKWIRE
NOTE
1. Install microswitch (8, figure 1) on inboard brake assembly half (5, figure 2) using screws (9, figure 1) and washers
(10).
3. Install inboard brake assembly half (5, figure 2) on rotor brake quill assembly (1) using bolts (2) and washers (3).
4. Torque bolts (2) to 80 to 100 in-lbs (9.04 to 11.30 Nm) and secure with lockwire (4) (C-405).
5. Install rotor brake disc (7) (module 63-27-04 paragraph "2. Disc - installation").
6. Install packings (22) in counterbored cavities in mating surfaces of inboard brake assembly half (5) and outboard brake
assembly half (11).
7. Insert brake oil transfer tube (14) through packing (22) in inboard brake assembly half (5) until it bottoms out in hole
in inboard brake assembly half (5).
NOTE
8. Install microswitch (8, figure 1) on outboards brake assembly half (11, figure 2) using screws (9, figure 1) and washers
(10).
10. Place brake assembly spacer (23, figure 2) over protruding oil transfer tube (14) in inboard brake assembly half (5).
63-27-03
Rev. 3 Page 3
E-AB412-PT6T-2
11. Ensure holes for bolts (12) in brake assembly spacer (23) align with corresponding holes in inboard brake assembly
half (5).
12. Install outboard brake assembly half (11) on inboard brake assembly half (5) using bolts (12) and washers (13).
13. Torque bolts (12) to 120 to 130 in-lbs (13,56 to 14,69 Nm) and secure with lockwire (C-405).
14. Install hydraulic hose (2, figure 1) on rotor brake assembly (1).
15. Bleed system module 63-27-01 paragraph "5-2. Bleeding - brake assembly P/N 9450103-1".
16. Check for proper system operation including illumination of ROTOR BRAKE light.
6. BRAKE ASSEMBLY - BRAKE LINING INSTALLATION
MATERIALS REQUIRED
NUMBER NOMENCLATURE
C-007 GREASE
C-405 LOCKWIRE
1. Remove brake assembly from transmission.
2. Cut lockwire and remove the two bolts (12, figure 2) with washers (13) and separate the inboard brake assembly half
(5) from outboard brake assembly half (11).
3. Relieve tension on cotter pin (17) and remove pin, each housing. Remove piston (21) and brake linings (16) from each
housing.
4. Remove brake linings (14) and piston seals (25) from each piston. Remove packings (20) from inboard brake assembly
half (5) and outboard brake assembly half (11).
NOTE
Linings are secured to piston by snap type button.
5. Lubricate half assembly cylinder walls, and seal grooves with a light coat of grease (C-007).
6. Install new packing (20) in each half.
7. Lubricate contacting surfaces of each piston seal groove with a light coat of grease, (C-007), and install new seal (25)
on piston (21).
8. Lubricate snap button fasteners on brake linings with a light coat of grease, (C-007), and snap brake lining (16) onto
piston.
9. Insert piston (21) onto inboard brake assembly half (5) and outboard brake assembly half (11).
10. Install brake return spring (18), spring retaining washer (26) and install cotter pin (17) on each assembly.
11. Install packings (22) and oil transfer tube (14) in outboard brake assembly half (11).
12. Put the inboard brake assembly half (5) in position on outboard brake assembly half (11) and install washers (13) and
bolts (12). Torque bolts to 120 to 130 in-lbs (13.56 to 14.69 Nm) and secure with lockwire (C-405).
63-27-03
Page 4 Rev. 3
E-AB412-PT6T-2
13. Install brake assembly on transmission.
14. Bleed rotor brake system. Refer to module 63-27-01 paragraph "5. Rotor brake system - bleeding".
15. Close transmission cowling.
7. BRAKE ASSEMBLY - INSPECTION
1. Replace brake lining (16, figure 2) when worn within 0.150 in (3.81 mm) or less of piston (21) or when overall
thickness of brake lining (16) measures 0.289 in (7.34 mm) or less.
2. Inspect brake assembly in accordance with figure 3.
3. Inspect bolts (12) for cleanliness, damage, and cracks.
4. Inspect piston return pin (19) for condition and nicks and burrs at cotter pin hole, which might damage return pin
packing (20) on installation.
5. Inspect return spring (18) for rust and condition.
6. Inspect microswitches (8, figure 1) for loose or cracked potting compound at electrical leads.
8. BRAKE ASSEMBLY - REPAIR
MATERIALS REQUIRED
NUMBER NOMENCLATURE
COMMERCIAL 400 GRIT ALUMINUM OXIDE CLOTH
COMMERCIAL CHROMIC ACID SOLUTION MIL-C-5541
NOTE
Repair of the brake is limited to the replacement of damaged parts and to the specific
repairs listed in this section and figure 3, detail A.
1. Clean nicks on pistons (21, figure 2), piston cavity (24), and throat with 400 grit aluminum oxide cloth.
2. Replace any damaged fasteners.
3. Bend out nicks and burrs on shaft of piston return pin (19). Pay particular attention to the area around the cotter pin
hole.
WARNING
CHROMIC ACID SOLUTIONS ARE CORROSIVE AND POISONOUS.

PROTECT THE EYES AND HANDS. DO NOT BREATHE IN THE FUMES.
OBEY MANUFACTURER’S INSTRUCTIONS.
4. Treat reworked surfaces of piston (21) and exterior surfaces of brake assembly halves (5 and 11) with chromic acid
solution MIL-C-5541.
63-27-03
Rev. 3 Page 5
E-AB412-PT6T-2
9. BRAKE ASSEMBLY - MICROSWITCH ACTUATOR ADJUSTMENT
NOTE
Each microswitch controls one warning light. If one light illuminates at the 0.030 in
(0.762 mm) travel position, only one of the switches is misadjusted.
1. Put the microswitches (4 and 8, figure 1) and actuators (12) in their approximate locations so that, with brake off and
MASTER CAUTION circuit breaker on, the caution lights are off.
2. Note the position of the microswitch actuator and brake assembly piston with respect to a nearby fixed point in the line
of brake assembly piston travel.
3. Carefully apply pressure by pulling downward on the master cylinder handle until the brake assembly pistons move
0.030 in (0.762 mm) from their location noted in step 2.
4. If the actuators are properly adjusted, the caution lights should be on when brake assembly pistons have moved 0.030
in (0.762 mm).
5. Loosen switch mounting screw and jam nut on adjusting screw, and adjust switches as necessary so that both lights
illuminate when both pistons have moved 0.030 in (0.762 mm) from the brake off position. Tighten screw and jam nut
after adjustment.
63-27-03
Page 6 Rev. 3
E-AB412-PT6T-2
2
SEE DETAIL A AND B
1
4
3
4
1
12
7
4
DETAIL A
BRAKE ASSEMBLY
3 9450103
G6AB1064A
Figure 1. Rotor brake system (sheet 1 of 2)
63-27-03
Rev. 3 Page 7
E-AB412-PT6T-2
DETAIL B
BRAKE ASSEMBLY (9450103-1)

2. Hydraulic line
3. Bleed valve
4. Microswitch
5. Handle
6. Master cylinder
7. Microswitch electrical harness
8. Microswitch
9. Screws
10. Washers
11. Lockwire
12. Actuator
NOTES:
1 Loosen screw while making adjustment.
2 Loosen jam nut, turn screw to adjust switch, tighten jam nut.
3 Do not mix brake assembly 9450103-1 and 9450103 in any installation.
G6AB1065A
Figure 1. Rotor brake system (sheet 2 of 2)
63-27-03
Page 8 Rev. 3
E-AB412-PT6T-2
G6AB01029A
Figure 2. Rotor brake assembly (sheet 1 of 3)
63-27-03
Rev. 3 Page 9
E-AB412-PT6T-2
15
14
8
9
7 10
VIEW B-B
1. Quill assembly 14. Oil transfer tube

2. Bolt 15. Lockwire
3. Washer 16. Brake lining
4. Lockwire 17. Cotter pin
5. Inboard brake assembly half 18. Return spring
6. Flanged adapter 19. Piston return pin
7. Brake disc 20. Packing
8. Bolt 21. Piston
9. Washer 22. Packing
10. Retaining nut 23. Spacer
11. Outboard brake assembly half 24. Piston cavity
12. Bolt 25. Piston seal
13. Washer 26. Spring retaining washer
G6AB1030B
63-27-03
Page 10 Rev. 3
E-AB412-PT6T-2
26
5
25
11
G6AB1031B
63-27-03
Rev. 3 Page 11
E-AB412-PT6T-2
G6AB1066A
Figure 3. Rotor brake assembly - damage limits (sheet 1 of 2)
63-27-03
Page 12 Rev. 3
E-AB412-PT6T-2
INSPECTION
No. REF LTR CHARACTERISTIC LIMIT
METHOD
1. C Wear Measure 0.015 in (0.38 mm) deep
1.0 in (25.4 mm) long 2
maximum two places.
2. D Mechanical/corrosion damage Visual/measure 0.002 in (0.051 mm) deep in piston
cavity area, provided sealing qualities are 2
maintained. Surface finish should be 15/30
microinches RHR.
3. E Wear Visual/measure 0.015 in (0.38 mm) maximum oversize on hole
diameter. Round off sharp edges (for P/N 9421067
and 9431108).
4. F Thread Visual Remove housing from service if threads are stripped
or badly damaged.
5. G Wear Measure 0.030 in (0.762 mm) deep, maximum on piston boss
face.
6. H Wear Measure 0.030 in (0.762 mm) deep, maximum on mounting
flange face. 2
0.010 in (0.25 mm) deep, maximum on flange face
area covered by mounting bolt washers (for P/N
9421067 and 9431108).
7. J Wear Measure 0.010 in (0.25 mm) deep, maximum on return spring
boss face and housing interface surface. 2
8. K Wear Measure 0.030 in (0.762 mm) deep, maximum on housing

exterior.
9. L Wear Visual/measure 0.030 in (0.762 mm) deep, maximum on housing
mounting flange; blend on both surfaces is permitted
as long as they are not directly opposite each other
(for P/N 9421067 and 9431108).
NOTES:
1. Inboard brake assembly half shown, outboard identical.
2 Since removal of material in areas C, D, H, and J can shorten the life of the part, it is recommended that if removal of metal in
these areas is necessary, it be kept to a minimum.
3. Scratches and/or pits in the areas designated, may be blended or polished out within the dimensional limits shown.
Figure 3. Rotor brake assembly - damage limits (sheet 2 of 2)
63-27-03
Rev. 3 Page 13
E-AB412-PT6T-2
63-27-03
Page 14 Rev. 3
E-AB412-PT6T-2
63-27-04
ROTOR BRAKE SYSTEM - DISC
1. DISC - REMOVAL
NUMBER NOMENCLATURE
T27 JACKSCREW SET
T121 BRAKE DISC HOLDING TOOL
1. Open left side engine and transmission cowling to gain access to transmission.
2. Remove outboard brake assembly half (7, figure 1) (module 63-27-03 paragraph "2. Brake assembly - removal (P/N
9450103)" or paragraph "3. Brake assembly - removal (P/N 9450103-1)".
3. Cut the lockwire and remove the retaining nut (6) using the brake disc holding tool (T121) (8) to restrain brake disc (3).
CAUTION
ROTOR BRAKE DISC AND FLANGE ASSEMBLY SHALL BE REMOVED AS

AN ASSEMBLY. DO NOT ATTEMPT TO REMOVE DISC FROM FLANGE
ADAPTER WHILE ASSEMBLY IS INSTALLED ON QUILL. DO NOT
SEPARATE DISC FROM FLANGE IF DISC IS NOT BEING REPLACED.
5. Remove disc and flange adapter from quill assembly (1).
6. Remove rotor brake disc (3) from flange adapter (2) (module 63-27-05 paragraph "1. Flange adapter - removal").
2. DISC - INSTALLATION
NUMBER NOMENCLATURE
MATERIALS REQUIRED
NUMBER NOMENCLATURE
C-405 LOCKWIRE
63-27-04
Rev. 3 Page 1
E-AB412-PT6T-2
1. If not previously accomplished, install brake disc (3, figure 1) on flange adapter (2) (module 63-27-05 paragraph "2.
Flange adapter - installation").
2. Apply a light coat of transmission oil (Chapter 12) to splines in rotor brake quill assembly (1) and mating splines on
flange adapter (2).
3. Install brake disc (3) and flange adapter (2) and install assembly on rotor brake quill assembly (1).
4. Lubricate a new packing (9) and install on the retaining nut (6).
5. Install the retaining nut (6) in center of brake disc (3) and flange adapter (2). Using the brake disc holding tool (T121)
(8) to hold disc, tighten the retaining nut to 125 to 150 ft-lbs (169.5 to 203.4 Nm) and secure the retaining nut with
lockwire (C-405).
NOTE
Do a torque check to make sure a torque of 50 to 70 in-lbs (5.65 to 7.91 Nm) has
been applied to the bolts (6).
6. Secure the bolts (4, figure 1) to retaining nut (6) with lockwire (C-405).
7. Install outboard brake assembly half (7) (module 63-27-03 paragraph "4. Brake assembly - installation (P/N 9450103)"
or paragraph "5. Brake assembly - installation (P/N 9450103-1)".
3. DISC - INSPECTION
NUMBER NOMENCLATURE
AN4-5A BOLT
AN960-416 WASHER
COMMERCIAL DIAL INDICATOR
COMMERCIAL LATHE
NOTE
If rotor brake disc has been removed using an arbor press (or equivalent), or warpage
is suspected, the following disc inspection is required.
1. Install inspection arbor (figure 2) in pilot hole of disc. Install four bolts (AN4-5A) and washers (AN960-416).
a. Install arbor and disc assembly between lathe centers.
b. While rotating disc, measure run out as indicator probe is swept across full radial width of each friction surface
(front and back).
c. Total indicator deflection shall not exceed 0.010 in (0.254 mm).
63-27-04
Page 2 Rev. 3
E-AB412-PT6T-2
2
3
6 4 5
7 B
G6AB1067A
Figure 1. Rotor brake assembly - brake disc (sheet 1 of 2)
63-27-04
Rev. 3 Page 3
E-AB412-PT6T-2
8
2 3
VIEW B
6
2
50 TO 70 IN-LBS
(5.65 TO 7.91 Nm)
125 TO 150 IN-LBS
(169.5 TO 203.4 Nm)
1. Quill assembly
2. Flange adapter
3. Brake disc
4. Bolt
5. Washer
6. Retaining nut
7. Outboard brake assembly half
8. Brake disc holding tool (T121)
9. Packing
G6AB1034B
Figure 1. Rotor brake assembly - brake disc (sheet 2 of 2)
63-27-04
Page 4 Rev. 3
E-AB412-PT6T-2
NOTES:
1. Material: AISI 4340 steel per MIL-S-5000. Heat treat to RC 36-40 in accordance with MIL-H-6875.
2. Surface finish 125 micro-in unless otherwise noted.
3. Break edges 0.015 in (0.381 mm) radius or 0.015 in (0.381 mm ) x 40 to 50° chamfer unless otherwise noted.
G6AB01033A
Figure 2. Rotor brake disc inspection arbor
63-27-04
Rev. 3 Page 5
E-AB412-PT6T-2
63-27-04
Page 6 Rev. 3
E-AB412-PT6T-2
63-27-05
ROTOR BRAKE SYSTEM - FLANGE ADAPTER
1. FLANGE ADAPTER - REMOVAL
NUMBER NOMENCLATURE
1. Cut lockwire. Using brake disc holding tool (T121) (3, figure 1), restrain disc (2) and remove bolts (6) and washers (7).
2. Using hand pressure only, separate flange adapter (1) from brake disc (2).
3. If brake disc (2) and flange adapter (1) cannot be separated by hand pressure, proceed as follows:
NOTE
The use of an arbor press, or equivalent to separate flange adapter (1) from brake
disc (2) requires brake disc to be inspected for warpage (module 63-27-04 paragraph
"3. Disc - inspection").
a. To prevent inadvertent separation of the assembly, reinstall bolts (6) and washers (7).
b. Place assembly in an arbor press. Remove bolts (6) and washers (7).
c. Apply sufficient pressure to separate flange adapter (1) from brake disc (2).
2. FLANGE ADAPTER - INSTALLATION
MATERIALS REQUIRED
NUMBER NOMENCLATURE
C-405 LOCKWIRE
1. Install brake disc (2, figure 1) on flange adapter (1) using bolts (6) and washers (7).
2. Torque bolts (6) to 50 to 70 in-lbs (5.65 to 7.91 Nm) and secure with lockwire (C-405).
63-27-05
Rev. 3 Page 1
E-AB412-PT6T-2
3
1 2
VIEW B
LOCKWIRE (C-405)
50 TO 70 IN-LBS
(5.65 TO 7.91 Nm)
1. Flange adapter
2. Brake disc
3. Brake disc holding tool (T121)
4. Packing
5. Nut
6. Bolt
7. Washer
G6AB1032B
Figure 1. Rotor brake disc - flange adapter
63-27-05
Page 2 Rev. 3
E-AB412-PT6T-2
63-31-01
TRANSMISSION MOUNTS - AFT ISOLATION MOUNT AND FRICTION
DAMPERS
1. AFT ISOLATION MOUNT AND FRICTION DAMPERS - DESCRIPTION
The transmission mounts consists of forward and aft isolation mounts, aft friction dampers, and a lift link.
NOTE
Maintenance procedures for left and right mounts are identical.
2. AFT ISOLATION MOUNT AND FRICTION DAMPERS - REMOVAL
1. Remove transmission and mast assembly (module 63-22-01 paragraph "2. Transmission - removal").
2. Remove bolts (15, figure 1) and thin steel washers (14).
3. Disengage boot (5) from isolation mount support (1). Remove mount and filler plate (2).
4. Remove nut (10) and bolt (8). Remove friction damper (9), bolt (13), bushing (6), and boot (5) as a unit.
3. AFT ISOLATION MOUNT AND FRICTION DAMPERS - INSTALLATION
1. Place bolt (13, figure 1) on friction damper (9), and install bolt (7), thin steel washer (11), and nut (12).
2. Place bushing (6) and boot (5) on bolt (13).
3. Place friction damper (9) and bolt (13) in pylon support (3) from inside pylon. Fit bottom of friction damper (9) on
damper fitting (4). Install bolt (8) and nut (10).
4. Place filler plate (2) on isolation mount support (1). Place isolation mount support (1) on bolt (13) and ensure bushing
(6), and boot (5) are installed on bolt (13).
CAUTION
BOLTS (15) ARE DIFFERENT LENGTHS. THE TWO LONGER BOLTS SHALL
BE INSTALLED IN FORWARD OUTBOARD AND AFT INBOARD HOLES.
THE TWO SHORTER BOLTS SHALL BE INSTALLED IN REMAINING
HOLES.
5. Install bolts (15) and washers (14). Ensure bolts (15) are correct grip length. Torque the bolts 100 to 140 in-pounds
(11.30 to 15.82 Nm).
6. Install boot (5) on isolation mount support (1).
7. Install transmission and mast assembly (module 63-22-01 paragraph "3. Transmission - installation").
63-31-01
Rev. 2 Page 1
E-AB412-PT6T-2
T 1
100 TO 140 IN-LBS

T (11.30 TO 15.82 Nm)
1. Isolation mount support

2. Filler plate
3. Pylon support
4. Damper fitting
5. Boot
6. Bushing
7. Bolt
8. Bolt
9. Friction damper
10. Nut
12. Nut
13. Bolt
15. Bolt
NOTE:
1 Install longer bolts in forward outboard and aft inboard mounting holes.
Install shorter bolts in remaining holes.
G6AB0502B
Figure 1. Transmission aft isolation mounts and friction dampers
63-31-01
Page 2 Rev. 2
E-AB412-PT6T-2
4. AFT ISOLATION MOUNT AND FRICTION DAMPERS - INSPECTION

(TRANSMISSION MOUNT)
NOTE
Inspection procedures for all four mounts are the same.
1. Perform spring rate check as follows:
a. Fabricate a steel support sleeve and pressing button (figure 2). Top and bottom of sleeve must be square in
relation to sides so mount will be deflected in vertical plane only.
b. Place mount, long end down, in support sleeve.
c. Place support and mount in a suitable press. Press indicator should be marked in 5 lb increments and should have
a range of 0 to 5000 lbs (or equivalent).
d. Center steel pressing button over inner sleeve of mount.
e. Apply pressure to button and mount with press ram so as to deflect mount in a vertical plane to 0.4 in (10.16 mm)
at approximately one cycle per minute. Repeat cycle three times.
f. Mount a dial indicator to press with the finger of indicator touching pressing button.
g. Apply slight pressure to button with ram to ensure button is seated.
h. Apply enough pressure to button to deflect mount 0.1 in (2.54 mm) and record load. Apply enough pressure to
pressing button to deflect mount 0.3 in (7.62 mm) and record load. Subtract load noted at 0.1 in (2.54 mm) from
the load at 0.3 in (7.62 mm). If the value is less than 1320 lbs (5872 N) for -105 mount or 1610 (7162 N) for
-107 mount, replace mount.
2. Inspect elastomer for cracks, tears, or debonded areas. Replace if a 0.005 in (0.127 mm) feeler gauge can be inserted
more than 0.25 in (6.35 mm). Normal elastomer fretting (eraser type dust) is not cause for replacement.
3. Inspect bolts and bushings for cracks, corrosion, scoring, wear, and scratches. Replace damaged parts. Replace
damaged boots.
4. Replace isolation mounts when excessive vibration is believed to be caused by defective mounts or when there is other
evidence of malfunction.
5. AFT ISOLATION MOUNT AND FRICTION DAMPERS - INSPECTION (AFT MOUNT

FRICTION DAMPERS)
1. Inspect friction damper (9, figure 1) for oil and grease contamination. If oil and grease contamination is present,
disassemble and inspect damper (E-AB412-PT6T-3).
2. Inspect bearing and damper fittings on dampers for maximum radial play of 0.004 in (0.101 mm) and no axial
movement.
3. Inspect dampers for binding, rough movement, or actual lack of movement by stationing personnel around pylon
mounting point. Move pylon fore and aft using the mast as a lever to rock pylon. If any of the above conditions are
noted replace damper(s).
63-31-01
Rev. 2 Page 3
E-AB412-PT6T-2
G6AB0503A
Figure 2. Isolation mount inspection work aid - tool application
63-31-01
Page 4 Rev. 2
E-AB412-PT6T-2
63-31-02
TRANSMISSION MOUNTS - FORWARD ISOLATION MOUNTS
1. FORWARD ISOLATION MOUNTS - REMOVAL
1. Remove transmission and mast assembly (module 63-22-01 paragraph "2. Transmission - removal").
3. Disengage boot (6) from isolation mount assembly (3). Remove boot (6) and bushing (7).
4. Remove bolts (1) and thin steel washer (2). Remove isolation mount assembly (3) and filler plate (4).
2. FORWARD ISOLATION MOUNTS - INSTALLATION
1. Place isolation mount assembly (3, figure 1) and filler plate (4) on pylon support (5).
2. Place bushing (7) and boot (6) on bolt (8). Install bolt assembly in isolation mount assembly (3) from the bottom. Fit
boot (6) to bushing (7) and isolation mount assembly (3).
3. Tie bolt (8) in position until transmission installation is completed.
CAUTION
BOLTS (1) ARE DIFFERENT LENGTHS. LONGER BOLTS SHALL BE

INSTALLED IN FORWARD MOUNTING HOLES AND SHORTER BOLTS
SHALL BE INSTALLED IN AFT MOUNTING HOLES.
4. Install bolts (1) and thin steel washers (2). Ensure bolts are correct grip length. Torque the bolts 100 to 140 in-pounds
(11.30 to 15.82 Nm).
5. Install transmission and mast assembly (module 63-21-01 paragraph "3. Main rotor mast - installation").
3. FORWARD ISOLATION MOUNTS - INSPECTION
Refer to module 63-31-01 paragraph "5. Aft isolation mount and friction dampers - inspection (aft mount friction dampers)"
for inspection procedures.
63-31-02
Rev. 2 Page 1
E-AB412-PT6T-2
T 1
100 TO 140 IN-LBS

T (11.30 TO 15.82 Nm)
1. Bolt (see note)

3. Isolation mount assembly
4. Filler plate
5. Pylon support
6. Boot
7. Bushing
8. Bolt
NOTE:
1 Install longer bolts in forward outboard and aft inboard mounting holes.
Install shorter bolts in remaining holes.
G6AB0504B
Figure 1. Forward isolation mount
63-31-02
Page 2 Rev. 2
E-AB412-PT6T-2
63-31-03
TRANSMISSION MOUNTS - LIFT LINK
1. LIFT LINK - REMOVAL
NUMBER NOMENCLATURE
T38 HOIST
T58 MAST NUT
T59 CLEVIS
1. Open transmission cowling. Remove right or left access doors on pylon support in cabin.
2. Erect hoist (T38 or equivalent) to steady transmission while link is removed.
WARNING
MAST NUT (CAP ASSEMBLY RETENTION NUT) (412-010-160-103) SHALL

NOT BE USED TO LIFT HELICOPTER OR HELICOPTER COMPONENTS
EXCEPT WHEN MAIN ROTOR HUB IS INSTALLED. IF MAIN ROTOR HUB
IS NOT INSTALLED, USE MAST NUT (T58) ON MAST.
3. Install clevis (T59) on mast nut. Attach hoist to clevis. Raise transmission sufficiently to remove bolt (12, figure 1) by
hand.
4. Remove cotter pin (8), nut (9), washer (10), and remove bolt (12) from lift beam (11).
5. Remove cotter pin (2), nut (3), steel washer (4), bolt (special) (6), washer (special) (5), and remove link assembly (7).
2. LIFT LINK - INSTALLATION
1. Install hoist and clevis (paragraph "1. Lift link - removal").
2. Position washer (special) (5, figure 1) and link assembly (7) on transmission lift link fitting (1).
3. Install bolt (special) (6), washers (4), and nut (3).
4. Torque nut (3) 60 to 80 ft.-lbs. (81 to 108 Nm). Install cotter pin (2).
5. Raise transmission sufficiently to allow insertion of bolt (special) (12) by hand pressure only.
NOTE
Large diameter of lift beam (11) fitting for bolt (12) shall be forward.
63-31-03
Page 1
E-AB412-PT6T-2
6. Position link (7) on beam fitting (11).
7. Install bolt (special) (12), thin steel washer (10), and nut (9). Torque nut (9) 108 to 125 ft.-lbs. (146,8 to 170 Nm).
8. Install cotter pin (8).
9. Remove hoist and clevis.
10. Close cowling and install access doors as required.
3. LIFT LINK - CLEANING
MATERIALS REQUIRED
NUMBER NOMENCLATURE
CAUTION
DO NOT IMMERSE BEARING END OF LINK IN SOLVENT.
1. Wipe link clean with a clean cloth damp with drycleaning solvent (C-304).
2. Dry with a clean, dry cloth or filtered, compressed air.
4. LIFT LINK - INSPECTION AND REPAIR
Refer to E-AB412-PT6T-3 for inspection criteria and repair limits and procedures.
63-31-03
Page 2
E-AB412-PT6T-2
(212-040-125-101)
(212-040-117-103) (212-030-155-1)
G6AB0505A
Figure 1. Transmission lift link
63-31-03
Page 3
E-AB412-PT6T-2
63-31-03
Page 4
E-AB412-PT6T-2
63-31-04
TRANSMISSION MOUNTS - LIFT LINK FITTING
1. LIFT LINK FITTING - DESCRIPTION
NOTE
S.B. adds a washer (2, figure 1) between lift link fitting (6) and existing washer (3).
It is recommended this washer (2) be added any time fitting is removed for any
reason.
2. LIFT LINK FITTING - REMOVAL
1. Remove lift link (module 63-31-03 paragraph "1. Lift link - removal").
2. Remove cotter pins (5, figure 1), nuts (4), steel washers (3), and washers (2) if installed.
3. Remove lift link fitting (6) from mounting studs of main support case (1).
3. LIFT LINK FITTING - INSTALLATION
1. Position lift link fitting (6, figure 1) on mounting studs of main support case (1).
2. Install washers (2 and 3). Install nuts (4). For helicopter not modified by S.B., torque nuts (4) 37 to 42 ft.-lbs. (50 to
56 Nm). For helicopters modified by S.B., torque nuts (4) 40 to 58 ft.-lbs. (54 to 79 Nm). Install cotter pins (5).
3. If desired, install lift link (module 63-31-03 paragraph "2. Lift link - installation").
4. LIFT LINK FITTING - CLEANING
MATERIALS REQUIRED
NUMBER NOMENCLATURE
1. Wipe fitting clean with a clean cloth damp with drycleaning solvent (C-304).
2. Dry with a clean, dry cloth or filtered, compressed air.
5. LIFT LINK FITTING - INSPECTION AND REPAIR
Refer to E-AB412-PT6T-3 for inspection criteria and repair limits and procedures.
63-31-04
Page 1
E-AB412-PT6T-2
G6AB0473A
Figure 1. Lift link fitting
63-31-04
Page 2
E-AB412-PT6T-2
63-41-01 TRANSMISSION OIL SYSTEM COMPONENTS - MAST BEARING ELECTRIC CHIP DETECTOR
63-41-01
TRANSMISSION OIL SYSTEM COMPONENTS - MAST BEARING ELECTRIC
CHIP DETECTOR
1. MAST BEARING ELECTRIC CHIP DETECTOR - DESCRIPTION
The mast bearing electric chip detector is installed in the transmission top case (figure 1) to detect foreign particles in the
transmission oil originating from the main rotor mast upper bearing.
2. MAST BEARING ELECTRIC CHIP DETECTOR - REMOVAL
1. Remove nut (1, figure 1) and disconnect wire from stud (2).
2. Push and twist chip detector (4) counterclockwise to disengage locking lugs (3). Remove chip detector (4) from chip
detector housing (6).
3. Cut and remove lockwire from chip detector housing (6), and remove chip detector housing from transmission.
4. Remove and discard packing (5) from chip detector (4) and, if removed, discard packing (7) from chip detector housing
(6).
3. MAST BEARING ELECTRIC CHIP DETECTOR - INSTALLATION
MATERIALS REQUIRED
NUMBER NOMENCLATURE
C-405 LOCKWIRE
1. Lubricate new packing (7, figure 1) with transmission oil (Chapter 12). Install packing (7) on chip detector housing (6).
NOTE
If a plug has been installed where the chip detector housing (6) is normally installed,
perform step 2.
2. Remove plug from top of transmission case were chip detector housing (6) is normally located.
3. Install chip detector housing (6) in top of transmission (8).
4. Torque chip detector housing (6) 30 to 108 in-lbs (3.4 to 12.2 Nm). Secure housing to transmission with lockwire
(C-405).
5. Lubricate new packing (5) with transmission oil (Chapter 12) and install new packing (5) on chip detector (4).
6. Insert chip detector (4) into chip detector housing (6). Push in on electric detector and twist clockwise to engage
locking lugs (3).
63-41-01
Rev. 3 Page 1
E-AB412-PT6T-2
7. Install electrical wire on stud (2).
8. Install nut (1) on stud (2). Tighten nut (1) to a maximum of 4.0 in-lbs (0.45 Nm) torque. Position nipple over nut (1).
4. MAST BEARING ELECTRIC CHIP DETECTOR - CLEANING
MATERIALS REQUIRED
NUMBER NOMENCLATURE
1. Clean electric chip detector (4, figure 1) with drycleaning solvent (C-304).
5. MAST BEARING ELECTRIC CHIP DETECTOR - INSPECTION
1. Inspect chip detector (4, figure 1) for presence of metal particles. If any particles are found, refer to module 63-00-00
paragraph "2. Main rotor drive - metal particle contamination" for required action.
2. Inspect chip detector (4) components in accordance with figure 2.
63-41-01
Page 2 Rev. 3
E-AB412-PT6T-2
TORQUE
30 TO 108 IN-LBS
(3.4 TO 12.2 Nm)
LOCKWIRE
(MS20995C32)
1. Nut
2. Stud
3. Locking lugs
4. Chip detector
5. Packing
6. Chip detector housing
7. Packing
8. Transmission
G6AB0457B
Figure 1. Mast bearing electric chip detector
63-41-01
Rev. 3 Page 3
E-AB412-PT6T-2
AREA LIMITS
All No cracks allowed
A Maximum depth of pitting is 0.030 in (0.762 mm ) with no more than 40% of any 1.0 sq-in (645.16 mm²) or
20% of total area of any pitted surface.
B Maximum depth of pitting is 0.020 in (0.508 mm) with no more than 40% of any 1.0 sq-in (645.16 mm²) or
20% of total area of any pitted surface. Thread damage is not permitted.
G6AB0458B
Figure 2. Electric chip detector (typical) - damage limits
63-41-01
Page 4 Rev. 3
E-AB412-PT6T-2
63-41-02 TRANSMISSION OIL SYSTEM COMPONENTS - MAIN INPUT GEAR QUILL ELECTRIC CHIP DETECTOR
63-41-02
TRANSMISSION OIL SYSTEM COMPONENTS - MAIN INPUT GEAR QUILL
ELECTRIC CHIP DETECTOR
1. MAIN INPUT GEAR QUILL ELECTRIC CHIP DETECTOR - DESCRIPTION
The main input gear quill electric chip detector (figure 1) is installed to detect metal particles in the transmission oil
originating from the main input gear quill.
2. MAIN INPUT GEAR QUILL ELECTRIC CHIP DETECTOR - REMOVAL
1. Remove nut (2, figure 1) and remove wire from stud (3).
2. Push in and twist electric chip detector (5) counterclockwise to disengage locking lugs (4).
3. Remove electric chip detector (5) from chip detector housing (7).
4. Cut and remove lockwire from chip detector housing (7), and remove chip detector housing from transmission (1).
5. Remove and discard packing (6) from electric chip detector (5) and, if removed, discard packing (8) from chip detector
housing (7).
3. MAIN INPUT GEAR QUILL ELECTRIC CHIP DETECTOR - INSTALLATION
MATERIALS REQUIRED
NUMBER NOMENCLATURE
C-405 LOCKWIRE
1. Lubricate new packings (6 and 8, figure 1) with transmission oil (Chapter 12). Install packing (8) on chip detector
housing (7) and packing (6) on electric chip detector (5).
2. Install chip detector housing (7) on transmission (1). Torque housing 280 to 300 in.-lbs. (31,7 to 33,9 Nm). Secure
housing to transmission (1) with lockwire (C-405).
3. Insert electric chip detector (5) into chip detector housing (7). Push in on electric chip detector (5) and twist clockwise
to engage locking lugs (4).
4. Install electrical wire on stud (3).
5. Install nut (2) on stud (3). Tighten nut (3) to a maximum of 4,0 in.-lbs. (0,45 Nm) torque. Position nipple over nut (1).
63-41-02
Page 1
E-AB412-PT6T-2
4. MAIN INPUT GEAR QUILL ELECTRIC CHIP DETECTOR - INSPECTION
1. Inspect electric chip detector (5, figure 1) for presence of metal particles. If any particles are found, refer to module
63-00-00 paragraph "2. Main rotor drive - metal particle contamination" for required action.
1. Inspect electric chip detector components in accordance with figure 2.
5. MAIN INPUT GEAR QUILL ELECTRIC CHIP DETECTOR - CLEANING
MATERIALS REQUIRED
NUMBER NOMENCLATURE
C-304 SOLVENT
1. Clean electric chip detector (5, figure 1) with dry-clean solvent (C-304).
63-41-02
Page 2
E-AB412-PT6T-2
G6AB0474A
Figure 1. Main input gear quill electric chip detector
63-41-02
Page 3
E-AB412-PT6T-2
G6AB0458A
Figure 2. Electric chip detector (typical) - damage limits
63-41-02
Page 4
E-AB412-PT6T-2
63-41-03 TRANSMISSION OIL SYSTEM COMPONENTS - SUMP CASE ELECTRICAL CHIP DETECTOR [A] [B] [C]
63-41-03
TRANSMISSION OIL SYSTEM COMPONENTS - SUMP CASE ELECTRICAL
CHIP DETECTOR [A] [B] [C]
1. SUMP CASE ELECTRICAL CHIP DETECTOR [A] [B] [C] - DESCRIPTION
The sump case electrical chip detector (4, figure 1) is installed to detect metal particles which collect in sump.
2. SUMP CASE ELECTRICAL CHIP DETECTOR [A] [B] [C] - REMOVAL
NOTE
The sump case electric chip detector (4, figure 1) may be removed for inspection
without draining sump. However, if the electric chip detector self-closing valve (2)
is to be removed the sump must be drained (Chapter 12).
1. Remove oil level access door on right side of pylon.
2. Move nipple (7) back on wire terminal (5) to expose nut (6). Remove nut (6) and wire terminal (5) from electric chip
detector (4).
3. Push in and twist electric chip detector (4) counterclockwise to disengage from locking detents.
4. Remove electric chip detector (4) from electric chip detector self-closing valve (2).
5. Remove and discard packings (3) from electric chip detector (4).
6. If the electric chip detector self-closing valve (2) is being removed perform the following steps:
a. Drain transmission sump case (Chapter 12).
b. Cut and remove lockwire from electric chip detector self-closing valve (2), pump screen (8), and plug (9).
c. Remove electric chip detector self-closing valve (2) from transmission sump case.
d. Remove gasket (1) from electric chip detector self-closing valve (2).
3. SUMP CASE ELECTRICAL CHIP DETECTOR [A] [B] [C] - INSTALLATION
MATERIALS REQUIRED
NUMBER NOMENCLATURE
C-405 LOCKWIRE
1. If the electric chip detector self-closing valve (2, figure 1) was removed perform the following steps:
a. Lubricate new gasket (1) with transmission oil (Chapter 12). Install gasket (1) on electric chip detector
self-closing valve (2).
63-41-03
Page 1
E-AB412-PT6T-2
b. Install electric chip detector self-closing valve (2) on transmission sump case and torque 300 to 400 in.-lbs. (33,9
to 45,2 Nm).
c. Secure electric chip detector self-closing valve (2) to pump screen (8) and plug (9) with lockwire (C-405).
2. Lubricate new packings (3) with transmission oil (Chapter 12). Install packings (3) on electric chip detector (4).
3. Insert electric chip detector (4) into electric chip detector self-closing valve (2). Push in on electric chip detector (5)
and turn clockwise to engage the locking detents.
4. Install wire terminal (5) on electric chip detector (4).
5. Install nut (6) on electric chip detector (4). Tighten nut (6) to a maximum of 4,0 in.-lbs. (0,45 Nm) torque. Position
nipple (7) over nut (6).
4. SUMP CASE ELECTRICAL CHIP DETECTOR [A] [B] [C] - CLEANING
MATERIALS REQUIRED
NUMBER NOMENCLATURE
5. SUMP CASE ELECTRICAL CHIP DETECTOR [A] [B] [C] - INSPECTION
1. Inspect electric chip detector (4, figure 1) for presence of metal particles. If any particles are found, refer to
module 63-00-00 paragraph "2. Main rotor drive - metal particle contamination" for required action.
2. Inspect electric chip detector (4) components in accordance with figure 2.
63-41-03
Page 2
E-AB412-PT6T-2
G6AB0496A
Figure 1. Sump case electric chip detector [A] [B] [C]
63-41-03
Page 3
E-AB412-PT6T-2
G6AB0497A
Figure 2. Sump case electric chip detector [A] [B] [C] - damage limits
63-41-03
Page 4
E-AB412-PT6T-2
CHAPTER 64 - TAIL ROTOR

Module Page
Number Title Number
64-00-00 TAIL ROTOR
1. Tail Rotor - general ................................................................................................................................. 1
64-11-01 TAIL ROTOR BLADES
1. Tail rotor blades - description ................................................................................................................. 1

2. Tail rotor blades - removal ...................................................................................................................... 1
3. Tail rotor blades - installation ................................................................................................................. 1
4. Tail rotor blades - balancing ................................................................................................................... 1
5. Tail rotor blades - buffer pad replacement .............................................................................................. 1
6. Tail rotor blades - blade butt sealing ...................................................................................................... 1
7. Tail rotor blades - inspection ................................................................................................................... 2
8. Tail rotor blades - leak check .................................................................................................................. 6
9. Tail rotor blades - minor repair ............................................................................................................. 11
10. Tail rotor blades - repair ....................................................................................................................... 12
11. Tail rotor blades - paint touch up .......................................................................................................... 12
12. Tail rotor blades - paint scheme............................................................................................................. 14
64-21-01 TAIL ROTOR HUB AND BLADE ASSEMBLY
1. Tail rotor hub and blade assembly - description ..................................................................................... 1

2. Tail rotor hub and blade assembly - removal ......................................................................................... 1
3. Tail rotor hub and blade assembly - installation ..................................................................................... 2
4. Tail rotor hub and blade assembly - inspection ...................................................................................... 4
5. Tail rotor hub and blade assembly - inspection - static stop (212-011-713) yielding ............................ 4
6. Tail rotor hub and blade assembly - repair ............................................................................................ 12
7. Tail rotor hub and blade assembly - troubleshooting ........................................................................... 12
8. Tail rotor hub and blade assembly - operational check ......................................................................... 13
64-31-01 TAIL ROTOR CONTROLS - COUNTERWEIGHT LINK
1. Counterweight link - removal ................................................................................................................. 1

2. Counterweight link - installation ............................................................................................................ 1
64-31-02 TAIL ROTOR CONTROLS - PITCH CONTROL LINKS
1. Pitch control links - removal ................................................................................................................... 1

2. Pitch control links - installation .............................................................................................................. 1
64-31-03 TAIL ROTOR CONTROLS - CONTROL TUBE
1. Control tube - removal ............................................................................................................................ 1

2. Control tube - installation ....................................................................................................................... 1
64-31-04 TAIL ROTOR CONTROLS - CONTROL HOUSING
1. Control housing - removal ...................................................................................................................... 1

2. Control housing - installation ................................................................................................................. 1
64-Index
Rev. 3 Page 1
E-AB412-PT6T-2

Module Page
Number Title Number
64-31-05 TAIL ROTOR CONTROLS - TAIL ROTOR LEVER
1. Tail rotor lever - removal ........................................................................................................................1

2. Tail rotor lever - installation ....................................................................................................................1
64-31-06 TAIL ROTOR CONTROLS - CONTROL LINK
1. Control link - removal .............................................................................................................................1

2. Control link - installation ........................................................................................................................1
64-31-07 TAIL ROTOR CONTROLS - IDLER
1. Idler - removal .........................................................................................................................................1

2. Idler - installation ....................................................................................................................................1
64-31-08 TAIL ROTOR CONTROLS - CROSSHEAD CONTROLS
1. Crosshead controls - removal ..................................................................................................................1

2. Crosshead controls - installation .............................................................................................................1
64-Index
Page 2 Rev. 3
E-AB412-PT6T-2
FIGURES
Figure Page
Number Title Number
64-11-01 TAIL ROTOR BLADES
Figure 1. Tail rotor blade ............................................................................................................................................... 8

Figure 2. Tail rotor blades assembly .............................................................................................................................. 9
Figure 3. Tail rotor blade - leak check ......................................................................................................................... 10
Figure 4. Tail rotor blade paint scheme ....................................................................................................................... 15
Figure 1. Tail rotor hub and blade assembly - removal and installation (sheet 1 of 2) ................................................. 5
Figure 2. Tail rotor controls - control housing - removal and installation..................................................................... 7
Figure 3. Tail rotor controls - lever - removal and installation...................................................................................... 8
Figure 4. Tail rotor controls - control link - removal and installation ........................................................................... 9
Figure 5. Tail rotor controls - control idler - removal and installation ........................................................................ 10
Figure 6. Tail rotor static stop (212-011-713) yielding ............................................................................................... 11
Figure 1. Tail rotor controls - counterweight link - removal and installation................................................................ 2
Figure 1. Tail rotor controls - pitch control link - removal and installation .................................................................. 3
Figure 1. Tail rotor hub and blade assembly (sheet 1 of 2) ........................................................................................... 2

Figure 2. Tail rotor controls - control tube - removal and installation........................................................................... 4
Figure 1. Tail rotor controls - control housing - removal and installation..................................................................... 2
Figure 1. Tail rotor controls - lever - removal and installation...................................................................................... 2
Figure 1. Tail rotor controls - control link - removal and installation ........................................................................... 2
Figure 1. Tail rotor controls - control idler - removal and installation .......................................................................... 2
Figure 1. Tail rotor crosshead controls - removal and installation ................................................................................ 2
64-Index
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E-AB412-PT6T-2
TABLES
Table Page
Number Title Number
Table 1. Tail rotor troubleshooting .............................................................................................................................12
64-Index
Page 4 Rev. 3
E-AB412-PT6T-2
64-0 -0 TAIL ROTOR
64-00-00
TAIL ROTOR
1. TAIL ROTOR - GENERAL
This chapter provides maintenance procedures for the tail rotor hub, blades, and controls. Tail rotor hub and blade tracking
and balancing procedures are contained in Chapter 18.
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E-AB412-PT6T-2
64-00-00
Page 2
E-AB412-PT6T-2
64-1 -01 TAIL ROTOR BLADES
64-11-01
TAIL ROTOR BLADES
1. TAIL ROTOR BLADES - DESCRIPTION
Each tail rotor blade is a bonded assembly consisting of a shaped stainless steel spar forming the leading edge, an aluminum
alloy honeycomb core, and aluminum alloy skins. A flat trailing edge is formed by the extension of skins over a narrow
aluminum strip. Aluminum alloy doublers and grip plates and butt blocks reinforce root end of blade. This section extends
inboard to form a “box” open toward hub and trailing edge. Two bolt holes through upper and lower surfaces provide for
attachment of blade to hub. Externally attached balance weights and balance screws inside blade tip facilitate blade
balancing.
NOTE
Removal and installation of tail rotor blades is not provided in this manual. If a
requirement exists to replace or repair any component of the hub and blade
assembly, tail rotor hub and blade must be statically balanced (E-AB412-PT6T-3).
2. TAIL ROTOR BLADES - REMOVAL
Refer to E-AB412-PT6T-3.
3. TAIL ROTOR BLADES - INSTALLATION
4. TAIL ROTOR BLADES - BALANCING
5. TAIL ROTOR BLADES - BUFFER PAD REPLACEMENT
6. TAIL ROTOR BLADES - BLADE BUTT SEALING
64-11-01
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E-AB412-PT6T-2
7. TAIL ROTOR BLADES - INSPECTION

MATERIALS REQUIRED
NUMBER NOMENCLATURE
C-323 EPOXY FILLER
C-331 ADHESIVE
C-424 PUTTY
1. Inspect tail rotor blade records. If records or physical appearance indicate that the tail rotor blades have been involved
in an accident or incident, refer to E-AB412-PT6T-6 inspection requirements manual.
CAUTION
DESCRIBING AND DEFINING ALL DEFECTS THAT COULD OCCUR ON A

TAIL ROTOR BLADE IS VIRTUALLY IMPOSSIBLE THEREFORE, USE THE
FOLLOWING INSPECTION CRITERIA ONLY AS A GUIDE. CONSULT
PRODUCT SUPPORT ENGINEERING BEFORE SCRAPPING ANY BLADE
EXCEPT IN CASES WHERE THE BLADES ARE OBVIOUSLY NON
REPARABLE.
2. Inspect tail rotor blades and record whether damage is within limits noted in steps a. through f.
CAUTION
IF A FATIGUE CRACK EXISTS IN ANY LOCATION, FORWARD THE

BLADE TO AN AUTHORIZED BLADE REPAIR STATION FOR
EVALUATION. INSPECT DENTS CLOSELY FOR NICKS, SCRATCHES AND
CRACKS. IF NICKS OR SCRATCHES EXIST IN DENTS AND THE TOTAL
DEPTH IS IN EXCESS OF THAT PERMITTED FOR DENTS ALONE,
REPLACE THE BLADE.
NOTE
Dents shall be separated into two classifications: non-sharp dents and sharp dents. A
dent is sharp if a 0.030 in (0.762 mm) radius probe bridges across the bottom of the
dent. If the probe makes a clicking sound or does not have a smooth feel when held
perpendicular to the blade contour and dragged across the dent surface, then it is a
sharp dent.
a. Nicks, scratches, dents, and corrosion on the skins, doublers, grip plates, and stainless steel spar (leading edge)
that fall within the following limits are considered repairable damage and are acceptable if repaired in
accordance with paragraph "9. Tail rotor blades - minor repair" and paragraph "11. Tail rotor blades - paint touch
up".
(1) Skins
(a) Inboard of blade station 40.50 (figure 1):
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E-AB412-PT6T-2
Nicks and scratches on the aluminium skin 0.003 in (0.08 mm) deep or less are acceptable when polished out in accordance
with paragraph "9. Tail rotor blades - minor repair".
Sharp dents 0.003 in (0.08 mm) deep or less are acceptable when polished out in accordance with paragraph "9. Tail rotor
blades - minor repair".
Sharp dents are not acceptable.
Non-sharp dents 0.015 in (0.38 mm) deep or less are permissible, provided all other repair limits are met.
Corrosion: Only superficial corrosion that can be removed with aluminum wool or very fine grade scotch-brite abrasive pad
is permissible. Repair in accordance with paragraph "9. Tail rotor blades - minor repair".
No damage permitted within 0.75 in (19.05 mm) of a double edge.
(b) Outboard of blade station 40.50 (figure 1):
Nicks and scratches on the aluminium skin 0.005 in (0.13 mm) deep or less are acceptable when polished out in accordance
with paragraph "9. Tail rotor blades - minor repair".
Sharp dents 0.005 in (0.13 mm) deep or less are acceptable when polished out in accordance with paragraph "9. Tail rotor
Non sharp dents 0.030 in (0.76 mm) deep or less are permissible, provided all other repair limits are met.
Corrosion: Only superficial corrosion that can be removed with aluminium wool or very fine grade scotch-brite abrasive pad
is permissible. Repair in accordance with paragraph "9. Tail rotor blades - minor repair".
(2) Spar
(a) Inboard of blade station 40.50 (figure 1):
Nicks and scratches on the steel spar 0.003 in (0.08 mm) deep or less are acceptable when polished out in accordance with
paragraph "9. Tail rotor blades - minor repair".
Sharp dents on the steel spar 0.005 in (0.13 mm) deep or less are acceptable when polished out in accordance with paragraph
"9. Tail rotor blades - minor repair".
Non sharp dents 0.015 in (0.38 mm) deep or less are permissible, provided all other repair limits are met.
Corrosion: Corrosion on steel spar 0.003 in (0.08 mm) deep or less is acceptable when polished out in accordance with
No damage permitted within 0.75 in (19.05 mm) of a doubler edge.
(b) Outboard of blade station 40.50 (figure 1):
Nicks and scratches on the steel spar 0.005 in (0.13 mm) deep or less are acceptable when polished out in accordance with
Sharp dents on the steel spar 0.015 in (0.38 mm) deep or less are acceptable when polished out in accordance with paragraph
"9. Tail rotor blades - minor repair".
Non-sharp dents 0.030 in (0.76 mm) deep or less are permissible, provided all other repair limits are met.
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E-AB412-PT6T-2
Corrosion: Corrosion on the steel spar 0.005 in (0.13 mm) deep or less is acceptable when polished out in accordance with
(3) Doublers and Grip Plates
Damage to edges: No damage or repair permitted on an edge of a doubler or grip plate, or within 0.5 in (12.7 mm) of an edge.
Nicks and scratches on the aluminium doublers and grip plates 0.005 in (0.13 mm) deep or less are acceptable when polished
out in accordance with paragraph "9. Tail rotor blades - minor repair".
Sharp dents are not acceptable.
Non sharp dents 0.010 in (0.254 mm) deep or less are permissible.
Corrosion: Corrosion on the aluminium doublers and grip plates 0.0025 in (0.06 mm) deep or less is acceptable when
polished out in accordance with paragraph "9. Tail rotor blades - minor repair". Repair must be twice the depth of the visible
corrosion to ensure complete removal.
(4) Limits - trailing edge
(a) Nicks and scratches in trailing edge up to 0.030 in (0.762 mm) in depth (chordwise) are acceptable if
polished out over a distance of at least 3.0 in (76.2 mm) each side of damage.
(b) Refer to paragraph "9. Tail rotor blades - minor repair" for instructions to polish out damage.
(5) Requirement to smooth and fair dented areas: Non-sharp dents that are within limits, but are more than
0.010 in (0.254 mm) deep shall be filled and fired with putty (C-424) or epoxy filler (C-323).
b. Void limits
NOTE
Voids are defined as unbounded areas which are supposed to be bonded. Many sub
definitions of voids are often given, such as lack of adhesion, gas pockets, misfits,
etc. The general term “void” as used herein makes no distinction between these
definitions. Where two voids of different limitations (Example: Void between core
and skin adjacent to a void between skin and doubler) are closer together than 1.0 in
(25.4 mm), consider the defect as one void and apply the stricter limitation.
(1) Edge voids (figure 2): Acceptable edge voids must be sealed in accordance with paragraph "9. Tail rotor
(a) Edge voids of 0.250 in (6.350 mm) maximum in depth by 1.50 in (3.81 cm) maximum in length
between butt block (13) and spar (10), or between butt block and inner grip plates (14).
(b) Edge voids of 0.060 in (1.524 mm) maximum in depth, by 2.0 in (5.08 cm) maximum in length
between grip plates (11) and doublers (4), doublers and skins (6), or spar (10), inner grip plates (14)
and skins (6) or spar, edge of butt block (13) and skins (6). Edge voids between the skin and spar are
not acceptable.
(c) Edge voids of 0.120 in (3.048 mm) maximum in depth by 3.0 in (7.62 cm) maximum in length
between the skins (6) and trailing edge (5).
(d) Edge voids of 0.50 in (12.7 mm) maximum in width (chordwise) between spar (10) and tip block (8).
64-11-01
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E-AB412-PT6T-2
CAUTION
NO VOIDS ARE ACCEPTABLE WITHIN 0.50 IN (12.7 MM) OF THE EDGES

OF THE DRAIN HOLE DOUBLER. NO VOIDS ARE ACCEPTABLE BETWEEN
THE DRAIN HOLE DOUBLER AND THE SPAR WITHIN 0.50 IN (12.7 MM)
OF THE EDGE OF THE DRAIN HOLE. NO VOIDS ARE ALLOWED
BETWEEN BLADE STATION 25.50 AND 40.50.
(2) Voids, other than edge voids:
(a) No voids are acceptable between the grip plates (11) and doublers (4), or between the inner grip plates
(14) and spar (10), except as described in step 1.(b).
(b) A void 0.50 in (12.7 mm) maximum chordwise by 2.0 in (50.8 mm) maximum spanwise between the
doublers (4) and skin (6), or spar (10), is acceptable provided it is not within 0.50 in (12.7 mm) of the
edge of the doubler.
(c) Inboard of blade station 25.50 a void 0.50 in (12.7 mm) maximum chordwise by 2.0 in (50.8 mm)
maximum spanwise, is acceptable between the skin (6) and spar (10), provided it is not within 0.250
in (6.350 mm) of the edge of the skin. Outboard of blade station 40.50 where the skin overlaps the
spar, the maximum size for acceptable voids is 0.250 in (6.350 mm) chordwise by 2.0 in (50.8 cm)
spanwise, provided it is not within 0.250 in (6.350 mm) of edge of skin.
(d) A void of 0.50 in (12.7 mm) maximum chordwise by 2.0 in (50.8 mm) maximum spanwise is
acceptable between the skin (6) and core (7).
(e) A void of 0.38 in (9.652 mm) maximum spanwise by 3.0 in (76.2 mm) maximum chordwise is
acceptable between the skin and tip closure in either the top or bottom or both, provided it is not
within 0.12 in (3.048 mm) from the edge of skin. If edge distance is less then 0.12 in (3.048 mm),
void may be repaired by carefully lifting the skin and rebounding with adhesive (C-331).
(f) Voids at Trailing Edge to Core Interface. A 0.38 in (9.6 mm) maximum gap/void between the trailing
edge of the honeycomb core and the trailing edge strip is acceptable.
CAUTION
IF A CRACK EXISTS IN ANY LOCATION, THE BLADE IS NOT

ACCEPTABLE AND MUST BE REMOVED FROM SERVICE.
c. Cracks defined in the following steps are not acceptable.
(1) Visually check for bond line cracks between phenolic blocks and skin, spar inside drain hole, inner grip
plates or joint between phenolic blocks.
(2) Inspect all butt area bond lines placing emphasis on those areas illustrated in figure 3.
(3) If cracks are suspected, remove paint in suspected areas by sanding the effected areas in a spanwise
direction using 400-grit abrasive cloth or paper (C-406). Remove sanding residue with a clean cloth
(C-516) moistened with aliphatic naphtha (C-305). Do a tail rotor blade leak check (paragraph "8. Tail rotor
blades - leak check".
(4) If no cracks are found, touch up paint after inspection is complete (paragraph "11. Tail rotor blades - paint
touch up").
d. Inspect buffer pads around blade bolt holes for wear, tears, or debonding. For repair refer to E-AB412-PT6T-3
Overhaul Manual.
e. Inspect bushings in tail rotor blade bolt holes (2, figure 2) for secure installation. Any looseness is cause for blade
replacement. Measure bushing inside diameter. If dimension exceeds 0.5005 in (12.71 mm), replace blade
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Rev. 3 Page 5
E-AB412-PT6T-2
bushing at an authorized blade overhaul facility.
f. Inspect bushings for cracks. Any crack is cause to remove the blade from service.
g. Damage defined in the following steps is cause to remove the tail rotor blade from service. The blade my be sent
to an authorized repair facility for evaluation of possible repair.
(1) Damage in excess of limits specified in inspection step 2.(a) through step 2.(c).
(2) One or more holes in the skin.
(3) Edge voids between the skin and the spar.
(4) Evidence of corrosion at any edge void.
h. Damage defined in the following steps is cause to replace tail rotor blade.
(1) Water or corrosion in rotor blade honeycomb core.
(2) Damage in excess of limits defined in inspection steps a. through c. and/or damage defined in
E-AB412-PT6T-3 Repair and Overhaul Manual on a rotor blade that has reached the maximum
airworthiness life (hours), or has less than 200 hours remaining airworthiness life (hours). Refer to
E-AB412-PT6T-6 Inspection Requirement Manual for airworthiness life hours for tail rotor blades.
(3) One or more cracks that extend from a previously repaired area.
(4) Holes in skin larger in area than acceptable for parching. Refer to E-AB412-PT6T-3 Overhaul Manual.
(5) Any corrosion that penetrates entirely through skin.
(6) Wears completely through blade spar at the tip.
(7) Loose balance screws (9, figure 2).
(8) Loose bushings at blade grip bolt holes (2).
8. TAIL ROTOR BLADES - LEAK CHECK
MATERIALS REQUIRED
NUMBER NOMENCLATURE
NOTE
The following inspection should be performed whenever signs of delamination/
separation are visible in the bond lines at the butt end area of the blade (figure 3), as
well as other tail rotor blade locations, or if excessive tail rotor vibrations are
reported with no apparent causes.
1. Thoroughly clean the tail rotor blade (1), including the surfaces and bond lines of the butt end (2), with a weak solution
of cleaning compound (C-318). Rinse with clear water.
NOTE
The intent is to obtain an approximate 37.7°C (100°F) temperature differential
between the tail rotor blade (1) and the water in the tank.
2. Cool the tail rotor blade (1) in a refrigerator for a minimum of 1 hour at a temperature of -1 to 7°C (30 to 45°F).
64-11-01
Page 6 Rev. 3
E-AB412-PT6T-2
CAUTION
DO NOT EXCEED A WATER TEMPERATURE OF 80°C (175°F) . OTHERWISE

DAMAGE TO THE TAIL ROTOR BLADE MAY OCCUR.
3. Fill the water tank with clean clear water. For best results, the water should be maintained at 60 to 80°C (140 to 175°F).
CAUTION
DO NOT SUBMERGE THE TAIL ROTOR BLADE IN WATER FOR MORE

THAN 2 MINUTES. MAINTAINING THE BLADE IN WATER FOR MORE
THAN 2 MINUTES COULD ALLOW WATER TO ENTER THE BLADE IF A
LEAK PATH IS PRESENT.
NOTE
The tail rotor blade (1) should be left in the heated water for a minimum of 1 minute
and a maximum of 2 minutes.
4. Wear protective gloves and place the cool tail rotor blade (1) into the heated water. The blade will float so it will be
necessary to manually submerge the blade.
NOTE
Be careful not to misinterpret random trapped surface air bubbles as a leak point.
5. Slightly rotate the tail rotor blade (1) back and forth about the blade pitch change axis to allow any air trapped on the
blade surfaces to be expelled.
NOTE
It may take several seconds before the air is forced out through any existing leak
path.
6. With the tail rotor blade (1) under water, check for air leaks, which will be indicated by a steady stream of fine bubbles
originating from a single point.
7. Slightly rotate the tail rotor blade (1) back and forth to allow a thorough inspection of all the blade surfaces. Pay
particular attention to the butt end (2) and around the leading edge drain hole (3).
8. If an air leak is found, the tail rotor blade is to be removed from service and scraped. Notify AgustaWestland Support
Engineering.
9. If no air leak is found, but the tail rotor assembly has a history of balance change or balance difficulties, additional
maintenance is required (Chapter 18).
10. If no air leak is found, then the tail rotor blade (1) is acceptable for return to service.
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E-AB412-PT6T-2
NOTE:
1 Tail rotor blade stations (212-011-702 yoke installed).
G6AB0828B
Figure 1. Tail rotor blade
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Page 8 Rev. 3
E-AB412-PT6T-2
1 1. Pitch horn bolt holes

2. Blade grip bolt holes
3. External balance weights
4. Doubler
5. Trailing edge
6. Skin
7. Honeycomb core
8. Tip block
9. Balance screws
10. Spar
11. Grip plate
12. Drain hole doubler
13. Butt block
14. Inner grip plate
15. Tip closure
16. External balance weight
NOTE:
1 External balance weight (16), installed if required.
G6AB0620C
Figure 2. Tail rotor blades assembly
64-11-01
Rev. 3 Page 9
E-AB412-PT6T-2
1. Tail rotor blade

2. Butt end
3. Leading edge drain hole
NOTES:
1 Water temperature to be maintained between 60 to 80°C (140 to 175°F).
2 Water tank should be 20 in (50.8 cm) wide x 52 in (132.1 cm) long by 20 in (50.8 cm) deep.
G6AB1068A
Figure 3. Tail rotor blade - leak check
64-11-01
Page 10 Rev. 3
E-AB412-PT6T-2
9. TAIL ROTOR BLADES - MINOR REPAIR
MATERIALS REQUIRED.
NUMBER NOMENCLATURE
C-344 ALCOHOL PHOSPHORIC CLEANER
C-363 ADHESIVE
C-407 ABRASIVE PAD
C-516 CLEAN CLOTH
All nicks, scratches, sharp dents, and corrosion that are within the repair limits in paragraph "7. Tail rotor blades - inspection"
must be removed by hand polishing in a spanwise direction (+/-15 degrees) only.
NOTE
Repair to the blade by material removal (polishing) is permitted only once at any
local area. Overlapping repairs are not permitted. Any permissible repair by
polishing should be accomplished by removing the minimum amount of material
required to remove the damage.
1. Nicks, Scratches, and Sharp Dents
Polish out all repairable nicks and scratches using aluminium wool or a very fine grade abrasive pad (C-407) when repairing
aluminium. On steel surfaces, fine abrasive cloth or paper (C-406) may be used (180 grit or finer, may be used to remove
damage, but must be followed by polishing with 400 grit or finer to improve the surface finish). Nicks in the trailing edge
may be polished out using very fine abrasive cloth or paper (C-406) if followed by polishing with aluminium wool or very
fine grade abrasive pad (C-407). Hand polish in a spanwise direction.
2. Non-sharp Dents
The bottom of a dent must be smooth and clearly non-sharp to be classified as a non-sharp dent. A dent with any crease in
it is considered to be a sharp dent. Non-sharp dents, which are within the limits in paragraph "7. Tail rotor blades -
inspection", are not to be polished out. Carefully inspect for any surface irregularities, such as a nick, scratch, or a burr, in
and around a non-sharp dent. Any additional damage must be within the limits in paragraph "7. Tail rotor blades -
inspection".
3. Corrosion
Polish out all repairable corrosion using aluminium wool or a very fine grade abrasive pad (C-407) on all aluminium
surfaces, or very fine abrasive cloth or paper (C-406) (400 grit or finer) may be used on the stainless steel spar. 180 grit
abrasive cloth or paper (C-406) may be used to polish out corrosion on the steel spar if followed with polishing using 400 grit
abrasive cloth or paper (C-406) to improve the surface finish. Repair depth on aluminium must be to twice the depth of the
visible corrosion to ensure complete removal. Hand polish in a spanwise direction. Do not over-polish. On all surfaces where
corrosion has been polished out, apply cleaner (C-344) using a clean cloth (C-516) or brush. Rub solution briskly into surface
for approximately 40 to 60 seconds. Carefully check for pits with a 10X magnifying glass following clean-up. No pitting is
permissible.
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E-AB412-PT6T-2
4. Sealing Edge Voids
Seal edge voids by thoroughly cleaning affected area using alcohol and clean wipes. A thin plastic spatula may be used to
solvent wipe the bond line. Do not stretch or gouge blade skins, spars or doublers. Allow to dry. Seal area using adhesive
(C-363) or equivalent. Adhesive and blade may be warmed to 120°F (48.9°C) to promote adhesive flow. A thin plastic
spatula may be used to work adhesive into bond lines. Allow to cure.
10. TAIL ROTOR BLADES - REPAIR
For repair of tail rotor blade, refer to E-AB412-PT6T-3 Overhaul Manual.
11. TAIL ROTOR BLADES - PAINT TOUCH UP
MATERIALS REQUIRED
NUMBER NOMENCLATURE
C-246 EPOXY PRIMER COATING
C-265 1 POLYURETHANE COATING
C-386 SOLVENT
C-407 ABRASIVE PAD
C-420 MASKING PAPER
C-434 TAPE
C-486 CHEESECLOTH
NOTE:
1 Polyurethane coating (C-245) or lacquer (C-594) may be used

as an alternate for touch-up.
NOTE
Touch up tail rotor blades when warranted by paint condition, or when paint is
removed to repair scratches, nicks, gouges, dents, or corrosion.
1. Thoroughly wipe blade with solvent (C-386). Allow solvent to wet blade a few minutes, then wipe dry with clean
cloths (C-486).
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E-AB412-PT6T-2
CAUTION
DO NOT USE ROTARY TYPE SANDING DEVICES. OTHERWISE DAMAGE

TO THE TAIL ROTOR BLADE CAN OCCUR.
2. Thoroughly sand the area to be painted with 240 grit, or finer, abrasive cloth or paper (C-406) until a uniform matte
finish is obtained.
3. Wash the sanded surface with an abrasive pad (C-407) and cleaning compound (C-318) to obtain a water break free
surface. Rinse with water. Repeat step 1 through step 3 as required to obtain a water break free surface.
NOTE
From completion of this step through final paint, the surface of the blades that are to
be painted shall not be handled with bare hands.
4. Apply chemical film material (C-100) on all bare aluminum surfaces.
5. Mask the tail rotor blade, pitch horn bolt holes, blade grip bolt holes and buffer pads, identification plate and leading
edge area, as applicable, with tape (C-434) and masking paper (C-420).
6. Apply one coat of epoxy primer coating (C-246) to touch-up areas only.
NOTE
Primer shall be overcoated not less than 1 no more than 8 hours after application. If
8 hours is exceeded, repeat step 2 through step 6.
NOTE
Refer to E-AB412-PT6T-3, Chapter 64 for the required paint color to match the area
being painted.
7. Using the required paint color to match the area being painted, apply one to two covering coats of coating (C-265).
Allow 30 minutes to 8 hours drying time between coats. If 8 hours is exceeded, the initial coat must be sanded and
reprimed with epoxy primer coating (C-246) prior to overcoating.
8. Remove masking tape and marking paper from the blade.
9. After air drying for a minimum of 8 hours and if touch-up was applied to leading edge, feather out paint lines on
leading edge as follows:
a. Mask approximately 1/4 in (6.35 mm) back from the forward edge of the paint using 2 in (50.8 mm) wide tape.
b. Hand sand, overlapping the tape and the edge to be feathered, in a spanwise direction with 240 grit or finer
abrasive cloth or paper (C-406). Do not sand through the tape.
c. c. A correctly feathered edge should show a uniform primer line of about 1/16 in (1.58 mm) in width in the
striation of the feathered paint. This indicates a smooth transition from metal to paint. A fingernail, when
dragged over the feathered edge, should not hang on the edge.
10. Static balancing of the tail rotor hub and blade assembly is required. Refer to E-AB412-PT6T-3, Chapter 64.
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E-AB412-PT6T-2
12. TAIL ROTOR BLADES - PAINT SCHEME
MATERIALS REQUIRED
NUMBER NOMENCLATURE
C-202A POLYAMMIDE PRIMER
C-216 ACRILIC LACQUER
C-304 SOLVENT
C-305 ALPHALITIC NAPHTA
C-344 ALCOHL PHOSPORIC CLEANER
1. Remove tail rotor hub and blade assembly (module 64-21-01 paragraph "2. Tail rotor hub and blade assembly -
removal").
2. Protect blade bearings and data plate by masking.
3. Clean blade with aliphatic (C-305) or (C-304) solvent. Allow solvent to wet blade for a few minutes before its removal
with clean dry rags or cheesecloth.
4. Sand all painted blade surfaces with 180 grit or finer abrasive coated cloth or paper (C-423) until a uniform matte
finish is achieved.
5. Wash all blade surfaces to obtain a water break free surface by scrubbing with abrasive pads and a non-etching alkaline
cleaning compound solution (C-318). Rinse with water to verify a water break free surface has been obtained. Repeat
Steps 5. through 6. if a water break free surface is not obtained.
6. Prepare bare stainless steel surfaces for painting by applying alcoholic treatment (C-344)
7. Apply one coat of Primer (C-202A) to all blade surfaces. The primer should be overcoated after 1 to 24 hours air dry.
If 24 hours air dry is exceeded, the primer must be sanded and reapplied prior to overcoating.
8. Apply 1 to 2 light covering coats of gloss white, allowing 30 minutes to 72 hours air dry between coats. If 72 hours air
dry is exceeded, the initial coat shall be sanded prior to overcoating.
9. After 6 to 72 hours air dry, mask off sections of the rotor blade to remain gloss white, (refer to figure 4). If 72 hours
air dry is exceeded, the area to be striped shall be sanded prior to overcoating.
10. Apply 1 to 2 light covering coats gloss black (C-216). Air dry 30 minutes to 72 hours between coats.
11. Air dry blade for 3 hours before handling and for a total of 48 hours before flying.
NOTE
If a fast paint cure is wished, air dry blade for one hour. Then dry in oven at
180-190°F (82-88°C).
12. Remove masking tape previously installed at steps 3. and 10.
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E-AB412-PT6T-2
13. Install tail rotor hub and blade assembly (module 64-21-01 paragraph "3. Tail rotor hub and blade assembly -
installation").
14. Static balance tail rotor hub and blade assembly (module 18-13-02 paragraph "5. Tail rotor hub and blade tracking and
balancing - tail rotor balancing").
15. Dynamic balance tail rotor hub and blade assembly.
NOTE
Only tail rotor blades with the same paint scheme may be utilized in the tail rotor
hub and blade assembly.
G6AB0829B
Figure 4. Tail rotor blade paint scheme
64-11-01
Rev. 3 Page 15
E-AB412-PT6T-2
64-11-01
Page 16 Rev. 3
E-AB412-PT6T-2
64-21-01
TAIL ROTOR HUB AND BLADE ASSEMBLY
1. TAIL ROTOR HUB AND BLADE ASSEMBLY - DESCRIPTION
The tail rotor installation consists of the two-bladed tail rotor hub and blade assembly and control linkage. The rotor turns
clockwise, as viewed from the gearbox, and counteracts main rotor torque to provide directional control.
The tail rotor hub assembly consists of a stainless steel yoke, a steel trunnion, two bearing housings, and two
grease-lubricated roller bearings. The yoke is a preconed, flex-beamed type that incorporates self-lubricating, spherical
bearings for attachment of the blades to the yoke. The yoke is mounted on the trunnion with grease-lubricated roller bearings
that are assembled into the housings. The trunnion is splined in the center section and interfaces with the tail rotor drive
shaft. A cross head assembly, mounted on the drive shaft. A cross head assembly, mounted on the drive shaft outboard of
the hub assembly, incorporates counterweights and pitch links that attach to the pitch horns. The pitch horns are attached to
the blades and transfer the pitch change motion to the hub assembly.
2. TAIL ROTOR HUB AND BLADE ASSEMBLY - REMOVAL
1. Cut and remove lockwire from bolt (2, figure 1). Loosen bolt (2).
2. Loosen nuts (37). Remove nuts (33) and steel washers (34) from bolts (36). Remove bolts (36) and steel washers (35)
and slide pitch horn (24) out so bolt (2) will clear bracket on hub and blade assembly (29).
3. Remove bolt (2) and separate pitch link (19) from pitch horn (24).
4. Reinstall hardware to prevent loss. Disconnect opposite pitch link in same manner.
5. Remove cotter pin (7), nut (6) and washer (5) from bolt (22). Remove bolt (22) and washer (21). Separate
counterweight link (20) from support (3). Disconnect opposite counterweight link in the same manner.
6. Cut and remove lockwire from screws (18). Remove screws (18), washers (17), lock (16), and retainer (15).
7. Push crosshead assembly (8) inboard to expose cotter pin (14). Remove cotter pin (14), nut (13), and washer (12).
8. Remove crosshead assembly (8), pitch links (19), and counterweight links (20) as a single unit.
9. Remove bearing (11) and special washer (9).
NOTE
Remove sleeve (10) only if control tube (4) is to be removed.
10. Pull sleeve (10) outboard and rotate to engage threads on control tube (4), rotate the sleeve until clear of threads and
remove sleeve from tube.
11. Cut and remove lockwire from nut (31). Remove nut (31) and shield (30) as a single unit. Remove shield (30) from
nut (31).
12. Remove support (3) and static stop (32). Remove tail rotor hub and blade assembly (29).
13. Remove cone set (27). Remove and discard packing (28) from cone set. Keep two halves of cone set together.
64-21-01
Rev. 3 Page 1
E-AB412-PT6T-2
NOTE
Accomplish steps 14. through 20. only if control linkage must be removed.
14. Remove counterweight links (20) from crosshead assembly (8) (module 64-31-01 paragraph "1. Counterweight link -
removal").
15. Remove pitch links (19) from crosshead assembly (8) (module 64-31-02 paragraph "1. Pitch control links - removal").
16. Remove tail rotor control tube (4) (module 64-31-03 paragraph "1. Control tube - removal").
17. Remove control housing (2, figure 2) (module 64-31-04 paragraph "1. Control housing - removal").
18. Remove lever (8, figure 3) (module 64-31-05 paragraph "1. Tail rotor lever - removal").
19. Remove tail rotor control link (5, figure 4) (module 64-31-06 paragraph "1. Control link - removal").
20. Remove tail rotor control idler (12, figure 5) (module 64-31-07 paragraph "1. Idler - removal").
3. TAIL ROTOR HUB AND BLADE ASSEMBLY - INSTALLATION
MATERIALS REQUIRED
NUMBER NOMENCLATURE
C-001 GREASE
C-405 LOCKWIRE
CAUTION
APPLY CORROSION PREVENTIVE COMPOUND (C-104) TO ALL BOLT

SHANKS (DO NOT APPLY TO THREADS), WASHER FAYING SURFACES
AND NUT FAYING SURFACES (DO NOT APPLY TO THREADS) PRIOR TO
INSTALLATION. AFTER FINAL INSTALLATION, COAT EXPOSED
SURFACES OF NUTS, WASHERS AND BOLTS (INCLUDING EXPOSED
THREADS) WITH CORROSION PREVENTIVE COMPOUND (C-101).
1. Apply a thin coat of corrosion preventive compound (C-104) to the inner and mating surfaces of cone set
(27, figure 1) and shaft (26). Place cone set with level outboard, in groove between splines and shoulder on shaft.
Install packing (28) on cone set with equal gaps at ends of cone set. Seat cone set in position on shaft (26).
2. Place hub and blade assembly (29) on shaft (26) with open side of pitch horns (24) outboard. Align master spline on
trunnion with master spline on shaft and press hub and blade assembly inboard to seat against cone set (27).
3. Align master spline on static stop (32) with master spline on shaft (26) and install against trunnion with flat side
outboard.
64-21-01
Page 2 Rev. 3
E-AB412-PT6T-2
4. Align tooth on support (3) with master tooth on shaft (26) and install against static stop (32) with arms angled outboard.
5. Install shield (30) on nut (31). Install nut (31) on shaft (26). Torque nut 900 in-lbs (101.70 Nm). Secure nut to support
(3) with lockwire (C-405).
6. If not previously accomplished, thread sleeve (10) onto control tube (4) with large diameter end inboard. Continue
turning until sleeve disengages from threads.
7. If not previously accomplished, assemble crosshead controls (module 64-31-08 paragraph "2. Crosshead controls -
installation").
8. Apply a thin film of grease (C-001) to splines in crosshead assembly (8). Align master splines in crosshead assembly
and shaft (26). Engage splines and press crosshead inboard carefully guiding crosshead into shield (30).
9. Clean bearing (11) thoroughly with solvent (C-304). Dry with clean dry air. Handpack bearing with grease (C-001).
CAUTION
ENSURE SPECIAL WASHER (9) SEATS AROUND LARGEST OUTSIDE

DIAMETER OF SLEEVE (10).
10. Install special washer (9) inside crosshead assembly (8), around largest outside diameter of sleeve (10). Install bearing
(11), steel washer (12), and nut (13). Torque nut (13) 70 to 100 in-lbs (7.91 to 11.30 Nm) and install cotter pin (14).
WARNING
ENSURE NUT (13) AND COTTER PIN (14) ARE PROPERLY INSTALLED IN
ACCORDANCE WITH STEP 10. PRIOR TO INSTALLATION OF RETAINER
(15).
11. Fill cavity of retainer (15) with grease (C-001) and install in crosshead assembly (8). Torque retainer 300 in-lbs
(33.90 Nm). Apply two shots of grease (C-001) to fitting with a hand held grease gun.
12. Position lock (16) over retainer (15) and secure with screws (18) and steel washers (17). Secure screws with lockwire
(C-405). Deform lock two places into retainer (15).
13. If not previously accomplished, loosen blade bolts (36). Remove assembly hardware from pitch horn (24) and slide
pitch horn out from hub and blade. Apply thin coat of corrosion preventive compound (C-101) to bushing (1), mating
surfaces of pitch horn (24), and tail rotor blade.
14. With pitch horn (24) removed, install pitch link (19) in pitch horn (24) with bolt (2), bushing (1) and barrel nut and
retainer (23). Do not torque bolt (2) at this time.
NOTE
Ensure chamfered sides of the steel washers (35) are toward head of bolts (36).
15. Position pitch horn (24) in hub and blade. Install bolts (36) with steel washers (35 and 34) and nuts (33). Torque nuts
(33) 150 in-lbs (17 Nm).
16. Torque nuts (37) 500 to 550 in-lbs (57 to 62 Nm).
17. Torque bolt (2) 135 in-lbs (15.25 Nm) and secure with lockwire (C-405).
18. Install opposite pitch link in same manner.
64-21-01
Rev. 3 Page 3
E-AB412-PT6T-2
19. Connect counterweight links (20) to support (3) with bolts (22), steel washers (21), steel washers (5), and nuts (6).
Torque nuts 60 to 110 in-lbs (6.78 to 12.43 Nm). Install cotter pins (7).
20. Perform rigging check of tail rotor (Chapter 67).
4. TAIL ROTOR HUB AND BLADE ASSEMBLY - INSPECTION
NOTE
If records or physical appearance indicate tail rotor has been involved in an accident
or incident, refer to E-AB412-PT6T-6, for conditional inspection requirements.
1. Inspect tail rotor blades (module 64-11-01 paragraph "7. Tail rotor blades - inspection").
2. Inspect retainer (15, figure 1) for damaged threads. Damage which can be detected visually is not acceptable.
3. Inspect crosshead (8) for damaged threads. Damage which can be detected visually is not acceptable.
4. Inspect bearing (11) for contamination, lack of grease, and separation of outer race. Check bearing for roughness by
feel. Rough bearings and/or bearings with loose races are not acceptable.
5. Inspect sleeve (10) for mechanical damage. Superficial scratches are acceptable.
6. Inspect special washer (9) for scratches, nicks, and distortion. Superficial scratches are acceptable.
7. Inspect shield (30) for nicks and cuts. Superficial damage is acceptable.
8. Inspect nut (31) for damaged threads. No damaged threads are acceptable.
9. For remainder of tail rotor components, refer to E-AB412-PT6T-3 manual.
5. TAIL ROTOR HUB AND BLADE ASSEMBLY - INSPECTION - STATIC STOP

(212-011-713) YIELDING
NOTE
This inspection is required by 25 Hour Special Inspection and certain Conditional
Inspections (E-AB412-PT6T-6). This inspection is also required if damaging/
excessive bending loads are suspected to have been sustained such as high wind
gusts, improper ground handling (tail rotor blade used as a hand hold), or static
ground strike that could cause yielding.
1. Gain access to tail rotor assembly using a maintenance stand or other means to allow close viewing of the trunnion
assembly. Perform visual inspection of flapping stop ears for deformation (figure 6).
a. Gently place tail rotor yoke against one static stop ear, allowing full view of the opposite stop.
b. Repeat in opposite direction to allow viewing of remaining stop.
2. If either static stop ear is deformed or bent as shown in figure 6, yoke assembly has been yielded. Both the yoke
assembly and static stop (ASB 412-96-89) are no longer serviceable and must be removed and discarded. If any doubt
exists about serviceability of these parts, contact AgustaWestland Product Support Engineering.
64-21-01
Page 4 Rev. 3
E-AB412-PT6T-2
LOCKWIRE (C-405)
4
60 TO 110 IN-LBS
1 (6.78 TO 12.43 Nm)
70 TO 100 IN-LBS
2 (7.91 TO 11.30 Nm)
300 IN-LBS (33.90 Nm)
3
135 IN-LBS (15.25 Nm)
4
1. Bushing 14. Cotter pin

2. Bolt 15. Retainer
3. Support 16. Lock
4. Control tube 17. Steel washer
5. Steel washer 18. Screw 3
6. Nut 19. Pitch link
7. Cotter pin 20. Counterweight link
8. Crosshead assembly 21. Steel washer
9. Special washer (212-010-714-3) 22. Bolt
10. Sleeve 23. Barrel nut and retainer
11. Bearing 24. Pitch horn
12. Steel washer 25. Tail rotor gearbox
13. Nut
G6AB0612B
Figure 1. Tail rotor hub and blade assembly - removal and installation (sheet 1 of 2)
64-21-01
Rev. 3 Page 5
E-AB412-PT6T-2
26
37
5
4
27
28
29 3
24
36
6
31
30
37
32
35
500 TO 550 IN-LBS

37
(57 TO 62 Nm) 34
33
900 IN-LBS 7
(101.70 Nm)
T 7
150 IN-LBS
(17 Nm)
26. Shaft
27. Cone set
28. Packing
29. Hub and blade assembly
30. Shield
31. Nut
32. Static stop
33. Nut
34. Steel washer
35. Steel washer
36. Bolt
37. Nut
NOTE:
1 Chamfered side of washer toward head of bolt.
G6AB0613C
Figure 1. Tail rotor hub and blade assembly - removal and installation (sheet 2 of 2)
64-21-01
Page 6 Rev. 3
E-AB412-PT6T-2
TORQUE
60 IN-LBS
(6.78 Nm)
2. Housing
3. Bearing
4. Excluder
5. Excluder housing
6. Retainer ring
7. Seal
8. Control tube
9. Nut
10. Steel washer
G6AB0614C
Figure 2. Tail rotor controls - control housing - removal and installation
64-21-01
Rev. 3 Page 7
E-AB412-PT6T-2
4 TORQUE 110 TO 165 IN-LBS

2
(12.43 TO 18.64 Nm)
3
7
5
6 9
10
21
12 TORQUE
60 TO 110 IN-LBS
(6.78 TO 12.43 Nm)
20
17
18
19 16
11 13
14
15
1. Tail rotor gearbox (ref)

2. Cotter pin
3. Steel washer
4. Nut
5. Control tube
6. Steel washer
7. Nut
8. Lever
9. Race
10. Cotter pin
11. Steel pin
12. Nut
13. Cotter
14. Link
15. Steel washer
16. Bolt
17. Idler
18. Steel washer
19. Bolt
20. Steel washer
21. Bolt
G6AB0615C
Figure 3. Tail rotor controls - lever - removal and installation
64-21-01
Page 8 Rev. 3
E-AB412-PT6T-2
TORQUE 60 TO 110 IN-LBS

(6.78 TO 12.43 Nm)

(6.78 TO 12.43 Nm)
1. Lever 8. Nut
2. Steel washer 9. Cotter pin
4. Cotter pin 11. Bellcrank
5. Link 12. Steel washer
6. Steel washer 13. Bolt
7. Bolt 14. Tail rotor gearbox
G6AB0616C
Figure 4. Tail rotor controls - control link - removal and installation
64-21-01
Rev. 3 Page 9
E-AB412-PT6T-2
TORQUE
110 TO 165 IN-LBS
(12.43 TO 18.64 Nm)
TORQUE
110 TO 165 IN-LBS
(12.43 TO 18.64 Nm)
TORQUE
110 TO 165 IN-LBS
(12.43 TO 18.64 Nm)

2. Cotter pin
3. Steel washer
4. Nut
5. Control tube
6. Steel washer
7. Nut
8. Cotter pin
9. Nut
10. Steel washer
11. Cotter pin
12. Idler
13. Lever
14. Race
15. Steel washer
16. Bolt
17. Steel washer
18. Bolt
19. Steel washer
20. Bolt
G6AB0617C
Figure 5. Tail rotor controls - control idler - removal and installation
64-21-01
Page 10 Rev. 3
E-AB412-PT6T-2
G6AB0618A
Figure 6. Tail rotor static stop (212-011-713) yielding
64-21-01
Rev. 3 Page 11
E-AB412-PT6T-2
6. TAIL ROTOR HUB AND BLADE ASSEMBLY - REPAIR
For repair of tail rotor components, refer to E-AB412-PT6T-3 manual.
7. TAIL ROTOR HUB AND BLADE ASSEMBLY - TROUBLESHOOTING
Potential troubles which may occur in tail rotor are listed in table 1 with probable causes indicated and corrective action
recommended.
NOTE
The following paragraphs provide information on removing, inspection, repair and
installing the hub and blade as an assembly. For separating the blades from the hub,
refer to E-AB412-PT6T-3, Chapter 64.
Table 1. Tail rotor troubleshooting
High frequency vibration. Tail rotor out of track. Check tracking of tail rotor
(Chapter 18).
Tail rotor out of balance. Check and balance tail rotor

(Chapter 18).
Loose tail rotor retaining nut. Torque retaining nut 900 in-lbs
(101.7 Nm).
Loose counterweight bellcrank reten- Replace bellcrank.

tion nuts.
Tail rotor pitch change links bent. Replace damaged links.
Worn or loose pitch change tube Replace bearing and/or wear sleeve on
bearing. tube.
90 gearbox mounting loose. Inspect gearbox mounting for loose riv-
ets or studs or elongated bolt holes.
Repair mounting.
Inability to make normal right and Faulty rigging. Rig tail rotor controls. (Chapter 67)
left turns in flight.
Controls creeping. Hydraulic cylinder in tail rotor con- Replace faulty hydraulic cylinder.
trols leaking internally.
64-21-01
Page 12 Rev. 3
E-AB412-PT6T-2
8. TAIL ROTOR HUB AND BLADE ASSEMBLY - OPERATIONAL CHECK
Operational check consists of the following:
1. Tail rotor track check by manual flag method (module 18-13-02 paragraph "3. Tail rotor hub and blade tracking and
balancing - tail rotor hub and blade flag tracking") or by Vibrex Track and Balance System (dynamic method)
(module 18-13-02 paragraph "4. Tail rotor hub and blade tracking and balancing - tail rotor tracking and balancing with
chadwick-helmuth vibrex equipment (dynamic method)").
2. Tail rotor rigging check for adequate right and left anti-torque control by flight test (Refer to E-AB412-PT6T-1 Flight
Manual).
3. Tail rotor vibration check by Vibrex Track and Balance System (dynamic method) (module 18-13-02 paragraph "4.
Tail rotor hub and blade tracking and balancing - tail rotor tracking and balancing with chadwick-helmuth vibrex
equipment (dynamic method)").
64-21-01
Rev. 3 Page 13
E-AB412-PT6T-2
64-21-01
Page 14 Rev. 3
E-AB412-PT6T-2
64-31-01
TAIL ROTOR CONTROLS - COUNTERWEIGHT LINK
1. COUNTERWEIGHT LINK - REMOVAL
1. Remove cotter pin (10, figure 1), nut (9) and steel washer (8). Remove bolt (2) and steel washer (3) to disconnect
counterweight link (11) from counterweight bellcrank (5). Loosely reinstall bolt (2), steel washers (3 and 8), and nut
(9) to prevent loss.
2. Remove cotter pin (14), nut (13) and steel washer (12). Remove bolt (7) and steel washer (6) to disconnect
counterweight link (11) from counterweight support (15). Remove counterweight link (11) from helicopter.
3. Loosely install bolt (7), steel washers (6 and 12), and nut (13) to prevent loss.
2. COUNTERWEIGHT LINK - INSTALLATION
1. Place counterweight link (11, figure 1) into counterweight support (15) and loosely install bolt (7), steel washers (6
and 12), and nut (13). Ensure head of bolt (7) is installed opposite direction of rotation.
2. Secure counterweight link (11) to counterweight bellcrank (5) with bolt (2) steel washers (3 and 8), and nut (9). Ensure
head of bolt (2) is installed opposite direction of rotation.
3. Torque nut (9) 60 to 110 in-lbs (6,78 to 12,43 Nm). Install cotter pin (10).
4. Torque nut (13) 60 to 110 in-lbs (6,78 to 12,43 Nm). Install cotter pin (14).
5. Move counterweight bellcrank (5) to check for freedom of movement.
64-31-01
Rev. 3 Page 1
E-AB412-PT6T-2
TORQUE
60 TO 110 IN-LBS
(6.78 TO 12.43 Nm)
TORQUE
60 TO 110 IN-LBS
(6.78 TO 12.43 Nm)
1. Blade assembly
2. Bolt
3. Steel washer
4. Crosshead assembly
5. Counterweight bellcrank
6. Steel washer
7. Bolt
8. Steel washer
9. Nut
10. Cotter pin
11. Counterweight link
12. Steel washer
13. Nut
14. Cotter pin
15. Counterweight support
G6AB0621B
Figure 1. Tail rotor controls - counterweight link - removal and installation
64-31-01
Page 2 Rev. 3
E-AB412-PT6T-2
64-31-02
TAIL ROTOR CONTROLS - PITCH CONTROL LINKS
1. PITCH CONTROL LINKS - REMOVAL
1. Remove cotter pin (2, figure 1), nut (3) and steel washer (4). Remove bolt (7) and steel washer (6) to disconnect pitch
link (10) from crosshead (5). Loosely install bolt (7), steel washers (6 and 4), and nut (3) to prevent loss.
2. Loosen nuts (17). Cut and remove lockwire from bolt (1). Loosen bolt (1). Remove nuts (8) and steel washers (9) from
two bolts (14). Remove two bolts (14) and steel washers (13) and slide pitch horn (11) out so bolt (1) will clear bracket
(15) on hub.
3. Remove bolt (1) and separate pitch link (10) from pitch horn (11). Remove floating bushing (16) and barrel nut and
retainer (12) from pitch horn (11).
4. Loosely reinstall bolt (1), floating bushing (16), and barrel nut and retainer (12) in pitch horn and reinstall pitch horn
(11) on hub and blade with bolts (14), steel washers (9 and 13), and nuts (8) to prevent loss.
5. Remove opposite pitch link in the same manner.
2. PITCH CONTROL LINKS - INSTALLATION
MATERIALS REQUIRED
NUMBER NOMENCLATURE
C-405 LOCKWIRE
NOTE
Helicopter that have the S.B. 412-80 incorporated, do not require tracking of the tail
rotor.
1. Adjust length of pitch control link (10, figure 1) to obtain a length between hole centers of 6.180  0.010 in
(156.972  0.254 mm). Lightly tighten jamnut on adjustable end. Refer to Chapter 18 for tail rotor tracking.
2. Remove loosely installed pitch horn (11) and attaching hardware. Apply thin coat of corrosion preventive compound
(C-101) to floating bushings (16), mating surfaces of pitch horn (11), and tail rotor blade.
NOTE
Replacement of the old link (P/N 212-011-710-001) with the new link
(P/N 212-310-701-101) requires the replacement of the T/R pitch horn
(P/N 212-011-708-001) with pitch horn (P/N 212-011-708-105). Pitch horns and
pitch links must be changed in pairs.
3. Place riveted end of pitch link (10) into pitch horn (11) and install floating bushing (16) and bolt (1). Do not torque
bolt at this time.
64-31-02
Rev. 3 Page 1
E-AB412-PT6T-2
NOTE
Ensure chamfered sides of the steel washers (13) are installed toward the head of the
bolt (14).
4. Install pitch horn (11) on hub and blade with bolts (14), steel washers (9 and 13), and nuts (8). Torque nuts (8) 150
in-lbs (16.95 Nm).
5. Torque nuts (17) 500 to 550 in-lbs (57 to 62 Nm).
6. Torque bolt (1) 135 in-lbs (15.25 Nm) and secure with lockwire (C-405).
NOTE
Ensure head of bolt (7) is installed in direction of rotation.
NOTE
Helicopters that have S.B. 412-80 incorporated, do not require tightening of the link
jamnut.
7. Place end of pitch link (10) into crosshead (5) and tighten link jamnut. Install bolt (7), steel washers (4 and 6), and nut
(3). Torque nut 110 to 165 in-lbs (12.43 to 18.64 Nm). Install cotter pin (2).
8. Install opposite pitch link in same manner.
64-31-02
Page 2 Rev. 3
E-AB412-PT6T-2
POST S.B. 412-80
NOTE:

LOCKWIRE (C-405)
110 TO 165 IN-LBS (12.43 TO 18.64 Nm)
135 IN-LBS (15.25 Nm) 1. Bolt 10. Pitch link

2. Cotter pin 11. Pitch horn
150 IN-LBS (16.95 Nm) 3. Nut 12. Barrel nut and retainer
500 TO 550 IN-LBS (52 TO 62 Nm) 4. Steel washer 13. Steel washer
5. Crosshead 14. Bolt
6. Steel washer 15. Bracket
7. Bolt 16. Floating bushing
8. Nut 17. Nut
9. Steel washer
G6AB0622C
Figure 1. Tail rotor controls - pitch control link - removal and installation
64-31-02
Rev. 3 Page 3
E-AB412-PT6T-2
64-31-02
Page 4 Rev. 3
E-AB412-PT6T-2
64-31-03
TAIL ROTOR CONTROLS - CONTROL TUBE
1. CONTROL TUBE - REMOVAL
1. Remove crosshead assembly (8, figure 1) and sleeve (10) from control tube (4) (module 64-21-01 paragraph "2. Tail
rotor hub and blade assembly - removal").
lever (5) from control tube (15). Loosely reinstall bolt (14), steel washers (12 and 13), and nut (11) to prevent loss.
3. Remove cotter pin (4), nut (3) and steel washer (6). Remove bolt (9) and steel washer (8) to disconnect lever (5) from
idler (7). Loosely reinstall bolt (9), steel washers (6 and 8), and nut (3) to prevent loss.
4. Pull control tube (15) from housing (2).
2. CONTROL TUBE - INSTALLATION
1. Thoroughly clean bearing inside housing (2, figure 2) with a clean, dry cloth. Lubricate bearing and control tube (15)
with gearbox oil (Chapter 12).
2. Install control tube (15) into tail rotor gearbox (1) while carefully guiding it through housing (2).
3. Rotate lever (5) into idler (7) and install bolt (9), steel washers (6 and 8), and nut (3). Torque nut (3) 110 to 165 in-lbs
(12,43 to 18,64 Nm) and install cotter pin (4).
4. Position lever (5) into clevis of control tube (15) and install bolt (14), steel washers (12 and 13), and nut (11). Torque
nut 110 to 165 in-lbs (12,43 to 18,64 Nm) and install cotter pin (10).
5. Install sleeve (10, figure 1) and crosshead assembly (8) onto control tube (4) (module 64-21-01 paragraph "3. Tail rotor
hub and blade assembly - installation").
64-31-03
Rev. 3 Page 1
E-AB412-PT6T-2
LOCKWIRE (C-405)
4
60 TO 110 IN-LBS
1 (6.78 TO 12.43 Nm)
70 TO 100 IN-LBS
2 (7.91 TO 11.30 Nm)
300 IN-LBS (33.90 Nm)
3
135 IN-LBS (15.25 Nm)
4
1. Bushing 14. Cotter pin

2. Bolt 15. Retainer
3. Support 16. Lock
4. Control tube 17. Steel washer
5. Steel washer 18. Screw 3
6. Nut 19. Pitch link
7. Cotter pin 20. Counterweight link
8. Crosshead assembly 21. Steel washer
9. Special washer (212-010-714-3) 22. Bolt
10. Sleeve 23. Barrel nut and retainer
11. Bearing 24. Pitch horn
12. Steel washer 25. Tail rotor gearbox
13. Nut
G6AB0612B
Figure 1. Tail rotor hub and blade assembly (sheet 1 of 2)
64-31-03
Page 2 Rev. 3
E-AB412-PT6T-2
26
37
5
4
27
28
29 3
24
36
6
31
30
37
32
35
500 TO 550 IN-LBS

37
(57 TO 62 Nm) 34
33
900 IN-LBS 7
(101.70 Nm)
T 7
150 IN-LBS
(17 Nm)
26. Shaft
27. Cone set
28. Packing
29. Hub and blade assembly
30. Shield
31. Nut
32. Static stop
33. Nut
34. Steel washer
35. Steel washer
36. Bolt
37. Nut
NOTE:
G6AB0613C
Figure 1. Tail rotor hub and blade assembly (sheet 2 of 2)
64-31-03
Rev. 3 Page 3
E-AB412-PT6T-2
TORQUE
110 TO 165 IN-LBS
(12.43 TO 18.64 Nm)
TORQUE
110 TO 165 IN-LBS
(12.43 TO 18.64 Nm)

2. Housing
3. Nut
4. Cotter pin
5. Lever
6. Steel washer
7. Idler
8. Steel washer
9. Bolt
10. Cotter pin
11. Nut
12. Steel washer
13. Steel washer
14. Bolt
15. Control tube
G6AB0623B
Figure 2. Tail rotor controls - control tube - removal and installation
64-31-03
Page 4 Rev. 3
E-AB412-PT6T-2
64-31-04
TAIL ROTOR CONTROLS - CONTROL HOUSING
1. CONTROL HOUSING - REMOVAL
NUMBER NOMENCLATURE
T27 JACKSCREW SET
1. Remove tail rotor control tube (module 64-31-03 paragraph "1. Control tube - removal").
2. Remove nuts (9, figure 1) and steel washers (10). Remove housing (2) with jackscrew set (T101308). Remove and
discard preformed packing (1).
3. Remove retainer ring (6) from housing (2).
4. Press bearing (3), excluder (4), excluder housing (5), and seal (7) out of housing (2) from inboard side. Discard seal (7).
2. CONTROL HOUSING - INSTALLATION
MATERIALS REQUIRED
NUMBER NOMENCLATURE
1. Inspect all components for wear and damage (E-AB412-PT6T-3).
2. Press bearing (3, figure 1) into housing (2).
3. Assemble excluder (4), new seal (7), and excluder housing (5) and install into housing (2) (section A-A).
4. Install retainer ring (6).
5. Lubricate new preformed packing (1) with gearbox oil (Chapter 12) and install on housing (2).
6. Apply a film of gearbox oil (Chapter 12) to inside diameter of bearing (3).
7. Apply a film of wet epoxy polyamide primer (C-204) to mating surface of flange of housing (2).
8. Install housing (2) over studs in case and install steel washers (10) and nuts (9). Alternately and evenly torque nuts 60
in-lbs (6,78 Nm).
9. Install tail rotor control tube (module 64-31-03 paragraph "2. Control tube - installation").
64-31-04
Rev. 3 Page 1
E-AB412-PT6T-2
TORQUE
60 IN-LBS
(6.78 Nm)
2. Housing
3. Bearing
4. Excluder
5. Excluder housing
6. Retainer ring
7. Seal
8. Control tube
9. Nut
10. Steel washer
G6AB0614C
Figure 1. Tail rotor controls - control housing - removal and installation
64-31-04
Page 2 Rev. 3
E-AB412-PT6T-2
64-31-05
TAIL ROTOR CONTROLS - TAIL ROTOR LEVER
1. TAIL ROTOR LEVER - REMOVAL
2. Remove cotter pin (10), nut (7) and steel washer (6). Remove bolt (19) and steel washer (18) to disconnect lever (8)
from idler (17). Loosely reinstall bolt (19), steel washers (6 and 18), and nut (7) to prevent loss.
3. Rotate lever (8) around lower end bearing to check for freedom of movement. If bearing is tight, use a spring scale to
measure force required to rotate bearing (install scale on lever upper bearing bolt (21)). If force required exceeds 10
lbs. (44,5 N), replace lever. Refer to E-AB412-PT6T-3.
from link (14). Loosely reinstall bolt (16), steel washers (11 and 15), and nut (12) to prevent loss.
5. Remove lever (8) from helicopter. Remove race (9) from lever (8).
2. TAIL ROTOR LEVER - INSTALLATION
MATERIALS REQUIRED
NUMBER NOMENCLATURE
C-001 GREASE
1. Clean race (9, figure 1) and upper end of lever (8) thoroughly with drycleaning solvent (C-304) and dry with filtered,
compressed air. Hand pack bearing and race (9) with grease (C-001). Install race (9) into bearing in lever (8).
2. Place upper end of lever (8) into control tube (5) and install bolt (21), steel washers (3 and 20), and nut (4). Torque nut
110 to 165 in-lbs (12.43 to 18.64 Nm) and install cotter pin (2).
3. Position lever (8) into idler (17) and install bolt (19), steel washers (6 and 18), and nut (7). Torque nut 110 to 165 in-lbs
(12.43 to 18.64 Nm) and install cotter pin (10).
4. Position lever (8) into link (14) and install bolt (16), steel washers (11 and 15), and nut (12). Torque nut 60 to 110 in-lbs
(6,78 to 12.43 Nm) and install cotter pin (13).
5. Move tail rotor controls through full range of travel to check for freedom of operation.
64-31-05
Rev. 3 Page 1
E-AB412-PT6T-2
4 TORQUE 110 TO 165 IN-LBS

2
(12.43 TO 18.64 Nm)
3
7
5
6 9
10
21
12 TORQUE
60 TO 110 IN-LBS
(6.78 TO 12.43 Nm)
20
17
18
19 16
11 13
14
15

2. Cotter pin
3. Steel washer
4. Nut
5. Control tube
6. Steel washer
7. Nut
8. Lever
9. Race
10. Cotter pin
11. Steel pin
12. Nut
13. Cotter
14. Link
15. Steel washer
16. Bolt
17. Idler
18. Steel washer
19. Bolt
20. Steel washer
21. Bolt
G6AB0615C
Figure 1. Tail rotor controls - lever - removal and installation
64-31-05
Page 2 Rev. 3
E-AB412-PT6T-2
64-31-06
TAIL ROTOR CONTROLS - CONTROL LINK
1. CONTROL LINK - REMOVAL
link (5) from bellcrank (11). Loosely reinstall bolt (13), steel washers (10 and 12), and nut (8) to prevent loss.
2. Remove cotter pin (4), nut (3), and steel washer (2). Remove bolt (7) and steel washer (6) to disconnect link (5) from
lever (1). Remove link from helicopter. Loosely reinstall bolt (7), steel washers (2 and 6), and nut (3) to prevent loss.
2. CONTROL LINK - INSTALLATION
1. Adjust length of link (5, figure 1) to 6,90 in. (17,53 cm) center to center of bolt holes in either end.
2. Place link (5) in position and secure to bellcrank (11) with bolt (13), steel washers (12 and 10), and nut (8). Do not
torque nut (8) at this time.
3. Secure link (5) to lever (1) with bolt (7), steel washers (6 and 2), and nut (3). Torque nut (3) 60 to 110 in-lbs (6.78 to
12.43 Nm) and install cotter pin (4).
4. Rig tail rotor controls as necessary (Chapter 67).
5. Torque nut (8) 60 to 110 in-lbs (6,78 to 12,43 Nm) and install cotter pin (9).
64-31-06
Rev. 3 Page 1
E-AB412-PT6T-2

(6.78 TO 12.43 Nm)

(6.78 TO 12.43 Nm)
1. Lever 8. Nut
2. Steel washer 9. Cotter pin
4. Cotter pin 11. Bellcrank
5. Link 12. Steel washer
7. Bolt 14. Tail rotor gearbox
G6AB0616C
Figure 1. Tail rotor controls - control link - removal and installation
64-31-06
Page 2 Rev. 3
E-AB412-PT6T-2
64-31-07
TAIL ROTOR CONTROLS - IDLER
1. IDLER - REMOVAL
1. Remove cotter pin (2, figure 1), nut (4) and steel washer (3). Remove bolt (20) and steel washer (19) and disconnect
2. Tie race (14) into upper end of lever (13) to prevent loss.
from idler (12). Loosely reinstall bolt (16), steel washers (10 and 15), and nut (9) to prevent loss.
4. Remove cotter pin (8) and nut (7). Remove bolt (18) to remove idler (12) from helicopter. Loosely reinstall bolt (18)
and nut (7) to prevent loss. The steel washers (6 and 17) should be bonded in place.
2. IDLER - INSTALLATION
MATERIALS REQUIRED
NUMBER NOMENCLATURE
C-001 GREASE
1. Bond steel washers (6 and 17, figure 1) to gearbox with sealing compound (C-328).
2. Place idler (12) in position and install bolt (18) and nut (7). Torque nut 110 to 165 in-lbs (12,43 to 18,64 Nm) and install
cotter pin (8).
3. Place lever (13) into idler (12) and install bolt (16), steel washers (15 and 10), and nut (9). Torque nut 110 to 165 in-lbs
(12.43 to 18.64 Nm) and install cotter pin (11).
4. Apply a thin film of grease (C-001) to race (14) in upper end of lever (13).
5. Place lever (13) into clevis of control tube (5) and install bolt (20), steel washers (3 and 19), and nut (4). Torque nut
110 to 165 in-lbs (12.43 to 18.64 Nm) and install cotter pin (2).
6. Move tail rotor control through full range of travel to check for freedom of movement.
64-31-07
Rev. 3 Page 1
E-AB412-PT6T-2
TORQUE
110 TO 165 IN-LBS
(12.43 TO 18.64 Nm)
TORQUE
110 TO 165 IN-LBS
(12.43 TO 18.64 Nm)
TORQUE
110 TO 165 IN-LBS
(12.43 TO 18.64 Nm)

2. Cotter pin
3. Steel washer
4. Nut
5. Control tube
6. Steel washer
7. Nut
8. Cotter pin
9. Nut
10. Steel washer
11. Cotter pin
12. Idler
13. Lever
14. Race
15. Steel washer
16. Bolt
17. Steel washer
18. Bolt
19. Steel washer
20. Bolt
G6AB0617C
Figure 1. Tail rotor controls - control idler - removal and installation
64-31-07
Page 2 Rev. 3
E-AB412-PT6T-2
64-31-08
TAIL ROTOR CONTROLS - CROSSHEAD CONTROLS
1. CROSSHEAD CONTROLS - REMOVAL
1. Remove cotter pin (4, figure 1), nut (5) and steel washer (6). Remove bolt (15) and steel washer (12) and remove
counterweight link (10) from counterweight bellcrank (11). Remove opposite link in same manner.
2. Remove cotter pin (22), nut (21) and steel washer (20). Remove bolt (14) and steel washer (16) and remove pitch
control link (18) from crosshead (23). Remove opposite link in same manner.
3. Remove cotter pin (7), nut (8), and special washer (9) and pull counterweight bellcrank (11) from crosshead (23).
Remove opposite bellcrank in same manner. Secure special washer (17) to prevent loss. Discard the nuts.
4. Remove nut (3), steel washer (2), and bolt (13) and remove counterweights (1) from counterweight bellcrank (11).
Remove opposite weights in same manner.
2. CROSSHEAD CONTROLS - INSTALLATION
1. Install two counterweights (1, figure 1) on one end of counterweight bellcrank (11) and secure with bolt (13), steel
washer (2), and nut (3). Torque nut 60 in-lbs (6,78 Nm). Install two counterweights (1) on opposite end of bellcrank
(11) in same manner. Assemble counterweights on bellcrank on opposite side of crosshead in same manner.
CAUTION
COUNTERWEIGHT BELLCRANK RETENTION NUTS, P/N MS14145L6 OR

ITS EQUIVALENT MS17826-6 ARE DESIGNATED AS ONE TIME USE ONLY.
IF MAINTENANCE ACTION REQUIRES THAT IT BE REMOVED, THE
COUNTERWEIGHT BELLCRANK NUT IS TO BE DISCARDED AND
REPLACED WITH A NEW NUT. OVERTORQUING OR INCORRECT
APPLICATION OF THE NUT COULD CASE MECHANICAL FAILURE
RESULTING IN EXCESSIVE VIBRATION AND OR DAMAGE TO THE TAIL
ROTOR BLADES.
2. Install special washer (17), counterweight bellcrank (11), special washer (9), and nut (8) on crosshead (23). Torque
nuts 100 to 170 in-lbs (11,30 to 19,21 Nm) and install cotter pin (7). Install opposite bellcrank in same manner.
3. Position counterweight bellcrank (11) with mounting lugs for counterweight links (10) opposite direction of rotation
(trailing studs).
4. Place counterweight link (10) into lugs of counterweight bellcranks (11) and install bolt (15), steel washers (12 and 6),
and nuts (5). Torque nuts 60 to 110 in-lbs (6,78 to 12,43 Nm) and install cotter pin (4). Install opposite counterweight
link (10) in same manner.
5. Place one end of pitch control link (18) into crosshead (23). Install bolt (14), steel washers (16 and 20), and nut (21).
Torque nut 110 to 165 in-lbs (12,43 to 18,64 Nm) and install cotter pin (22). Install opposite pitch control link (18) in
same manner.
6. Check all bearings for freedom of movement.
64-31-08
Rev. 3 Page 1
E-AB412-PT6T-2
TORQUE
60 IN-LBS
(6.78 Nm)
TORQUE
60 TO 110
IN-LBS TORQUE
(6.78 TO 100 TO 170 IN-LBS
12.43 Nm) (11.30 TO 19.21 Nm)
POST S.B. 412-80
TORQUE
110 TO
165 IN-LBS
(12.43 TO 18.64 Nm)
1. Counterweights 13. Bolt

3. Nut 15. Bolt
4. Cotter pin 16. Steel washer
5. Nut 17. Special washer
6. Steel washer 18. Pitch control link
7. Cotter pin 19. Rivet
9. Special washer 21. Nut
10. Counterweight link 22. Cotter pin
11. Counterweight bellcrank 23. Crosshead
12. Steel washer
G6AB0624B
Figure 1. Tail rotor crosshead controls - removal and installation
64-31-08
Page 2 Rev. 3
E-AB412-PT6T-2
CHAPTER 65 - TAIL ROTOR DRIVE

Module Page
Number Title Number
65-00-00 TAIL ROTOR DRIVE
1. Tail rotor drive - general ......................................................................................................................... 1
65-11-01 TAIL ROTOR DRIVESHAFT [A] [B] [C]
1. Tail rotor driveshaft - description ........................................................................................................... 1

2. Tail rotor driveshaft - removal ................................................................................................................ 1
3. Tail rotor driveshaft - installation ........................................................................................................... 2
4. Tail rotor driveshaft - troubleshooting .................................................................................................... 6
5. Tail rotor driveshaft - cleaning ................................................................................................................ 7
6. Tail rotor driveshaft - inspection ............................................................................................................ 7
7. Tail rotor driveshaft - repair .................................................................................................................... 7
65-11-02 DRIVESHAFT HANGER ASSEMBLIES [A] [B] [C]
1. Driveshaft hanger assemblies - description ............................................................................................ 1

2. Driveshaft hanger assemblies - removal ................................................................................................. 1
3. Driveshaft hanger assemblies - installation ............................................................................................ 1
4. Driveshaft hanger assemblies - cleaning ................................................................................................ 2
5. Driveshaft hanger assemblies - inspection .............................................................................................. 5
6. Driveshaft hanger assemblies - lubrication ............................................................................................. 8
65-12-01 TAIL ROTOR DRIVESHAFTS AND HANGERS [D]
1. Tail rotor driveshafts and hanger - description ....................................................................................... 1

2. Tail rotor driveshafts and hanger - removal ............................................................................................ 1
3. Tail rotor driveshafts and hanger - installation ....................................................................................... 9
4. Tail rotor driveshafts and hanger - alignment ....................................................................................... 14
5. Tail rotor driveshafts and hanger - cleaning .......................................................................................... 16
6. Tail rotor driveshafts and hanger - inspection ...................................................................................... 16
7. Tail rotor driveshafts and hanger - repair ............................................................................................. 17
8. Tail rotor driveshafts and hanger - lubrication ..................................................................................... 17
65-13-01 TAIL ROTOR DRIVE SYSTEM - ALIGNMENT
1. Alignment - description .......................................................................................................................... 1

2. Alignment - procedure ............................................................................................................................ 1
65-21-01 INTERMEDIATE GEARBOX
1. Intermediate gearbox - description ......................................................................................................... 1

2. Intermediate gearbox - removal .............................................................................................................. 1
3. Intermediate gearbox - installation ......................................................................................................... 2
4. Intermediate gearbox - troubleshooting .................................................................................................. 5
5. Intermediate gearbox - inspection (installed) ......................................................................................... 5
6. Intermediate gearbox - cleaning ............................................................................................................. 6
7. Intermediate gearbox - inspection (not installed) ................................................................................... 6
8. Intermediate gearbox - inspection (conditional) ..................................................................................... 6
65-Index
Rev. 3 Page 1
E-AB412-PT6T-2

Module Page
Number Title Number
9. Intermediate gearbox - repair ..................................................................................................................6

10. Intermediate gearbox - alternate run-in test ............................................................................................7
65-21-02 INTERMEDIATE GEARBOX - SIGHT GLASS
1. Sight glass - removal ...............................................................................................................................1

2. Sight glass - installation ..........................................................................................................................1
65-21-03 INTERMEDIATE GEARBOX - ELECTRICAL CHIP DETECTOR
1. Electrical chip detector - removal ...........................................................................................................1

2. Electrical chip detector - installation .......................................................................................................1
3. Electrical chip detector - cleaning ...........................................................................................................2
4. Electrical chip detector - inspection ........................................................................................................2
5. Electrical chip detector - repair ...............................................................................................................2
65-21-04 INTERMEDIATE GEARBOX - OIL FILLER CAP
1. Oil filler cap - removal ............................................................................................................................1

2. Oil filler cap - installation .......................................................................................................................1
3. Oil filler cap - inspection .........................................................................................................................1
4. Oil filler cap - repair ................................................................................................................................1
65-21-05 INTERMEDIATE GEARBOX - FLEXIBLE COUPLINGS (P/N 212-040-004)
1. Flexible couplings (P/N 212-040-004) - inspection and lubrication .......................................................1
1. Flexible couplings (P/N 412-040-006) - lubrication ...............................................................................1
65-22-01 TAIL ROTOR GEARBOX [A] [B] [C]
1. Tail rotor gearbox - description ...............................................................................................................1

2. Tail rotor gearbox - removal ...................................................................................................................1
3. Tail rotor gearbox - installation ...............................................................................................................2
4. Tail rotor gearbox - troubleshooting ........................................................................................................4
5. Tail rotor gearbox - inspection (installed)................................................................................................7
6. Tail rotor gearbox - cleaning ...................................................................................................................7
7. Tail rotor gearbox - inspection (not installed) .........................................................................................7
8. Tail rotor gearbox - inspection (conditional) ..........................................................................................8
9. Tail rotor gearbox - repair .......................................................................................................................8
10. Tail rotor gearbox - alternate run-in test .................................................................................................8
65-22-02 TAIL ROTOR GEARBOX [D]
1. Tail rotor gearbox - description ...............................................................................................................1

2. Tail rotor gearbox - removal ...................................................................................................................1
3. Tail rotor gearbox - installation ...............................................................................................................2
4. Tail rotor gearbox - troubleshooting .......................................................................................................4
5. Tail rotor gearbox - inspection (installed)................................................................................................7
6. Tail rotor gearbox - cleaning ...................................................................................................................7
7. Tail rotor gearbox - inspection (not installed) .........................................................................................7
65-Index
Page 2 Rev. 3
E-AB412-PT6T-2

Module Page
Number Title Number
8. Tail rotor gearbox - inspection (conditional) .......................................................................................... 8

9. Tail rotor gearbox - repair ....................................................................................................................... 8
10. Tail rotor gearbox - alternate run-in test ................................................................................................. 8
65-22-03 TAIL ROTOR GEARBOX - SIGHT GLASS
1. Sight glass - removal ............................................................................................................................... 1

2. Sight glass - installation .......................................................................................................................... 1
65-22-04 TAIL ROTOR GEARBOX - ELECTRICAL CHIP DETECTOR
1. Electrical chip detector - removal ........................................................................................................... 1

2. Electrical chip detector - installation ...................................................................................................... 1
3. Electrical chip detector - cleaning .......................................................................................................... 2
4. Electrical chip detector - inspection ........................................................................................................ 2
5. Electrical chip detector - repair ............................................................................................................... 2
65-22-05 TAIL ROTOR GEARBOX - OIL FILLER CAP
1. Oil filler cap - removal ............................................................................................................................ 1

2. Oil filler cap - installation ....................................................................................................................... 1
3. Oil filler cap - inspection ........................................................................................................................ 1
4. Oil filler cap - repair ............................................................................................................................... 1
65-22-06 TAIL ROTOR GEARBOX - FLEXIBLE COUPLINGS
1. Flexible couplings - lubrication .............................................................................................................. 1
65-Index
Rev. 3 Page 3
E-AB412-PT6T-2
FIGURES
Figure Page
Number Title Number
Figure 1. Tail rotor driveshaft [A] [B] [C] (sheet 1 of 2) ...............................................................................................4

Figure 2. Tail rotor driveshaft - damage limits...............................................................................................................9
Figure 3. Tail rotor driveshaft - corrosion damage limits (sheet 1 of 2) ......................................................................10
Figure 4. Drive system..................................................................................................................................................12
Figure 1. Tail rotor driveshaft hanger [A] [B] [C] (sheet 1 of 2) ...................................................................................3
Figure 2. Tail rotor driveshaft hanger assembly.............................................................................................................7
Figure 1. Tail rotor driveshaft [D] (sheet 1 of 5)............................................................................................................4

Figure 2. Disc pack assembly wear limits (412-340-610-101) ....................................................................................19
Figure 3. Tail rotor driveshaft - damage limits.............................................................................................................20
Figure 1. Tail rotor driveshaft alignment (sheet 1 of 2) .................................................................................................3
Figure 1. Intermediate gearbox.......................................................................................................................................4
Figure 1. Intermediate gearbox sight glass.....................................................................................................................2
Figure 1. Intermediate gearbox electrical chip detector .................................................................................................3

Figure 2. Intermediate gearbox chip detector (P/N B3703) - damage limits .................................................................4
Figure 1. Intermediate gearbox oil filler cap ..................................................................................................................2
Figure 1. Intermediate gearbox flexible couplings (P/N 212-040-004) .........................................................................3

Figure 2. Workaid for lubrication of tail rotor drive couplings......................................................................................4
Figure 1. Intermediate gearbox flexible coupling (P/N 412-040-006)...........................................................................3
Figure 1. Tail rotor gearbox............................................................................................................................................5

Figure 2. Tail rotor gearbox pusher T23-1 (T101264-103) - tool application ...............................................................6
65-Index
Page 4 Rev. 3
E-AB412-PT6T-2
FIGURES (CONT.D)
Figure Page
Number Title Number
65-22-02 TAIL ROTOR GEARBOX [D]
Figure 1. Tail rotor gearbox ........................................................................................................................................... 5

Figure 2. Tail rotor gearbox pusher T23-1 (T101264-103) - tool application ............................................................... 6
65-22-03 TAIL ROTOR GEARBOX - SIGHT GLASS
Figure 1. Tail rotor gearbox sight glass ......................................................................................................................... 2
65-22-04 TAIL ROTOR GEARBOX - ELECTRICAL CHIP DETECTOR
Figure 1. Tail rotor gearbox electrical chip detector...................................................................................................... 3

Figure 2. Tail rotor gearbox electrical chip detector - damage limits............................................................................ 4
65-22-05 TAIL ROTOR GEARBOX - OIL FILLER CAP
Figure 1. Tail rotor gearbox oil filler cap....................................................................................................................... 3
65-22-06 TAIL ROTOR GEARBOX - FLEXIBLE COUPLINGS
Figure 1. Tail rotor gearbox flexible coupling ............................................................................................................... 3

Figure 2. Workaid for lubrication of tail rotor drive couplings ..................................................................................... 4
65-Index
Rev. 3 Page 5
E-AB412-PT6T-2
TABLES
Table Page
Number Title Number
Table 1. Tail rotor driveshaft - troubleshooting ............................................................................................................6
Table 1. Tail rotor driveshaft TEMP-PLATE condition and correction action ............................................................6
Table 1. Intermediate gearbox - troubleshooting .........................................................................................................5
Table 1. Tail rotor gearbox - troubleshooting ...............................................................................................................4
65-Index
Page 6 Rev. 3
E-AB412-PT6T-2
65-0 -0 TAIL ROTOR DRIVE
65-00-00
TAIL ROTOR DRIVE
1. TAIL ROTOR DRIVE - GENERAL
This chapter contains maintenance information on tail rotor driveshafts, couplings and hanger assemblies, intermediate
gearbox, and tail rotor gearbox.
65-00-00
Page 1
E-AB412-PT6T-2
65-00-00
Page 2
E-AB412-PT6T-2
65-1 -01 TAIL ROTOR DRIVESHAFT [A] [B] [C]
65-11-01
TAIL ROTOR DRIVESHAFT [A] [B] [C]
1. TAIL ROTOR DRIVESHAFT - DESCRIPTION
The tail rotor driveshaft sections are identical except that driveshaft (6, figure 4) is shorter than the other five driveshafts.
Each section of driveshaft is made from an anodized aluminium alloy tube with a coupling riveted to each end of the
driveshaft. The driveshaft are balanced by metal strips bonded to the driveshaft. Hinged covers with turn-lock fasteners
provided access to the driveshaft.
2. TAIL ROTOR DRIVESHAFT - REMOVAL
NOTE
The removal procedure for driveshaft (6, figure 1) is given. The removal procedure
for remaining tail rotor driveshafts is the same except for access provisions and
component removal. Following is required access/component removal for each
driveshaft on figure 1.
Driveshaft access/component removal.
1. To access driveshaft (2), proceed as follows:
a. Remove oil cooler fairing.
b. Open reduction gearbox side cowling.
c. Remove left and right access doors on pylon support.
d. Open hinged cover for driveshaft (4).
e. Remove driveshafts (3 and 4) (refer to step 7.) and hanger bearing (5) between driveshafts (2 and 3)
(module 65-11-02 paragraph "1. Driveshaft hanger assemblies - description").
b. Open reduction gearbox side cowling.
c. Open hinged cover for driveshaft (4).
b. Open hinged cover for driveshaft (4).
a. Open hinged cover for driveshaft (7).
b. Remove cowling from intermediate gearbox (11).
65-11-01
Rev. 2 Page 1
E-AB412-PT6T-2
a. Remove cowling from intermediate gearbox (11).
b. Open vertical fin cover (8).
6. Open hinged covers to provide access to driveshaft (6).
CAUTION
DO NOT INTERMIX PARTS OF CLAMP SETS.
DO NOT DISPLACE EITHER END OF DRIVESHAFT UNTIL BOTH CLAMPS

ARE REMOVED. FAILURE TO COMPLY MAY RESULT IN DAMAGE TO
DRIVESHAFT HANGER BEARING AND/OR CURVIC COUPLINGS.
7. Remove nuts (15) and bolts (22). Remove clamp set (16). Reassemble clamp set to prevent intermixing of parts.
8. Remove nuts (17) and bolts (21). Remove clamp set (18). Reassemble clamp set to prevent intermixing parts.
9. Push flexible coupling (19) aft to disengage driveshaft (6) and remove driveshaft.
3. TAIL ROTOR DRIVESHAFT - INSTALLATION
NOTE
Installation procedure for driveshaft (6, figure 1) is given. Installation procedures for
remaining driveshafts are the same except for access and component removal
provisions given for each driveshaft in note in paragraph "2. Tail rotor driveshaft -
removal".
CAUTION
CLAMP SETS ARE MATCHED HALVES. IF IT IS NECESSARY TO REPLACE

A CLAMP HALF, MATCH WITH ONE OF EQUAL WEIGHT WITHIN ONE
GRAM.
1. Position driveshaft (6, figure 1) between hanger assembly (14) and hanger assembly (20) with teeth meshed on each
end.
2. Install clamp set (16) with heads of bolts (22) in direction of rotation. Do not torque nuts (15) at this time.
3. Install clamp set (18) indexed 90° to clamp set (16) with head of bolts (21) in direction of rotation. Do not torque nuts
(17) at this time.
4. Adjust clamp sets (halves) (16 and 18) to obtain equal gaps at both ends within 0.030 in (0.762 mm).
5. Torque nuts (17) evenly 30 to 35 in-lbs (3.39 to 3.95 Nm) in sequence (view A, figure 1). Tap lightly around outside
of clamp set (18) with a plastic mallet and re-torque nuts (17).
6. Torque nuts (15) evenly 30 to 35 in-lbs (3.39 to 3.95 Nm) in sequence (view A, figure 1). Tap lightly around outside
of clamp set (16) with a plastic mallet and re-torque nuts (15).
65-11-01
Page 2 Rev. 2
E-AB412-PT6T-2
7. Close driveshaft hinged cover.
8. Install components and access doors or panels removed to facilitate removal of driveshaft other than driveshaft (6)
(paragraph "2. Tail rotor driveshaft - removal").
65-11-01
Rev. 2 Page 3
E-AB412-PT6T-2
1. Tail rotor drive quill (ref)

2. Driveshaft (204-040-620-11)
3. Driveshaft (204-040-620-9)
4. Driveshaft (204-040-620-11)
5. Hanger bearing
6. Driveshaft (204-040-620-11)
7. Driveshaft (204-040-620-11)
8. Vertical fin cover
9. Driveshaft (204-040-620-11)
12. Hanger bearing support (ref)
NOTES:
1 Location of visual over-temperature indicator stripes and “TEMP-PLATES”.
2 Torque clamp set nuts 30 to 35 in-pound (3.39 to 3.95 Nm) above nut friction.
3 Adjust clamp set halves to obtain equal gap on each side within 0.030 in (0.762 mm).
G6AB0509B
Figure 1. Tail rotor driveshaft [A] [B] [C] (sheet 1 of 2)
65-11-01
Page 4 Rev. 2
E-AB412-PT6T-2
13. Bolt
14. Hanger assembly
15. Nut
16. Clamp set
17. Nut
18. Clamp set
19. Flexible coupling
20. Hanger assembly
21. Bolt
G6AB0510B
Figure 1. Tail rotor driveshaft [A] [B] [C] (sheet 2 of 2)
65-11-01
Rev. 2 Page 5
E-AB412-PT6T-2
4. TAIL ROTOR DRIVESHAFT - TROUBLESHOOTING
Refer to table 1.
Table 1. Tail rotor driveshaft - troubleshooting
Vibration believed to be originating Bolts in V-band couplings loose. Inspect all V-band clamps for loose
in tail rotor drive system. bolts.
Replace or torque bolts as required.
Broken hanger or hanger support. Inspect hangers and supports for

cracks. Replace defective parts.
Tail rotor driveshaft out of balance. Verify driveshaft balance weights are
secure. Balance weights are small
metal strips bonded to driveshaft
(one empty bonded space should be
open where a test strip was
removed). If more than one space is
open, a balance weight is missing.
Replace driveshaft.
Shaft hanger bearings rough or over- Check visually for signs of over-
heating. heated bearings. If no sign of over-
heating is noted, recheck after five
hours of operation.
Replace bearings if overheating.

Replace bearings, if rough, whether
or not evidence of overheating is
present.
Excessive loss of grease from Misalignment of bearing in hangers. Check and correct alignment of bear-
hanger bearings. ings.
Binding or roughness when rotor Dry or faulty hanger bearings. Lubricate bearings.
and tail rotor driveshaft is turned by
hand.
Remove driveshaft segments, if nec-

essary, to reidentify faulty bear-
ing(s).
Faulty tail rotor gearbox. Inspect electric chip detectors in

intermediate and tail rotor gear-
boxes for evidence of internal fail-
ure. Replace faulty gearbox.
65-11-01
Page 6 Rev. 2
E-AB412-PT6T-2
5. TAIL ROTOR DRIVESHAFT - CLEANING
MATERIALS REQUIRED
NUMBER NOMENCLATURE
C-304 SOLVENT
NOTE
Do not allow solvent to enter driveshaft.
1. Clean driveshafts with clean cloth damp with solvent (C-304).
6. TAIL ROTOR DRIVESHAFT - INSPECTION
1. Inspect driveshafts in accordance with figure 2 and figure 3.
2. Inspect clamp sets for cracks, worn bolt holes, and distortion. Damage which can be detected visually is not acceptable.
3. Inspect clamp sets for gouges or wear pattern extending into fillet radius at bottom of internal groove. Damage which
can be detected visually is not acceptable.
4. Inspect clamp sets for mechanical damage on spot face, lug fillets, and internal groove. Damage not exceeding 0.008 in
(0.203 mm) is acceptable without repair. Damage exceeding this limit is not acceptable and shall be repaired or part
replaced. Inspect remaining surfaces of clamp set for mechanical damage. Damage not exceeding 0.010 in (0.254 mm)
is acceptable without repair. Damage exceeding this limit is not acceptable and clamp set shall be repaired or replaced.
7. TAIL ROTOR DRIVESHAFT - REPAIR
MATERIALS REQUIRED
NUMBER NOMENCLATURE
C-202 PRIMER
CAUTION
DO NOT USE GRINDING WHEEL TO POLISH OUT DAMAGE.
DRIVESHAFT MUST BE CHECKED FOR BALANCE IF REWORKED AREA

IS 8.0 SQ-IN (51.6 SQ-CM) MORE ON ONE SIDE THAN THE OTHER.
65-11-01
Rev. 2 Page 7
E-AB412-PT6T-2
NOTE
Repair instructions for tail rotor driveshaft assemblies in this chapter are restricted to
polishing out mechanical or corrosion damage.
1. Polish out mechanical and corrosion damage on driveshaft assemblies within limits shown (figure 2). Use 400 to 600
grit abrasive cloth or paper (C-423).
2. Make radius in rework areas 0.50 in (12.7 mm) or greater. Surface finish shall be 32 RMS or better. When rework is
complete, verify damage limits have not been exceeded (figure 2).
3. Treat repaired areas with chemical film material (C-100).
4. Apply one coat of primer (C-202).
5. Touch up paint to match existing finish (refer to Appendix I).
65-11-01
Page 8 Rev. 2
E-AB412-PT6T-2
AREA A AREA B

AFTER POLISHING OUT
CRACKS ALLOWED See note 6 See note 6
NICKS AND SCRATCHES 0.008 in (0.203 mm) 0.012 in (0.305 mm)
SHARP DENTS 0.010 in (0.254 mm) 0.015 in (0.381 mm)
NONSHARP DENTS 0.020 in (0.508 mm) 0.030 in (0.762 mm)
NOTES:
1. Damage defined on the chart above is acceptable if repaired as follows:

a. Damage is polished out with a fine abrasive cloth with minimum radius of 0.5 in (12.7 mm) and with surface finish of 32
RMS or better.
b. Maximum depth after rework does not exceed limits shown in chart.
c. Reworked area is treated for corrosion preventive.
d. If rework area is 8.0 sq-in more on one side than the other, shaft balance must be checked.
2. Loss of one or more balance weights is cause to replace driveshaft. One empty bonding space should be open where bond test
coupon was removed. If more than one empty space is observed, replace the driveshaft.
3. Damaged curvic coupling splines that result in radial play and/or backlash between assembled couplings when fully meshed
without clamps are not acceptable.
4. Grooves worn on shaft coupling by clamp to extent that wear prevents proper clamping are cause to replace driveshaft.
5. If tail rotor driveshaft distortion is suspected, support driveshaft on “V” blocks and measure run out. Maximum acceptable total
indicator reading on long shafts is 0.050 in (1.27 mm). Maximum acceptable total indicator reading on short shaft is 0.020 in
(0.508 mm). Do not attempt to straighten driveshaft.
6. Any crack in a driveshaft is cause to replace the affected driveshaft except cracks in rivet heads are acceptable if they do not
exceed the following limits:
a. Cracks are approximately radial when viewing top of shop head.
b. No cracks extends into an area with a diameter less than 1.25 diameters of rivet shank.
c. Cracks do not intersect.
d. The minimum distance between cracks is less than one shank diameter.
e. A maximum of three such cracks.
f. Crack width does not exceed 0.06 in (1.52 mm) times rivet shank diameter.
g. Maximum or ten percent of rivet shop heads may have cracks within above limits.
G6AB0511B
Figure 2. Tail rotor driveshaft - damage limits
65-11-01
Rev. 2 Page 9
E-AB412-PT6T-2
G6AB1035A
Figure 3. Tail rotor driveshaft - corrosion damage limits (sheet 1 of 2)
65-11-01
Page 10 Rev. 2
E-AB412-PT6T-2
REF INSPECTION
No. CHARACTERISTIC LIMIT
LTR METHOD
1. A, B Corrosion damage Visual/measure 0.005 in (0.13 mm) maximum depth and 1.0 sq-in
(645 mm²) maximum area or 0.90 in (22.8 mm)
wide for 1/4 of circumference.
2. A, B Corrosion damage Visual/measure 0.002 in (0.05 mm) maximum depth and 0.25 in
(6.3 mm) wide for a full circumference.
3. C, D, E, F Corrosion damage Visual/measure 0.012 in (0.30 mm) maximum depth for 25% of
any 1.0 sq-in (645 mm²) and 25% of any surfaces. 1
4. G Corrosion damage Visual/measure 0.005 in (0.13 mm) maximum depth for 20% of
any 1.0 sq-in (645 mm²) and 10% of any surfaces. 2
5. H, I, J, K, N, O Corrosion damage Visual None permitted.

6. L Corrosion damage on Visual/measure 0.012 in (0.30 mm) maximum depth for 10% of
curvic tooth top and any surfaces. 3
bottom lands
7. M Corrosion damage on Visual None permitted.
curvic tooth working
faces and fillets
NOTES:
1 No corrosion allowed within 0.20 in (5.1 mm) of rivets or mounting holes.
2 No corrosion allowed within 0.20 in (5.1 mm) of mounting holes or mounting diameter.
3 No corrosion or repair allowed within 0.030 in (0.76 mm) of the curvic tooth fillets area.
4 All dimensions, wear, and damage limits provided are limits required after repair except where indicated.
Figure 3. Tail rotor driveshaft - corrosion damage limits (sheet 2 of 2)
65-11-01
Rev. 2 Page 11
E-AB412-PT6T-2
MAIN ROTOR HUB
ENGINE
1. Mast assembly
2. Transmission
3. Input quill
4. Engine to transmission driveshaft
6. Tail rotor driveshaft (short section)
13. Hanger assembly
14. Hanger assembly
15. Hanger assembly
16. Hanger assembly
17. Tail rotor drive quill
18. Hydraulic pump and tachometer (system 1)
19. Cover
20. Hydraulic pump drive quill (system 2)
G6AB0823B
Figure 4. Drive system
65-11-01
Page 12 Rev. 2
E-AB412-PT6T-2
65-1 -02 DRIVESHAFT HANGER ASSEMBLIES [A] [B] [C]
65-11-02
DRIVESHAFT HANGER ASSEMBLIES [A] [B] [C]
1. DRIVESHAFT HANGER ASSEMBLIES - DESCRIPTION
The tail rotor driveshaft hangers are mounted on three supports on the tailboom and one support on the engine deck. Each
consists of a flexible crowned tooth coupling and a non-flexible coupling attached on a splined shaft mounted trough a sealed
single-row bearing in a ring shaped hanger. The hanger has two support lugs that are used to attach the hanger to the supports.
The supports are aligned by use of shims, located under the hanger supports.
2. DRIVESHAFT HANGER ASSEMBLIES - REMOVAL
CAUTION
DO NOT DISPLACE EITHER END OF DRIVESHAFT FROM MATING

COUPLING UNLESS CLAMP SET IS REMOVED FROM BOTH ENDS OF
DRIVESHAFT. FAILURE TO COMPLY MAY RESULT IN DAMAGE TO
HANGER BEARING AND/OR CURVIC COUPLING.
1. Remove tail rotor driveshaft sections from each end of driveshaft hanger to be removed (module 65-11-01
paragraph "2. Tail rotor driveshaft - removal").
2. Remove two bolts (12, figure 1), washers (13, 14, 15, and 17), and nuts (18). Remove hanger assembly (2) from
support (10).
3. Remove two bolts (19) and washers (20). Remove hanger assembly (3) from fitting (9).
4. Remove two bolts (22), washers (23, 24, and 25), and nuts (26). Remove hanger assembly (4) from fitting (8).
5. Remove hanger assembly (5) from fitting (7) same as previous step.
3. DRIVESHAFT HANGER ASSEMBLIES - INSTALLATION
1. Position hanger assembly (2, figure 1) on support (10) with flexible coupling (11) forward. Install washers (14 and 15)
between support (10) and brace assembly (16) on each side. Install bolts (12) with washers (13) through hanger
assembly (2), support (10), and brace assembly (16). Install washers (17) and nuts (18).
CAUTION
VERIFY BOLTS (19) FOR PROPER LENGTH. BOLTS THAT ARE TOO LONG
COULD RESULT IN IMPROPER TORQUE APPLICATION.
2. Position hanger assembly (3) on fitting (9) with flexible coupling (11) forward. Ensure barrel nuts (21) are aligned on
each side. Install two bolts (19) and thin steel washers (20).
65-11-02
Rev. 3 Page 1
E-AB412-PT6T-2
NOTE
Use additional thin steel washers (23) if necessary to obtain proper bolt thread
engagement when installing hanger assembly (4 or 5).
3. Position hanger assembly (4) on fitting (8) with flexible coupling (11) forward. Install bolts (22) and thin steel washers
(23) through hanger assembly (4) and fittings (8). Install aluminium washer (24) next to fitting (8), thin steel washer
(25), and nut (26).
4. Install hanger assembly (5) on fitting (7) using procedures in previous step.
5. Install tail rotor driveshafts (module 65-11-01 paragraph "3. Tail rotor driveshaft - installation").
6. Operate helicopter for 5 minutes at 100% (E-AB412-PT6T-1).
7. Shut down engine and inspect coupling and surrounding structure for evidence of grease leakage. If there is any
evidence of grease leakage, remove hanger assembly and replace defective part(s).
8. Inspect hangers assemblies (2, 3, 4, and 5) exterior surfaces for discoloration and overheat condition. A change in color
indicates a possible overheat condition and/or component degradation. The cause of exterior surface discoloration
shall be determined and corrected prior to continued operation (E-AB412-PT6T-3, Chapter 65).
9. Inspect flexible couplings (11) overtemperature indicators (TEMP-PLATES) for discoloration and overheat condition.
Refer to paragraph "5. Driveshaft hanger assemblies - inspection".
4. DRIVESHAFT HANGER ASSEMBLIES - CLEANING
MATERIALS REQUIRED
NUMBER NOMENCLATURE
C-304 SOLVENT
CAUTION
DO NOT IMMERSE HANGER BEARING ASSEMBLIES IN SOLVENT. DO

NOT ALLOW SOLVENT TO CONTACT INTERNAL SURFACES OF HANGER
ASSEMBLIES.
Clean external surfaces of hanger assemblies with clean cloth damp with solvent (C-304).
65-11-02
Page 2 Rev. 3
E-AB412-PT6T-2
1. Drive quill (transmission) (ref) 9. Fitting 18. Nut

2. Hanger assembly 10. Support 19. Bolt
3. Hanger assembly 11. Flexible coupling 20. Thin steel washer
4. Hanger assembly 12. Bolt 21. Barrel nut
5. Hanger assembly 13. Steel washer 22. Bolt
6. Intermediate gearbox 14. Aluminum washer 23. Thin steel washer
assembly (ref) 15. Steel washer 24. Aluminum washer
7. Fitting 16. Brace assembly 25. Thin steel washer
8. Fitting 17. Steel washer 26. Nut
G6AB0513B
Figure 1. Tail rotor driveshaft hanger [A] [B] [C] (sheet 1 of 2)
65-11-02
Rev. 3 Page 3
E-AB412-PT6T-2
G6AB0514A
Figure 1. Tail rotor driveshaft hanger [A] [B] [C] (sheet 2 of 2)
65-11-02
Page 4 Rev. 3
E-AB412-PT6T-2
5. DRIVESHAFT HANGER ASSEMBLIES - INSPECTION
MATERIALS REQUIRED
NUMBER NOMENCLATURE
C-464 INDIA STONE
1. Inspect installed tail rotor driveshaft hanger assemblies for cracks, elongated bolt holes, or other visible damage.
NOTE
Procedures for hanger assembly (6, figure 2) are typical for all hanger assemblies.
2. Inspect hanger assembly (6) exterior surfaces for discoloration and overheat condition. A change in color indicates a
possible overheat condition and/or component degradation. The cause of exterior surface discoloration shall be
determined and corrected prior to continued operation (E-AB412-PT6T-3, Chapter 65).
3. Inspect non-flexible couplings (9) for nicks, dents, and cracks. Minor damage which can be polished out with fine India
stone (C-464) is acceptable.
4. Inspect outer coupling (3) for nicks, dents, and cracks. Minor damage which can be polished out with fine India stone
(C-464) is acceptable. Inspect outer coupling (3) overtemperature indicators TEMP-PLATES (10) for discoloration
and overheat condition. Perform a serviceability check as follows:
a. Overtemperature indicators TEMP-PLATES (10) must not show evidence of overtemperature, deterioration,
debonding, or discoloration of the epoxy coating that prevents interpretation of the indicating dots. If any of
these conditions exist, proceed to step b.
b. If only one TEMP-PLATE is missing, and no dot on other TEMP-PLATE (on same coupling) is discolored or
shows mechanical damage or degradation of the epoxy overcoating, the helicopter may be returned to service.
The discrepant TEMP-PLATE should be replaced as soon as practical. If any indicator dot on the TEMP-PLATE
has changed color to black, refer to table 1 for probable cause and required corrective action.
5. Inspect seal (18) for protrusions, leakage, cuts, tears, and deterioration. Replace unserviceable seals
(E-AB412-PT6T-3).
6. Inspect bearing (4) in hanger (6) and outer coupling for grease leakage. A small amount of grease expelled from around
lip of bearing seals indicates a slight overservicing and is not cause for hanger replacement. If leakage is detected,
perform an evaluation of grease leakage as follows:
CAUTION
DO NOT CLEAN OR SPRAY BEARING HANGER ASSEMBLY WITH ANY

TYPE OF SOLVENT DURING INSPECTION. USE CLEAN, DRY CLOTHS
ONLY TO CLEAN EXTERIOR OF HANGER ASSEMBLIES.
a. Wipe grease from exterior of inner coupling (17), outer coupling (3), and bearing (4) in hanger assembly (6).
b. Record which bearing is leaking and keep under observation for the next 10 flight hours. If amount of grease
expelled from bearing seal does not decrease after 10 flight hours, replace hanger assembly.
65-11-02
Rev. 3 Page 5
E-AB412-PT6T-2
Table 1. Tail rotor driveshaft TEMP-PLATE condition and correction action
ONE RED OTHER RED PROBABLE SEE NOTE

TEMP-PLATE TEMP-PLATE CAUSE
Good Black Defect/Instl 1
Black Black Overtemp 2
Part Black Good Chem. Contamination 1
Missing Good Defect/Instl 1
Missing Missing Possible Overtemp 2
NOTES:
1. Resume operation. Defective TEMP-PLATE or improper installation, replace defective TEMP-PLATE as soon as
practical in accordance with E-AB412-PT6T-3 Manual.
2. Coupling overtemperature condition is very likely. Remove coupling assembly and perform overtemperature inspection
in accordance with E-AB412-PT6T-3 Manual.
7. Inspect bearing (4) in hanger assembly (6) for wear, roughness, and binding as follows:
a. Remove driveshaft from each side of hanger assembly (6).
b. Rotate bearing while pressing in axially on non-flexible coupling end of hanger bearing assembly. Bearing may
feel smooth when turned with no load, but rough when loaded by pressing in with hand. Obvious roughness or
binding when turned by hand is cause for replacement of hanger bearing assembly.
8. Inspect hanger bearing fittings (7, 8 and 9, figure 1) and support (10) for mechanical and corrosion damage.
Mechanical damage in excess of superficial and/or any corrosion damage that can be detected visually is not
acceptable.
9. Replace driveshaft hanger assemblies for the following conditions:
a. Bearing is rough, binds when rotated, or exhibits excessive wear.
b. Hanger assembly (6, figure 2) excessively worn, cracked, or exhibits signs of overheating.
c. Signs of metal particles and/or rust colored fretting debris near bearing.
d. Curving face of couplings are excessively worn.
e. Couplings show signs of overheating or being run without lubricant.
10. Lubricate hanger bearing assembly as required (Chapter 12).
11. Replace visual overtemperature indicators ( TEMP-PLATES) if mutilated or discolored (E-AB412-PT6T-3).
65-11-02
Page 6 Rev. 3
E-AB412-PT6T-2
1. Driveshaft 10. Over-temperature indicators “TEMP-PLATES”

2. Clamp 11. Bolt
3. Outer coupling 12. Hanger bolt hole
4. Bearing 13. Hanger bolt hole
5. Deleted 14. Spring
6. Hanger assembly 15. Plate
7. Clamp 16. Retainer ring
8. Driveshaft 17. Inner coupling
9. Coupling 18. Seal
G6AB0515C
Figure 2. Tail rotor driveshaft hanger assembly
65-11-02
Rev. 3 Page 7
E-AB412-PT6T-2
6. DRIVESHAFT HANGER ASSEMBLIES - LUBRICATION
1. Remove tail rotor driveshaft sections attached to hanger bearing to be lubricated (module 65-11-01 paragraph "2. Tail
rotor driveshaft - removal").
2. Remove tail rotor driveshaft hanger assemblies (paragraph "2. Driveshaft hanger assemblies - removal").
3. Clean tail rotor drive shaft hanger assemblies (paragraph "4. Driveshaft hanger assemblies - cleaning").
4. Disassemble and lubricate tail rotor driveshaft hanger assemblies (E-AB412-PT6T-3).
5. Install tail rotor driveshaft hanger assemblies (paragraph "3. Driveshaft hanger assemblies - installation").
NOTE
repaired, or relubricated flexible couplings.
6. Make an entry in helicopter log and in flex couplings lubrication log of date lubricated, date grease manufactured and
helicopter hours (Chapter 12).
65-11-02
Page 8 Rev. 3
E-AB412-PT6T-2
65-12-01
TAIL ROTOR DRIVESHAFTS AND HANGERS [D]
1. TAIL ROTOR DRIVESHAFTS AND HANGER - DESCRIPTION
For helicopters codes [A] [B] [C], refer to module 65-11-01 "TAIL ROTOR DRIVESHAFT [A] [B] [C]" and to
module 65-11-02 "DRIVESHAFT HANGER ASSEMBLIES [A] [B] [C]".
2. TAIL ROTOR DRIVESHAFTS AND HANGER - REMOVAL
1. Open the following covers as necessary to gain access to driveshafts and hangers:
b. Open reduction gearbox fairing.
c. Remove left and right access doors.
d. Open driveshaft covers (8 and 12, figure 1).
e. Remove intermediate gearbox cover (14).
f. Open vertical fin cover (15).
g. Remove cover (5).
2. Remove driveshafts and adjacent disc pack coupling (40) as follows:
CAUTION
SUPPORT DRIVESHAFTS DURING DISCONNECTING AND REMOVAL

PROCESSES TO PREVENT DAMAGE TO DISC PACK COUPLINGS. THE
FREE END OF DRIVESHAFT (4) SHALL NOT BE ALLOWED TO DISPLACE
MORE THAN 0.34 IN (8.64 MM) WHEN OPPOSITE END IS SUPPORTED BY
DISC PACK COUPLING. FREE ENDS OF DRIVESHAFTS (7, 10, 13, AND 16)
SHALL NOT BE ALLOWED TO DISPLACE MORE THAN 1.0 IN (25.4 MM)
WHEN OPPOSITE ENDS ARE SUPPORTED BY DISC PACK COUPLINGS.
THE DISASSEMBLY OPERATION SHALL BE PERFORMED IN SEQUENCE
WITH THE FOLLOWING STEPS TO MINIMIZE THE CHANCE OF DAMAGE
TO DRIVESHAFT HANGER BEARINGS.
65-12-01
Rev. 2 Page 1
E-AB412-PT6T-2
NOTE
If the tailboom alignment is changed, if any damage has occurred that makes the tail
rotor drive alignment suspect, or if any tail rotor driveshaft hanger support is
disturbed (loosened) or replaced, the entire tail rotor drive system shall be aligned in
accordance with step 7., paragraph "3. Tail rotor driveshafts and hanger -
installation". If driveshafts (3, 4, 7, 10, 13 and 16), disc pack couplings (40), washers
(43 and 53), or intermediate gearbox (18) are disturbed (loosened) or replaced,
inspect disc pack coupling for gaps in accordance with step 5.g., paragraph "3. Tail
rotor driveshafts and hanger - installation".
a. Remove nuts (32), washers (31), and bolts (30) from forward end of driveshaft (4).
b. Remove nuts (29), washers (28), and bolts (27) from forward ends of driveshafts (7,10, 13 and 16).
c. Remove uppermost nut (46), washers (42 through 45), and bolt (41) from disc pack coupling (40) and adapter
of hanger assembly (6, 9 and 11) or tail rotor gearbox (17) at aft end of driveshaft (16).
d. Remove nuts (56), washers (53 through 55), and bolts (52) from disc pack coupling (40) and driveshaft adapter
(39).
e. Remove driveshaft and place in a suitable rack. Mark driveshaft with regard to original location in helicopter.
3. If required, remove disc pack coupling (40) as follows:
CAUTION
DO NOT DISASSEMBLE DISC PACK COUPLING.
a. Tie disc of disc pack couplings (40) together through at least two bolt holes with string or other nonscratching
material.
b. Remove remaining nuts (46), washers (42 through 45), and bolts (41) from disc pack coupling and adapter of
hanger assembly (6, 9 or 11), tail rotor gearbox (17), or intermediate gearbox (18).
c. Remove disc pack coupling. Mark disc pack with regard to original location on helicopter.
4. Remove driveshaft (3), coupling assembly (2), and coupling assembly (38) as follows:
CAUTION
DRIVESHAFT MUST BE SUPPORTED DURING DISCONNECTING AND

REMOVAL PROCESS TO PREVENT OVERLY DISTORTING SEAL IN
COUPLING ASSEMBLIES. THE FREE END OF DRIVESHAFT SHALL NOT
BE ALLOWED TO BE DISPLACED MORE THAN 2.0 IN (50.8 MM) WHEN
OPPOSITE END IS SUPPORTED AT COUPLING.
a. Remove driveshaft (4) (step 2.).
b. Remove nuts (24), washers (25), and bolts (26) from transmission adapter (1) and coupling assembly (2).
c. Remove nuts (29), washers (28), and bolts (27) from aft end of driveshaft (3) and coupling assembly (38).
NOTE
Before removing driveshaft, place suitable protective material on engine deck below
driveshaft to prevent damage to driveshaft.
65-12-01
Page 2 Rev. 2
E-AB412-PT6T-2
d. Force driveshaft (3) forward by hand. Compress coupling assembly (2) and separate aft end of driveshaft from
coupling assembly (38).
e. Gently lower driveshaft with coupling assembly (2) onto engine deck within driveshaft enclosure.
NOTE
Do not remove washers (34 and 35) from between upper end of brace (36) and
support (20) unless brace or support requires repair or replacement.
f. Remove coupling assembly (38) by removing nuts (37), washers (34), and bolts (33) from support (20), brace
(36) and coupling assembly (38). Loosely reinstall bolts (33), washers (34), and nuts (37) to prevent loss of
washers (34 and 35) that are between upper end of brace and support.
CAUTION
USE CARE WHEN REMOVING DRIVESHAFT FROM ENCLOSURE TO

PREVENT DAMAGE.
g. Carefully withdraw driveshaft (3) with coupling assembly (2) from aft end of driveshaft enclosure. Place
driveshaft on suitable rack.
h. If required, remove coupling assembly (2) from driveshaft (3) by removing nuts (23), washers (22), and bolts
(21).
i. Mark driveshaft to show original location in helicopter.
5. Remove hanger assembly (6) as follows:
a. Remove driveshafts (4 and 7) and disc pack (40) (step 2.).
b. Remove bolts (57) with washers (58) from hanger assembly (6) and support (59).
c. Remove hanger assembly from support. Mark hanger to show original location in helicopter.
6. Remove hanger assemblies (9 and 11) as follows:
a. Remove driveshafts (7, 10 and 13) and disc pack couplings (40) (step 2.).
b. Remove nuts (50), washers (48 and 49), and bolts (47) from hanger assembly (9 or 11) and support (51).
c. Remove hanger assembly from support. Mark hanger to show original location in helicopter.
65-12-01
Rev. 2 Page 3
E-AB412-PT6T-2
G6AB0520B
Figure 1. Tail rotor driveshaft [D] (sheet 1 of 5)
65-12-01
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G6AB0521B
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G6AB0522B
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CAUTION
THESE FLATS ARE PREFERENTIALLY ORIENTED

AND SHOULD NOT BE DISTURBED IN HANDLING.
G6AB0523B
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1. Adapter (tail rotor drive quill) 32. Nut

2. Coupling assembly 33. Bolt
3. Driveshaft 34. Steel washer
4. Driveshaft 35. Aluminum washer
5. Cover 36. Brace assembly
6. Hanger bearing assembly 37. Nut
7. Driveshaft 38. Coupling assembly
8. Driveshaft cover 38A. Hanger bearing assembly
9. Hanger bearing assembly 39. Driveshaft adapter (typical)
10. Driveshaft 40. Disc pack coupling
11. Hanger bearing assembly 41. Bolt
12. Driveshaft cover 42. Chamfered steel washer
13. Driveshaft 43. Special washer
14. Intermediate gearbox cover 44. Thick steel washer
15. Vertical fin cover 45. Thin steel washer
16. Driveshaft 46. Nut
17. Tail rotor gearbox 47. Bolt
18. Intermediate gearbox 48. Thin steel washer
19. Tailboom 49. Aluminum washer
20. Hanger bearing support 50. Nut
21. Bolt 51. Support
23. Nut 53. Special washer
24. Nut 54. Thick steel washer
25. Steel washer 55. Thin steel washer
26. Bolt 56. Nut
29. Nut 58. Thin steel washer
30. Bolt 59. Support
31. Steel washer 60. Barrel nut
50 TO 70 IN-LBS
(5.65 TO 7.91 Nm)
120 TO 160 IN-LBS
(13.56 TO 18.08 Nm)
280 TO 300 IN-LBS
(31.64 TO 33.90 Nm)
NOTES:
1 Detail C shows typical installation of forward end of driveshafts (7, 10, 13 and 16).
2 Detail D shows typical installation of tailboom mounted hanger assembly and aft end installation of driveshaft assemblies
(4, 7, 10, and 13).
3 Place radiused outer edge of washers adjacent to surface of disc pack (40).
4 Position heads of bolts (41 and 52), Detail D, 180° from each other, as shown.
5 Place chamfered bore of chamfered steel washer (42) adjacent to bolt head (41).
Figure 1. Tail rotor driveshaft (sheet 5 of 5)
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3. TAIL ROTOR DRIVESHAFTS AND HANGER - INSTALLATION
NOTE
If any of the following tail rotor drive train components is replaced or installed in a
different location other than originally installed, entire tail rotor drive train shall be
aligned in accordance with step 7.
Driveshafts (4, 7, 10 or 13, figure 1),
Coupling assembly (38),
Hanger assemblies (6, 9 or 11),
Disc pack couplings (40),
Washers (43 and 53), or
Intermediate gearbox (18).
If the tail boom alignment is changed, if any damage has occurred that makes the tail
disturbed (loosened) or replaced, the entire tail rotor drive system shall be aligned in
accordance with step 7. If driveshafts (3, 4, 7, 10, 13 and 16), disc pack couplings
(40), washers (43 and 53), or intermediate gearbox (18) are disturbed (loosened) or
replaced, inspect disc pack coupling for gaps in accordance with step 5.g.
NOTE
If any tail rotor driveshaft hanger support 20, 51, 59 is disturbed (loosened), or
replaced, the entire tail rotor drive train shall be realigned in accordance with step 7.
If any two or more hanger assemblies (6, 9 or 11) or if hanger assembly (6) and
coupling assembly (38) are loosened at the same time, or if intermediate gearbox
(18) is loosened, entire tail rotor drive system shall be aligned in accordance with
step 7.
1. Install hanger assembly (9 or 11, detail D) as follows:
a. Position hanger assembly (9 or 11) on top of support (51) with grease fitting in hanger on left side of helicopter.
b. Install bolts (47), washers (48), washers (49) adjacent to support (51) and nuts (50). Torque nuts 50 to 70 in-lbs
(5.65 to 7.91 Nm), then loosen one-half turn.
c. Install disc pack coupling (40). Refer to step 3.
d. Install adjacent driveshaft. Refer to step 5.
NOTE
If maintenance does not necessitate drive system alignment, perform procedures in
steps 5.e. through 5.g. If alignment is required, proceed to step 7.
e. Before torquing nuts (50) at hanger assembly, manually rotate yaw bearing hanger housing clockwise, then
counterclockwise to limits of travel while looking down from above. Note the limits of travel. Position hanger
approximately in center of range of motion and tighten hardware attaching hanger to support (51).
f. Torque nuts (50) between hanger assembly (9 or 11, Detail D) and support (51) 50 to 70 in-lbs (5.65 to 7.91 Nm).
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E-AB412-PT6T-2
2. Install hanger assembly (6, detail E) as follows:
a. Position hanger assembly (6) on top of support (59) with grease fitting in hanger on left side of helicopter.
b. Install bolts (57) with washers (58) through hanger and support into barrel nuts (60). Torque bolts 50 to 70 in-lbs
(5.65 to 7.91 Nm), then loosen bolts one-half turn.
c. Install disc pack couplings (40, detail D). Refer to step 3.
d. Install adjacent driveshafts. Refer to step 5.
NOTE
If maintenance does not necessitate drive train alignment, perform procedures 5.f.
and 5.g. If alignment is required, proceed to step 7.
e. Before torquing bolts (57) at hanger assembly, manually rotate yaw bearing hanger housing hanger clockwise,
then counterclockwise to limits of travel while looking down from above. Note the limits of travel. Position
hanger approximately in center of range of motion and tighten hardware attaching hanger to support (59).
f. Torque bolts (57) between hanger assembly (6) and support (59) 50 to 70 in-lbs (5.65 to 7.91 Nm).
3. If disc pack couplings (40, figure 1, details F and G) are removed, install as follows:
CAUTION
INDEXING FLATS ON DISCS OF DISC PACK COUPLINGS (40) ARE

PREFERENTIALLY ORIENTED. DISCS SHOULD NOT BE DISTURBED IN
HANDLING. IF ORIENTATION IS INADVERTENTLY DISTURBED, REINDEX
DISCS BY ALTERNATELY INDEXING FLATS ON EACH DISC 60° FROM
FLAT ON ADJACENT DISC (FIGURE 1, DETAIL H). IT IS NOT ACCEPTABLE
TO CHANGE RELATIVE POSITION OF A DISC WITHIN A PACK EXCEPT AS
NOTED ABOVE OR TO INTERCHANGE DISCS FROM ONE DISC PACK TO
ANOTHER.
WHEN INSTALLING BOLTS (WITH SPECIAL WASHERS) THROUGH A DISC

PACK COUPLING, WASHERS SHALL BE CAREFULLY INSPECTED TO
ENSURE RADIUSED EDGES ON WASHERS ARE INSTALLED AGAINST
DISC PACK. RELATIVE ORIENTATION OF BOLTS (HEADS FACING
FORWARD OR AFT) SHALL BE AS SHOWN IN DETAIL D.
a. Install disc pack coupling on forward facing adapters of hanger assemblies (6, 9, or 11) or on input adapter of
intermediate gearbox (18), or on tail rotor gearbox (17), using two lower-most bolts (41), countersunk washers
(42) (with chamfers adjacent to boltheads), special washers (43) (with radiused outer edge of washers adjacent
to surface of disc pack), thick washers (44), thin washers (45), and nuts (46). Tighten nuts until torque increases
above tare value, then loosen one-fourth turn. The top bolt (41), washers (42, 43, 44 and 45) and nut (46) are
installed when driveshafts are installed.
b. Install adjacent driveshaft (4, 7, 10, 13 or 16). Refer to steps 4. and/or 5.
4. Install driveshaft (16) as follows:
NOTE
Tail rotor gearbox and intermediate gearbox shall be fully installed at time driveshaft
(16) is installed.
a. Place driveshaft in position between disc pack coupling (40) that is installed on tail rotor gearbox (17) (step 3.)
and output coupling of intermediate gearbox (18).
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b. Connect upper end of driveshaft (detail D).
CAUTION
WHEN INSTALLING BOLTS, WITH SPECIAL WASHERS, THROUGH DISC

PACK COUPLING, WASHER SHALL BE CAREFULLY INSPECTED TO
ENSURE RADIUSED EDGE ON WASHERS ARE INSTALLED AGAINST DISC
PACK (DETAIL F AND G). THE RELATIVE ORIENTATION OF BOLTS,
HEADS FACING FORWARD OR AFT, SHALL BE AS SHOWN IN DETAIL D.
(1) Align bolt holes in disc pack coupling (40) on tail rotor gearbox with holes in driveshaft flange. Install bolts
(52), special washers (53) (with radiused edge adjacent to disc) under heads of bolts, special washers (53)
(with radiused edge adjacent to disc), thick washers (54), thin washers (55), and nuts (56). Refer to detail
G for installation of hardware.
(2) Torque nuts (56) evenly until torque increases above tare value, then loosen nuts one-fourth turn.
(3) Loosen two remaining nuts (46) attaching disc pack coupling (40) to adapter of tail rotor gearbox one to
two turns.
(4) Install bolt (41), chamfered washer (42) (with chamfer adjacent to bolthead), washers (43) (with radiused
edge adjacent to disc pack coupling), thick washer (44), thin washer (45), and nut (46) at disc pack coupling
and adapter of tail rotor gearbox. Refer to detail F for installation of hardware.
(5) Torque nuts (46) evenly until the torque increases above tare value, then loosen one-fourth turn.
c. Connect lower end of driveshaft (detail C).
(1) Align bolt boles in driveshaft flange with those in coupling of intermediate gearbox (18). Install bolts (27),
washers (28), and nuts (29).
(2) Torque nuts evenly 120 to 160 in-lbs (13.56 to 18.08 Nm).
d. Progressively torque three nuts (56) at upper end of driveshaft uniformly 280 to 300 in-lbs (31.64 to 33.90 Nm).
e. Progressively torque three nuts (46) at tail rotor gearbox adapter uniformly 280 to 300 in-lbs (31.64 to 3.90 Nm).
f. Inspect disc pack coupling for gaps between disc. Gaps in excess of 0.010 in (0.254 mm) are not acceptable. If
excessive gaps are present, proceed as follows:
(1) Loosen three nuts (56) and three nuts (46) approximately one-half turn.
(2) Rotate disc pack coupling (40) back and forth on bolts and repeat steps d. through f.
5. Install driveshafts (4, 7, 10, and 13) as follows:
NOTE
Intermediate gearbox (18) shall be fully installed at time driveshaft (13) is installed.
a. Position driveshaft(s) as follows:
NOTE
If more than one driveshaft is removed, install driveshafts beginning at the
intermediate gearbox (18) (or the most aft driveshaft) and proceed forward.
Detail C shows typical installation of forward end of driveshafts (7, 10 and 13).
Detail D shows typical installation of aft end of driveshaft assemblies (4, 7, 10, and
13). Aft end of driveshaft assemblies are mated to the disc pack coupling(s) (40)
already installed on intermediate gearbox (18), hanger assemblies (6, 9, and 11) and
coupling assembly (38) in step 3.
(1) Position driveshaft (13) between disc pack coupling (40) and hanger assembly (11).
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NOTE
If driveshaft (3) is removed, do not install driveshaft (4) until driveshaft (3) is
installed (step 6.).
(4) Position driveshaft (4) between disc pack coupling (40) installed on hanger assembly (6) and coupling
assembly (38). Refer to detail B to show installation of forward end of driveshaft (4) to coupling (38).
b. Insert bolt (27) through uppermost bolt hole in forward end flange and in mating hanger assembly or coupling
assembly adapter and bolt (52) through uppermost bolt hole in driveshaft aft end flange and in mating disc pack
coupling to hold driveshaft in position until permanently installed.
c. Connect aft end of driveshaft (detail D).
CAUTION
WHEN INSTALLING BOLTS WITH SPECIAL WASHERS, THROUGH A DISC

PACK COUPLING, ENSURE RADIUSED EDGES ON WASHERS ARE
INSTALLED AGAINST DISC PACK. THE RELATIVE ORIENTATION OF
BOLTS, HEADS FACING FORWARD OR AFT, SHALL BE AS SHOWN IN
DETAIL D.
(1) Align bolt holes in disc pack coupling (40) with holes in driveshaft flange. Install bolts (52) and washers
(53) under heads of bolts (52) (with countersunk side adjacent to bolt heads). Install washers (53) (with
radiused edge adjacent to disc), thick washers (54), thin washers (55), and nuts (56).
(2) Torque nuts (56) evenly until torque increases above tare value, then loosen nuts one-fourth turn.
(3) Loosen two remaining nuts (46) attaching disc pack coupling (40) to adapter of hanger assembly or
intermediate gearbox one to two turns.
(4) Install bolt (41), chamfered washer (42) (with chamfer adjacent to bolthead), special washers (43) (with
radiused edge adjacent to disc pack coupling), thick washer (44), thin washer (45), and nut (46) at disc pack
coupling and adapter of hanger assembly or intermediate gearbox.
(5) Torque nuts (46) evenly until torque increases above tare value, then loosen one-forth turn.
d. Connect forward end of driveshaft (details B and C).
(1) Align bolt holes in driveshaft flange with holes in adapter of hanger assembly (6, 9, or 11) or of coupling
assembly (38). Install bolts (27 or 30), washers (28 or 31), and nuts (29 or 32).
(2) Torque nuts evenly 120 to 160 in-lbs (13.56 to 18.08 Nm).
NOTE
If maintenance requires drive train alignment (refer to note preceding step 1.),
proceed to step 7. If alignment is not required, proceed to step e. below.
e. Progressively torque nuts (56) at aft end of driveshaft uniformly to 280 to 300 in-lbs (31.64 to 33.90 Nm).
f. Progressively torque three nuts (46) at intermediate gearbox, or aft end hanger assembly adapter uniformly 280
to 300 in-lbs (31.64 to 33.90 Nm).
g. Inspect each disc pack coupling for gaps between disc. Gaps in excess of 0.010 in (0.254 mm) are not acceptable.
If excessive gaps are present in any disc pack coupling, proceed as follows:
(1) Loosen nuts (56) and nuts (46) approximately one-half turn.
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E-AB412-PT6T-2
(2) Rotate disc pack coupling (40) back and forth on bolts, then repeat steps e. through g.
6. Install driveshaft (3) and coupling assembly (2) and coupling assembly (38) as follows:
CAUTION
WHEN INSTALLING DRIVESHAFT INTO ENCLOSURE, PLACE SUITABLE

PROTECTIVE MATERIAL ON ENGINE DECK WITHIN DRIVESHAFT
ENCLOSURE TO PREVENT DAMAGE TO DRIVESHAFT.
a. Install coupling assembly (2) on forward end of driveshaft (3) using bolts (21), washers (22), and nuts (23).
Torque nuts evenly 120 to 160 in-lbs (13.56 to 18.08 Nm).
b. Install driveshaft (3) with coupling assembly (2), coupling end first, into driveshaft enclosure. Gently lower
driveshaft onto engine deck.
c. Install coupling assembly (38) on top of support (20) as follows:
(1) Remove bolts (33), washers (34), and nuts (37) that were loosely installed in support (20). Inspect upper
ends of braces (36) to confirm aluminum washers (35) and washers (34) are still in place between upper
ends of braces (36) and lower surfaces of support (20). If washers are in place, proceed directly to step (3).
If washers are not present, proceed to step (2).
(2) Install washers (35 and 34) between the upper end of brace(s) (36) and lower surface(s) of support (20).
Washer(s) (35) shall be adjacent to the lower surface of support (20) and washer(s) (34) shall be adjacent
to upper end of brace(s) (36). Refer to detail B.
(3) Place coupling assembly (38) on top of support (20) with grease-packed coupling facing forward.
(4) Install bolts (33), washers (34), and nuts (37) through coupling assembly (38), support (20), and braces
(36) (refer to detail B). Temporarily torque nuts 50 to 70 in-lbs (5.65 to 7.91 Nm).
(5) Check installed brace assemblies (36) for preload condition. Remove bolts attaching braces to service
deck. If brace is properly adjusted, there will be no spring-back or hard contact with service deck when
bolts are removed. If spring-back is in excess of 0.020 in (0.508 mm), or hard contact is evident, adjust
brace assemblies as follows:
(a) Adjust thickness of peel shims between lower ends of brace assemblies (36) and service deck, so there
is no excessive spring-back or hard contact (preload).
(b) After proper brace shimming has been achieved, install bolts attaching braces to service deck. Torque
bolts 50 to 70 in-lbs (5.65 to 7.91 Nm).
(6) Loosen nuts (37) at coupling assembly (38) and support (20) one to one and one-half turns.
(7) Install driveshaft (4). Refer to step 5., except do not perform steps e. through g.
NOTE
If subject maintenance is such that tail rotor drive alignment is required (refer to
notes preceding step 1.), proceed to step 7. If alignment is not required, proceed with
note and step (8). below.
Before tightening bolts at coupling assembly (38), manually rotate bearing hanger
housing clockwise and then counterclockwise while looking down from above, to
limits of travel. Position hanger approximately in center of range of motion and
tighten hardware attaching hanger to fuselage support.
(8) Tighten two nuts (37) at coupling assembly (38) and support (20). Torque nuts 50 to 70 in-lbs (5.65 to
7.91 Nm).
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E-AB412-PT6T-2
(9) Progressively torque nuts (56) at aft end of driveshaft uniformly 280 to 300 in-lbs (31.64 to 33.90 Nm).
(10) Progressively torque nuts (46) at intermediate gearbox or aft end hanger assembly uniformly 280 to 300
in-lbs (31.64 to 33.90 Nm).
(11) Inspect disc pack coupling for gaps between disc. Gaps in excess of 0.010 in (0.254 mm) are not
acceptable. If excessive gaps are present, proceed as follows:
(a) Loosen nuts (56) and nuts (46) approximately one-half turn.
(b) Rotate disc pack coupling back and forth on bolts and repeat steps (9) through (11).
d. Position driveshaft (3) with coupling assembly (2) between transmission adapter (1) and grease packed coupling
of coupling assembly (38).
e. Align bolt holes in coupling (2) with those in adapter (1). Install bolts (26), washers (25), and nuts (24). Torque
nuts 120 to 160 in-lbs (13.56 to 18.08 Nm).
f. Align bolt holes in aft end flange of driveshaft (3) with those in grease packed coupling of coupling assembly
(38). Install bolts (27), washers (28), and nuts (29). Torque nuts 120 to 160 in-lbs (13.56 to 18.08 Nm).
g. Remove protective material from driveshaft enclosure.
4. TAIL ROTOR DRIVESHAFTS AND HANGER - ALIGNMENT
1. Align tail rotor drive train as follows:
NOTE
If the tailboom alignment is changed, if any damage has occurred that makes the tail
disturbed (loosened) or replaced, the entire tail rotor drive system shall be aligned. If
driveshafts (3, 4, 7, 10, 13 and 16, figure 1), disc pack couplings (40), washers (43
and 53), or intermediate gearbox (18) are disturbed (loosened) or replaced, inspect
disc pack coupling for gaps in accordance with step 5.g.
NOTE
Certain steps in the following procedures, such as loosening of specific fasteners or
partial removal of certain components may have already been accomplished during
conditional installation of components in steps 1. through 6.
CAUTION
USE CARE WHEN INSTALLING DRIVESHAFT INTO ENCLOSURE. PLACE

SUITABLE PROTECTIVE MATERIAL ON ENGINE DECK WITHIN
DRIVESHAFT ENCLOSURE TO PREVENT DAMAGE TO DRIVESHAFT
DURING INSTALLATION.
a. Remove driveshaft (3) and coupling assembly (2) from between transmission adapter (1) and coupling assembly
(38). Rest assembly on engine deck within driveshaft enclosure. Do not remove driveshaft from enclosure or
coupling assembly (38) from support (20).
b. Starting at intermediate gearbox and working forward, loosen nuts (46) securing each disc pack coupling (40) to
adapters of hanger assemblies (11, 9, and 6), and to adapter of intermediate gearbox. Loosen nuts (56) securing
each disc packing to driveshaft (13, 10, 7, and 4). Loosen nuts one to one and one-half turns.
c. Starting at intermediate gearbox and working forward, tighten nuts (loosened in step b.) until torque increases
above tare value, then loosen one-forth turn.
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E-AB412-PT6T-2
d. Starting at intermediate gearbox and working forward, loosen nuts (50) securing hanger assemblies (9 and 11)
to supports (51) one to one and one-half turns.
e. Loosen bolts (57) securing hanger assembly (6) to support (59), one to one and one-half turns.
f. Loosen nuts (37) securing coupling assembly (38) to support (20), one to one and one-half turns.
NOTE
Before tightening bolts at each hanger and coupling assembly, manually rotate
bearing hanger housing clockwise, then counterclockwise to limits of travel while
looking down from above. Position hanger approximately in center of range of
motion and tighten hardware attaching hanger to tailboom or fuselage support.
g. Starting at intermediate gearbox and working forward, progressively torque nuts (46) and nuts (56), securing
disc pack couplings (40) to adapter of intermediate gearbox, adapters of hanger assemblies (11, 9, and 6) and to
driveshafts (13, 10, 7 and 4) uniformly to 280 to 300 in-pounds (31.64 to 33.90 Nm).
h. Inspect each disc pack coupling (40) for gaps between the disc. Gaps in excess of 0.010 in (0.254 mm) are not
acceptable. If excessive gaps are present in any disc pack coupling, proceed as follows:
(1) Loosen nuts (56) and nuts (46) approximately one-half turn.
(2) Rotate disc pack coupling (40) back-and-forth on its bolts, then progressively retorque nuts (56) and nuts
(46) uniformly to 280 to 300 in-pounds (31.64 to 33.90 Nm).
i. Repeat step h.
NOTE
Before tightening bolts at each hanger and coupling assembly, manually rotate
bearing hanger housing clockwise, then counterclockwise, to limits of travel while
looking down from above. Position hanger approximately in center of range of
motion and tighten hardware attaching hanger to tailboom or fuselage support.
j. Starting at intermediate gearbox and working forward, torque nuts and bolts (loosened in steps d. through f.) to
50 to 70 in-pounds (5.65 to 7.91 Nm).
k. Install driveshaft (3) (refer to paragraph "3. Tail rotor driveshafts and hanger - installation").
2. Install or close covers, fairings, and doors that were removed in paragraph "2. Tail rotor driveshafts and hanger -
removal".
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E-AB412-PT6T-2
5. TAIL ROTOR DRIVESHAFTS AND HANGER - CLEANING
MATERIALS REQUIRED
NUMBER NOMENCLATURE
C-304 SOLVENT
CAUTION
DO NOT SUBMERGE COUPLING (2, FIGURE 1) OR HANGER ASSEMBLIES

(6, 9, AND 11) IN SOLVENT.
1. Wash parts with solvent (C-304).
2. Dry clean with clean, filtered compressed air.
6. TAIL ROTOR DRIVESHAFTS AND HANGER - INSPECTION
MATERIALS REQUIRED
NUMBER NOMENCLATURE
C-344 ALCHOL PHOSPHORIC CLEANER
1. Inspect driveshafts (figure 1) for cracks, rivet failure, distortion, and corrosion.
2. Inspect for damage to anodized finish. Damage to finish requires anticorrosion treatment.
3. Inspect areas A and B (figure 3) for nicks, scratches, and dents as follows:
a. Nicks or scratches aligned within 15° of spanwise axis are acceptable without repair to a maximum depth of
0.002 in (0.051 mm) in area A or 0.004 in (0.101 mm) in area B.
b. Maximum acceptable depth of nicks or scratches is 0.008 in (0.203 mm) in area A or 0.012 in (0.305 mm) in
area B.
c. Maximum acceptable depth of sharp dents is 0.010 in (0.254 mm) in area A or 0.015 in (0.381 mm) in area B.
d. Maximum acceptable depth of nonsharp dents is 0.020 in (0.508 mm) in area A or 0.030 in (0.762 mm) in area B.
4. Inspect splined coupling of coupling assembly (2, figure 1) visual overtemperature indicators (TEMP-PLATES) for
discoloration indicating a possible overheat condition. A change in color of TEMP-PLATES dots (from white to black)
indicates a possible overheat condition and/or component degradation. Cause of discoloration shall be determined and
corrected prior to continued operation. Refer to module 65-11-02 paragraph "5. Driveshaft hanger assemblies -
inspection".
5. Replace supports if damaged.
6. Inspect brace assembly (36) for cracks, corrosion, and damaged threads.
7. Inspect hanger bearing assemblies (6, 9, 11 and 38A) and coupling assembly (38) for obvious damage and excessive
lubricant leakage.
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E-AB412-PT6T-2
8. Inspect hanger bearing assemblies (6, 9, 11, and 38A) exterior surfaces for discoloration and overheat condition. A
change in color indicates a possible overheat condition and/or component degradation. The cause of exterior surface
discoloration shall be determined and corrected prior to continued operation (E-AB412-PT6T-3, Chapter 65).
9. Inspect hanger bearing assemblies visual overheat indicator stripes for discoloration indicating a possible overheat
condition. A change in color of indicator stripes (from green to brown) indicates a possible overheat condition and/or
component degradation. Cause of discoloration shall be determined and corrected prior to continued operation. Refer
to E-AB412-PT6T-3.
10. Inspect disc assembly (refer to figure 2) as follows:
NOTE
Keep disc pack as an assembly.
a. Clean the grease and oil from each disc.
b. Examine the disc for cracks, nicks and scratches. None are permitted.
c. Examine the disc for fretting and corrosion.
d. Clean the light fretting and corrosion with a soft rubber eraser. If light fretting and corrosion still exists, soak
disc in alcohol phosphoric cleaner (C-344). If the disc cannot be cleaned, discard it.
e. Replace unserviceable laminate(s) with new laminate(s) as necessary. The disc assembly must be within 0.126
to 0.138 in (3.200 to 3.505 mm) thick. A maximum of 11 laminates may be used to make a disk assembly. Each
laminate is 0.010 to 0.014 in (0.254 to 0.355 mm) thick.
7. TAIL ROTOR DRIVESHAFTS AND HANGER - REPAIR
Refer to module 65-11-01 paragraph "7. Tail rotor driveshaft - repair" and module 65-11-02 paragraph "5. Driveshaft hanger
assemblies - inspection".
8. TAIL ROTOR DRIVESHAFTS AND HANGER - LUBRICATION
1. Remove tail rotor driveshaft sections attached to hanger bearing to be lubricated (paragraph "2. Tail rotor driveshafts
and hanger - removal").
2. Remove tail rotor driveshaft hanger assemblies (paragraph "2. Tail rotor driveshafts and hanger - removal").
3. Clean tail rotor drive shaft hanger assemblies (paragraph "5. Tail rotor driveshafts and hanger - cleaning").
CAUTION
DO NOT LUBRICATE IN DETAIL D FIGURE 1.
4. Disassemble and lubricate tail rotor driveshaft hanger assemblies (E-AB412-PT6T-3 Manual).
5. Install tail rotor driveshaft hanger assemblies (paragraph "3. Tail rotor driveshafts and hanger - installation").
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CAUTION
GROUND RUN AND LEAK CHECK MUST BE PERFORMED FOLLOWING

INSTALLATION OF NEW, REPAIRED, OR RELUBRICATED FLEXIBLE
COUPLINGS.
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NOTES:
1. Cracks, nicks or scratches: none allowed.
2 No damage allowed within 0.050 in (1.270 mm) of any edge.
3 Circular scratches are acceptable on outside faces of outer laminate adjacent to bolt hole.
4 Area of light fretting and corrosion, surfaces distress not greater than 0.001 in (0.025 mm), which can be repaired by soaking
in alcohol phosphoric cleaner (C-344) are acceptable.
5 Random light fretting and corrosion pitting are permitted if not greater than 5 percent of each quadrant is affected, and any
pitted areas do not exceed 0.050 in (1.270 mm) diameter.
6 Light fretting and corrosion pitting is allowed if area affected is not greater than 40 percent (maximum four places on each side).
G6AB0524B
Figure 2. Disc pack assembly wear limits (412-340-610-101)
65-12-01
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E-AB412-PT6T-2
AREA A AREA B

AFTER POLISHING OUT
CRACKS ALLOWED See note 6 See note 6
NICKS AND SCRATCHES 0.008 in (0.203 mm) 0.012 in (0.305 mm)
SHARP DENTS 0.010 in (0.254 mm) 0.015 in (0.381 mm)
NONSHARP DENTS 0.020 in (0.508 mm) 0.030 in (0.762 mm)
NOTES:
1. Damage defined on the chart above is acceptable if repaired as follows:

a. Damage is polished out with a fine abrasive cloth with minimum radius of 0.5 in (12.7 mm) and with surface finish of 32
RMS or better.
b. Maximum depth after rework does not exceed limits shown in chart.
c. Reworked area is treated for corrosion preventive.
d. If rework area is 8.0 sq-in more on one side than the other, shaft balance must be checked.
2. Loss of one or more balance weights is cause to replace driveshaft. One empty bonding space should be open where bond test
coupon was removed. If more than one empty space is observed, replace the driveshaft.
3. Damaged curvic coupling splines that result in radial play and/or backlash between assembled couplings when fully meshed
without clamps are not acceptable.
4. Grooves worn on shaft coupling by clamp to extent that wear prevents proper clamping are cause to replace driveshaft.
5. If tail rotor driveshaft distortion is suspected, support driveshaft on “V” blocks and measure run out. Maximum acceptable total
indicator reading on long shafts is 0.050 in (1.27 mm). Maximum acceptable total indicator reading on short shaft is 0.020 in
(0.508 mm). Do not attempt to straighten driveshaft.
6. Any crack in a driveshaft is cause to replace the affected driveshaft except cracks in rivet heads are acceptable if they do not
exceed the following limits:
a. Cracks are approximately radial when viewing top of shop head.
b. No cracks extends into an area with a diameter less than 1.25 diameters of rivet shank.
c. Cracks do not intersect.
d. The minimum distance between cracks is less than one shank diameter.
e. A maximum of three such cracks.
f. Crack width does not exceed 0.06 in (1.52 mm) times rivet shank diameter.
g. Maximum or ten percent of rivet shop heads may have cracks within above limits.
G6AB0511B
Figure 3. Tail rotor driveshaft - damage limits
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65-13-01
TAIL ROTOR DRIVE SYSTEM - ALIGNMENT
1. ALIGNMENT - DESCRIPTION
In order to align the tail rotor drive system, perform one of the procedures that follow.
2. ALIGNMENT - PROCEDURE
MATERIALS REQUIRED
NUMBER NOMENCLATURE
C-001 GREASE
C-251 SEALANT
C-309 SOLVENT
C-317 ADHESIVE
C-508 LOCKWIRE
NUMBER NOMENCLATURE
T52 INTERMEDIATE GEARBOX SIMULATOR
T54 TAIL ROTOR GEARBOX SIMULATOR
T77 ALIGNMENT PLATE
T78 HANGER SIMULATOR (2)
T79 HANGER SIMULATOR
T80 HANGER SIMULATOR
T111 BUSHING (PART OF T77 TOOL

ASSEMBLY)
T116 BUSHING (PART OF T77 TOOL

ASSEMBLY)
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1. A tail rotor drive system alignment check shall be made whenever driveshaft misalignment is suspected, when damage
to airframe structure in area of driveshaft hangers requires structural repair or parts replacement, or when major
structural repairs are performed in any area of tailboom or in aft section of forward fuselage. Alignment of driveshaft
hanger supports and intermediate gearbox shall be accomplished as follows:
a. Open tail rotor driveshaft covers and intermediate gearbox cover.
b. Remove tail rotor driveshafts and hangers (module 65-11-01 paragraph "2. Tail rotor driveshaft - removal",
module 65-11-02 paragraph "2. Driveshaft hanger assemblies - removal" and module 65-12-01 paragraph "2.
Tail rotor driveshafts and hanger - removal").
NOTE
Do not remove driveshaft hanger support assemblies from tailboom or forward
fuselage.
c. Remove intermediate gearbox (module 65-21-01 paragraph "2. Intermediate gearbox - removal"). Ensure any
shims between gearbox and tailboom remain in their original locations on tailboom.
d. Remove tail rotor gearbox (module 65-22-01 paragraph "2. Tail rotor gearbox - removal").
e. Remove tailboom from helicopter and place in suitable support cradle (Chapter 53).
f. Clean surfaces on tailboom and hanger supports where hangers and gearboxes were removed of primer and
sealant. Use a plastic scraper and a clean cloth damp with MEK (C-309) or aliphatic naphtha (C-305).
g. Install alignment plate (T77) on forward tailboom bulkhead as follows:
NOTE
Alignment plate (T77) has two bolts going through bushings in lower part of plate
and are secured with two barrel nuts. These barrel nuts have to be removed prior to
installing alignment plate to forward tailboom bulkhead.
(1) Position alignment plate (T77) on forward tailboom bulkhead with bushing (T111) on left side and bushing
(T116) on right side. Reference figure 1, view A, detail A.
NOTE
Before fully tightening AN9-31A and AN8-31A bolts, centralize position of
alignment plate (T77) within limits of looseness on bolts.
(2) Secure left side of alignment plate (T77) to forward tailboom bulkhead with AN9-31A bolt going through
washer AN960-916 and bushing (T111).
(3) Secure right side alignment plate (T77), to forward tailboom bulkhead with AN8-31A bolt going through
washer AN960-816 and bushing (T116).
h. Install tail rotor/90° gearbox simulator (T54) on top of vertical fin.
CAUTION
MAKE SURE THREE LEVELING SCREWS IN INTERMEDIATE GEARBOX

SIMULATOR ARE BACKED OFF SO THEY DO NOT PROJECT BELOW THE
MOUNTING SURFACE OF THE SIMULATOR BEFORE PROCEEDING.
i. Install intermediate gearbox simulator (T52) using AN4-13A bolts and sufficient number of AN960-416 and
AN960-416L washers under heads of bolts so bolt grips do not bottom out in mating tailboom nutplates.
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E-AB412-PT6T-2
G6AB0516A
Figure 1. Tail rotor driveshaft alignment (sheet 1 of 2)
65-13-01
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E-AB412-PT6T-2
G6AB0517A
Figure 1. Tail rotor driveshaft alignment (sheet 2 of 2)
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Page 4 Rev. 2
E-AB412-PT6T-2
CAUTION
VERIFY TAIL ROTOR GEARBOX SIMULATOR (T54) AND BULKHEAD

ALIGNMENT PLATE (T77) ARE SECURED BEFORE PROCEEDING.
j. Install unkinked 0.020 steel lockwire (C-508) in hole of tail rotor gearbox simulator (T54). Secure end of wire
on upper side of plate.
k. Pass other end of wire through hole in top of plate of intermediate gearbox simulator (T52) around “V” groove
in pin and out through hole of forward (vertical) end plate (figure 1, view E).
l. Pass wire through hole in tailboom bulkhead alignment plate (T77) and tighten wire until all slack is removed
and secure end of wire. Secure end of wire with safety wire spinner pliers or other positive locking pliers.
NOTE
Ensure wire is still unkinked and is still positioned in “V” groove in the pin in
intermediate gearbox simulator (T52).
m. Check for alignment of intermediate gearbox by confirming wire clears the edges of holes in top and forward
end plates by at least 0.005 in (0.127 mm). See view B. Pluck wire and check to see if the wire continues to
vibrate. If vibration continues, wire clearance is sufficient to proceed. Using a 6.0 in ruler or equivalent, measure
distance from center of wire to top surface of tailboom deck at forward face of gearbox simulator (T52). Distance
must measure 2.470 to 2.560 in (62.738 to 65.024 mm).
NOTE
If either the above conditions are not satisfactory, proceed to step (1).
If both conditions are satisfactory, proceed directly to step n.
(1) Loosen 0.020 in diameter alignment wire and remove intermediate gearbox simulator (T52).
(2) Remove all shims on tailboom at intermediate gearbox location, note thickness of shim-stacks removed.
Using a plastic scraper and a cloth damp with MEK (C-309) remove any adhesive or sealant residue around
gearbox mounting hole locations on tailboom.
(3) Adjust three levelling screws on intermediate gearbox simulator (T52) so they project below mounting
surface an amount approximately equal to thickness of shim-stack established in step (2) at corresponding
mounting bolt location.
CAUTION
WHEN GEARBOX SIMULATOR (T52) IS SUPPORTED ON ITS THREE

LEVELING SCREWS. TIGHTEN 4 SIMULATOR MOUNTING BOLTS TO
ONLY 20 TO 30 IN-LBS (2.26 TO 3.39 NM).
(4) Install intermediate gearbox simulator (T52) on tailboom in accordance with step i. and reinstall alignment
wire in accordance with steps k. and l. Ensure alignment wire is positioned in “V” groove in simulator pin.
(5) Loosen or tighten each of four simulator mounting bolts while adjusting each of three levelling bolts until
an acceptable simulator position is obtained. See step m.
(6) Ensure simulator mounting bolts are torqued to only 20 to 30 in-lbs (2.26 to 3.39 Nm); then using a
thickness gage, measure and record gaps between lower surface of simulator and tailboom at each of the
mounting bolt locations.
(7) Size thickness of shim-stacks for each simulator mounting bolt location equal to the respective gaps
measured in step (6).
65-13-01
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E-AB412-PT6T-2
(8) Loosen alignment wire and remove intermediate gearbox simulator (T52). Retract each of three leveling
bolts so it does not project below lower surface of simulator.
(9) Reinstall simulator in accordance with step i. using shim-stacks manufactured in step (7) and reinstall
alignment wire in accordance with steps k. and l. Tighten simulator mounting bolts 50 to 70 in-lbs (5.65 to
7.91 Nm) and confirm satisfactory wire positions in holes in top and forward end plates of simulator and
satisfactory wire elevation above tailboom in accordance with step m. If wire placement is satisfactory
proceed to step (10) otherwise repeat steps (1) through (9) until satisfactory alignment is obtained.
(10) Loosen alignment wire and remove intermediate gearbox simulator (T52). Measure and record final
thickness of shims at each of four mounting bolt locations.
(11) Clean the bonding surfaces of the shims and the tailboom with aliphatic naphtha (C-305).
(12) Bond the solid portion of the shims on the tailboom with adhesive (C-317). Do not put adhesive within
0.250 in (6.35 mm) of the bolt holes.
(13) Seal the edges of the shims with sealant (C-251).
NOTE
Coat bottom surface of intermediate gearbox simulator (T52) and the threads and
shank of each simulator mounting bolt with a very light coat of petroleum jelly or
grease (C-001) prior to installation.
(14) Reinstall intermediate gearbox simulator and tighten four mounting bolts 50 to 70 in-lbs (5.65 to 7.91 Nm).
Do not remove simulator until shim adhesive has set.
(15) Reinstall alignment wire in accordance with steps k .and l. and confirm satisfactory wire positions in holes
in top and forward end plates of simulator in accordance with step m.
n. Remove alignment wire from alignment plate (T77) and thread wire through forward and aft holes of a hanger
simulator (T78).
o. Install hanger simulator (T78) at number four location on tailboom using two AN4-10A bolts, two
MS35650-3252 nuts and sufficient number of AN960-416L washers under nut to keep nut from bottoming out
in bolt grip, see detail B. Leave fasteners slightly loose at this point.
p. Using uniform hand pressure on extreme aft end of simulator, push hanger simulator forward and hold in this
position while tightening the two bolts.
q. Tighten alignment wire in accordance with steps k. and l. Ensure alignment wire is positioned in “V” groove in
the intermediate gearbox simulator (T52) pin.
r. Verify acceptable alignment of hanger simulator (T78) by confirming alignment wire clears edges of holes in
forward and aft end plates of simulator by at least 0.005 in (0.127 mm), see view B. Pluck wire and watch wire
closely to see if the wire continues to vibrate. If vibration continues, wire clearance in holes is sufficient to
proceed. Also verify alignment wire is in acceptable positions in holes in forward and top end plates of
intermediate gearbox simulator (T52). If alignment of hanger simulator is acceptable proceed directly to step s.;
otherwise proceed as follows:
CAUTION
DO NOT LOOSEN HANGER SUPPORT TO AIRFRAME BOLTS ONCE “YAW”,

“LATERAL POSITION”, AND “ELEVATION” ADJUSTMENTS HAVE BEEN
MADE.
(1) If hanger simulator (T78) position error is in “yaw”, loosen four bolts securing hanger support to tailboom
and shift support to obtain acceptable alignment. Retighten bolts and verify acceptable alignment in
accordance with step r.
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E-AB412-PT6T-2
(2) If hanger simulator error is in “pitch” direction, remove four bolts securing hanger support to tailboom. To
adjust hanger simulator “pitch” forward, add equal shims under both aft support mounting pads and
remove same thickness of shims from under both forward mounting pads. Do the opposite to adjust hanger
simulator “pitch” aft. Install four mounting bolts and verify acceptable alignment in accordance with step
r. It will likely be necessary to perform step r. (1) to achieve acceptable “yaw” alignment.
NOTE
Elongation of the four mounting holes in the hanger support (20), figure 1 on the
forward fuselage is not permitted.
No more than two hanger supports on any tailboom may be reworked to facilitate
lateral alignment.
(3) If a “lateral position” error exists at any hanger (not simply a “yaw” error), remove alignment wire and
hanger simulator. Remove four bolts securing hanger support to tailboom and remove support. Rework
only the problem support in accordance with figure 1, view F. Following rework, reinstall support.
Reinstall hanger simulator and alignment wire in accordance with steps n. through q. Loosen four bolts
slightly and adjust lateral position of support so as to obtain satisfactory lateral alignment of simulator.
Verify acceptable alignment in accordance with step r. It will likely be necessary to repeat step (1) to restore
acceptable “yaw” alignment.
(4) If hanger simulator position error is in “elevation” (vertical position), remove four bolts securing hanger
support to tailboom and add or remove same thickness of shims under each of four support mounting pads.
Install four mounting bolts and verify acceptable hanger simulator alignment in accordance with step r. It
will likely be necessary to repeat steps (1) and (3) to achieve acceptable “yaw” and lateral position
alignment.
(5) When all three alignment conditions are satisfied proceed to step s.
NOTE
Ensure alignment wire remains free of kinks and is seated in “V” groove in
intermediate gearbox simulator pin in the following operations.
s. Remove hanger simulator (T78) from number four hanger location and install at location three. Perform steps o.
through r.
(1) Loosen the alignment wire and remove hanger simulator (T78) from hanger location three.
NOTE
Hanger simulators T80 and T79, are very similar in appearance. Confirm the correct
simulator is installed in the following operation.
(2) Install hanger simulator (T80) at hanger location two using two AN4H7A bolts and a sufficient number of
AN960-416L washers to keep the bolts from bottoming out in the bolt grip. Leave fasteners slightly loose
at this point. Perform steps p. through r., except, in step r. the hanger simulator will be the T80.
t. Tail rotor driveshaft hanger assembly alignment on tailboom is now complete. Remove tailboom bulkhead
alignment plate (T77), alignment wire, and hanger simulator, (T80).
u. Install tailboom on helicopter (Chapter 53).
65-13-01
Rev. 2 Page 7
E-AB412-PT6T-2
CAUTION
THE FOLLOWING PROCEDURES FOR ALIGNMENT OF HANGER BEARING

ASSEMBLY AT HANGER POSITION NUMBER ONE MUST BE PERFORMED
USING A TAILBOOM KNOWN TO HAVE ACCEPTABLE TAIL ROTOR DRIVE
SYSTEM ALIGNMENT.
v. Install hanger assemblies as follows:
(1) Install hanger simulator (T79) at number two hanger location in accordance with step s.(2) for (T80)
hanger simulator except perform only referenced step p. See view C.
(2) Install hanger simulators (T78) at number three and number four hanger locations in accordance with steps
o. and p. See view C.
(3) Install hanger simulator (T80) at number one hanger position in accordance with instructions given for
(T78) hanger simulator in steps o. and p. See view C.
NOTE
In steps w., x., and y., the (T80) hanger simulator at hanger number one location is
used as a wire anchor. Alignment of number one hanger support is accomplished in
accordance with steps z. through ab.
CAUTION
DO NOT LOOSEN BOLTS SECURING ANY HANGER SUPPORT TO

TAILBOOM IN AN EFFORT TO ACHIEVE SATISFACTORY ALIGNMENT IN
STEPS W. THROUGH AB.
w. Install a length of unkinked 0.020 in diameter wire in accordance with steps j. and k. Route wire through each
of three hanger simulators. Tighten wire until all slack is removed. Secure wire at forward end of hanger
simulator (T80) at number one hanger location. Secure end of wire with safety-wire spinner pliers or other
positive-locking pliers. Ensure alignment wire is positioned in “V” groove in the intermediate gearbox simulator
pin.
NOTE
A stable cushion such as shot bags or a sand bag should be placed between tailboom
skin and support so as to distribute the load and prevent damage to tailboom
structure. Tension on alignment wire may require adjustment during tailboom
position operation to prevent wire sag.
x. Position an adjustable support under tailboom. This support should be located at a point approximately 12.0 in
(30.48 cm) forward of intermediate gearbox location where extension of canted vertical fin spar approaches
adjacent tailboom bulkhead at lower surface of tailboom, see view C. Slowly adjust elevation of support as
required to position alignment wire within acceptable limits in each of three hanger simulators, see view B. Once
this position is obtained do not reposition helicopter or readjust tailboom support until tail rotor drive system
alignment is complete.
y. Remove alignment wire and hanger simulator (T80) from number one hanger location. Reposition hanger
simulator (T79) from number two hanger location to number one hanger location on forward fuselage. Install
hanger simulator (T79) in accordance with instructions given for the simulator (T78) in steps o. and p. See view
D.
65-13-01
Page 8 Rev. 2
E-AB412-PT6T-2
z. Remove hanger simulator (T78) from number four hanger location. Install hanger simulator (T80) at number
two hanger location in accordance with step s.(2).
aa. Install a new length of unkinked 0.020 in diameter wire in accordance with steps j. and k. Route wire through
hanger simulators at number three, two and one hanger locations. Tighten wire until all slack is removed and
secure wire at the forward end of hanger simulator (T79) at number one hanger location. Secure end of wire with
safety-wire spinner pliers or other positive-locking pliers. Ensure alignment wire is seated in “V” groove in
intermediate gearbox simulator (T52) pin.
NOTE
As an alternate procedure the alignment wire may be anchored at forward face of
hanger simulator (T79) and tension/clamped at top end plate of intermediate gearbox
simulator (T52).
ab. Verify acceptable alignment of hanger simulator by confirming alignment wire clears edges of holes in forward
and aft end plates of hanger simulators on tailboom, in aft end plate of hanger simulator at number one hanger
location and in forward and top end plates of intermediate gearbox simulator. See view B. If alignment of hanger
simulator (T79) is acceptable proceed directly to step ac; otherwise proceed as follows:
NOTE
Elongation of the four mounting holes in the No. 1 hanger support is not permitted.
(1) If hanger simulator error is in “yaw” direction, loosen four bolts securing hanger support to airframe and
shift support to obtain acceptable alignment. Tighten four bolts and verify acceptable alignment in
accordance with step ab.
(2) If hanger simulator error is in “pitch” position, relax tension on alignment wire and remove four bolts
securing hanger support to airframe. To “pitch” hanger simulator forward add equal shims under both aft
support mounting pads and remove same thickness of shims from under both forward mounting pads. Do
just the opposite to “pitch” support aft. Install four support mounting bolts, tighten alignment wire and
verify acceptable hanger simulator alignment in accordance with step ab. It may be necessary to perform
step (1) to achieve acceptable “yaw” alignment.
(3) If hanger simulator error is in “elevation” position (alignment wire hits top or bottom of holes in hanger
simulator at number two hanger location), relax tension on alignment wire and remove four bolts securing
hanger support to airframe. Add or remove equal shim thickness under each of four support mounting pads
to obtain required elevation. Install four mounting bolts and verify acceptable hanger simulator alignment
in accordance with step ab. It may be necessary to repeat step (1) to achieve acceptable “yaw” alignment.
ac. Tail rotor drive system alignment is complete. Remove all alignment tools and tailboom support. Verify bolts
securing hanger supports to forward fuselage and to tailboom are properly torqued. Remove any grease
remaining on uppermost shim at intermediate gearbox location.
2. Install tail rotor gearbox (module 65-22-01 paragraph "3. Tail rotor gearbox - installation").
3. Install intermediate gearbox (module 65-21-01 paragraph "3. Intermediate gearbox - installation").
4. Install tail rotor hangers and tail rotor driveshafts (module 65-11-02 paragraph "3. Driveshaft hanger assemblies -
installation" and module 65-11-01 paragraph "3. Tail rotor driveshaft - installation").
5. Close and secure tail rotor driveshaft covers.
65-13-01
Rev. 2 Page 9
E-AB412-PT6T-2
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Page 10 Rev. 2
E-AB412-PT6T-2
65-21-01
INTERMEDIATE GEARBOX
1. INTERMEDIATE GEARBOX - DESCRIPTION
The intermediate gearbox is installed on the tailboom forward of the vertical fin. The gearbox is aligned by use of shims
between the gearbox and the tailboom. The gearbox has an electric chip detector and an oil level sight gage located on the
right side. A vented filler plug is installed on top of the case. A cover with cowl fasteners provides access to the gearbox.
The maintenance procedures contained within the following paragraphs consist of troubleshooting, inspection, removal,
cleaning, limited repair, and installation. When any doubt exists as to the serviceability of a gearbox, perform serviceability
checks defined in Chapter 63.
2. INTERMEDIATE GEARBOX - REMOVAL
MATERIALS REQUIRED
NUMBER NOMENCLATURE
NUMBER NOMENCLATURE
T90 DRAIN LINE
1. If intermediate gearbox is to be replaced, accomplish preservation by one of the following methods:
a. If the operation is practical, perform a ten minute ground run-up and drain oil using DB 3703-30 drain line (T90).
b. If run-up is not practical, remove gearbox and spray inside through opening with approximately one liter of
applicable lubricating oil mixed with corrosion preventive compound (C-124). Use 150cc of corrosion
preventive compound (C-124) per liter of lubricating oil if the gearbox is serviced with lubricating oil
MIL-PRF-23699 (C-011) (15% concentration). Use 45cc of corrosion preventive compound (C-124) per liter of
lubricating oil if the gearbox is serviced with lubricating oil DOD-PRF-85734 (C-030) (5% concentration).
While spraying manually rotate internal gears and bearings with input drive quill. Ensure all gears, bearings and
surfaces are coated. Drain the gearbox.
c. Finally, attach tag to intermediate gearbox stating: “PRESERVED WITH OPERATING LUBRICANT”.
2. Open tail rotor driveshaft covers and remove intermediate gearbox cover.
3. Remove tail rotor driveshafts (1 and 10 or 14 and 15, figure 1) (module 65-11-01 paragraph "2. Tail rotor driveshaft -
removal".
65-21-01
Rev. 3 Page 1
E-AB412-PT6T-2
4. Remove chip detector (module 65-21-03 paragraph "1. Electrical chip detector - removal").
5. Cut and remove lockwire from bolts (3) (four places). Remove bolts (3) and washers (4 and 5).
6. Remove gearbox (7 or 12). Inspect shims (9) for secure installation on tailboom (8). If shims are not bonded to
tailboom, index shims for installation in same location.
3. INTERMEDIATE GEARBOX - INSTALLATION
MATERIALS REQUIRED
NUMBER NOMENCLATURE
C-405 LOCKWIRE
CAUTION
PRIOR TO INSTALLATION OF INTERMEDIATE GEARBOX, ACCOMPLISH

THE FOLLOWING:
ENSURE FLEXIBLE COUPLINGS IN INPUT AND OUTPUT QUILLS ARE

PROPERLY LUBRICATED (REFER TO MODULE 65-21-06 INTERMEDIATE
GEARBOX - FLEXIBLE COUPLINGS (P/N 412-040-006)).
ROTATE FLEXIBLE COUPLING ON INPUT QUILL AND CHECK FOR

BINDING AND PRESENCE OF BACKLASH BETWEEN PINION ON INPUT
QUILL AND GEAR ON OUTPUT QUILL.
DRAIN OIL FROM INTERMEDIATE GEARBOX AND SERVICE WITH

APPROVED LUBRICATING OIL (CHAPTER 12).
REFER TO THE TAIL ROTOR DRIVE SYSTEM ALIGNMENT PROCEDURE

(MODULE 65-13-01 TAIL ROTOR DRIVE SYSTEM - ALIGNMENT) TO
DETERMINE IF AN ALIGNMENT CHECK OR GEARBOX SHIMMING IS
REQUIRED.
SHIMS (9, FIGURE 1) SHOULD BE BONDED TO TAILBOOM (8). IF SHIMS

(9) ARE NOT BONDED TO TAILBOOM (8), ENSURE SAME SHIMS THAT
WERE REMOVED, OR SHIMS OF IDENTICAL THICKNESS ARE
INSTALLED. FAILURE TO COMPLY COULD CAUSE MISALIGNMENT AND
FAILURE OF TAIL ROTOR DRIVE COMPONENTS.
1. Clean mating surfaces of intermediate gearbox (7, figure 1) and tailboom (8).
2. Position intermediate gearbox on tailboom.
3. Check gearbox for contact with shim (9) at four points with bolts (3) installed and torque 20 to 30 in-lbs (2.26 to 3.39
Nm). Maximum acceptable gap at any of the four points is 0.001 in (0.025 mm).
65-21-01
Page 2 Rev. 3
E-AB412-PT6T-2
4. Remove gearbox and coat all faying surfaces, bolts, washers and bolt holes with unreduced zinc chromate primer
(C-201) or unreduced epoxy polyamide primer (C-204). Do not apply primer to the bolt threads.
5. Position gearbox on tailboom and wet install bolts (3) with steel washer (4) next to bolt head and aluminum washer
(5) next to gearbox. Bottoming of bolt (3) grip is to be determined as follows:
a. Additional aluminum washers (5) may be required if bolt (3) grip bottoms in the nut plate prior to securing the
gearbox.
b. Torque each bolt (3) 30 to 40 in-lbs (3.39 to 4.52 Nm) and check steel washers (4) under bolt heads for looseness.
If any of the steel washers are loose, add aluminum washers (5) as required at each bolt location to ensure no
looseness.
c. After completion of bolt-grip-bottoming test, re-torque bolts (3) 50 to 70 in-lbs (5.65 to 7.91 Nm). Apply
lockwire (C-405) to bolts in pairs at each side.
6. Install driveshafts (1 and 10) (module 65-11-01 paragraph "3. Tail rotor driveshaft - installation").
7. Verify actual presence of oil in sight gauge and check oil level on full mark on indicator.
8. Install chip detector (module 65-21-03 paragraph "2. Electrical chip detector - installation").
9. If intermediate gearbox has not previously been qualified on run-in test stand, accomplish alternate run-in test
(paragraph "10. Intermediate gearbox - alternate run-in test").
10. Install intermediate gearbox cover and close tail rotor driveshaft covers.
11. Do the special inspection between 5 and 10 hours of flight after each installation (refer to E-AB412-PT6T-6).
65-21-01
Rev. 3 Page 3
E-AB412-PT6T-2
TORQUE
50 TO 70 IN-LBS
(5.65 TO 7.91 Nm)
1. Driveshaft
2. Overtemperature indicators
(TEMP-PLATES)
3. Bolt
4. Steel washer
5. Aluminum washer
6. Coupling
7. Gearbox (412-040-006)
8. Tailboom
9. Shim
10. Driveshaft
11. Coupling
12. Gearbox (212-040-004)
13. Coupling
14. Driveshaft
15. Driveshaft
G6AB0525C
Figure 1. Intermediate gearbox
65-21-01
Page 4 Rev. 3
E-AB412-PT6T-2
4. INTERMEDIATE GEARBOX - TROUBLESHOOTING
Refer to table 1.
Table 1. Intermediate gearbox - troubleshooting
CHIP 42/90 BOX caution segment Metal chips have accumulated on chip Remove and inspect electric chip detec-
illuminated. detector. tor. If chips are found, retain in a clean
container for subsequent investigation
(module 65-21-03 paragraph "1. Elec-
trical chip detector - removal").
Faulty wiring or faulty chip detector. Check wiring to electric chip detector
for continuity and grounding (Chapter
98). Repair faulty wiring or replace
electric chip detector as required
(Chapter 95).
Oil leakage from intermediate gear- Faulty seals, packings, or wear sleeves. Clean gearbox and recheck for oil leak
box. both static and dynamic (engine operat-
ing). Measure and record rate of leak-
age. Maximum allowable static or
dynamic leakage at input drive quill is
two drops per minute. Total allowable
leakage from all sources on gearbox is
six drops per minute.
Replace gearbox seals, packings, or

wear sleeves, if maximum allowable
leakage rate is exceeded
(E-AB412-PT6T-3).
Cracked gearbox housing. Inspect gearbox for cracks in housing.

Replace gearbox if cracks are found.
5. INTERMEDIATE GEARBOX - INSPECTION (INSTALLED)
1. Open tail rotor driveshaft covers and remove intermediate gearbox cover.
2. Shake gearbox (7, figure 1) and check for looseness on tailboom. No looseness is acceptable.
3. Check for evidence of fretting corrosion at mating surface between gearbox and tailboom which could be caused by
movement of gearbox on tailboom. A gray residue is an indication of fretting corrosion. If residue is present, remove
gearbox and inspect in accordance with E-AB412-PT6T-3.
NOTE
Inspection steps 4. through 7. are not applicable if gearbox is removed in step 3.
65-21-01
Rev. 3 Page 5
E-AB412-PT6T-2
4. Inspect bolts (3) for correct torque and correct thread engagement.
5. Inspect couplings (6, 11) for grease leakage and visual overtemperature indicators (TEMP-PLATE) for discoloration
and overheat condition. A change in color of TEMP-PLATE dots (white to black) indicates a possible overheat
condition and/or component degradation. Cause of TEMP-PLATE discoloration shall be determined and corrected
prior to continued operation. Refer to module 65-11-02 paragraph "5. Driveshaft hanger assemblies - inspection". If
coupling has overheated, remove gearbox for inspection of inner and outer couplings. Refer to E-AB412-PT6T-3
manual for inspection procedures and module 65-21-05 paragraph "1. Flexible couplings (P/N 212-040-004) -
inspection and lubrication" for lubrication.
6. Inspect oil sight glass for correct oil level. Inspect sight glass and indicator for staining and/or cracks and crazing.
Damage which can cause oil leakage or make oil level difficult to determine is not acceptable.
7. Inspect electrical chip detector for metal particles (module 65-21-03 paragraph "4. Electrical chip detector -
inspection"). Refer to Chapter 63 for serviceability check required if metal particles are found.
6. INTERMEDIATE GEARBOX - CLEANING
MATERIALS REQUIRED
NUMBER NOMENCLATURE
1. Clean gearbox with clean cloth dampened with drycleaning solvent (C-304).
CAUTION
DO NOT FORCE SOLVENT AND\OR DIRT INTO FLEXIBLE COUPLING

WHEN USING COMPRESSED AIR.
7. INTERMEDIATE GEARBOX - INSPECTION (NOT INSTALLED)
Refer to E-AB412-PT6T-3 manual.
8. INTERMEDIATE GEARBOX - INSPECTION (CONDITIONAL)
NOTE
Conditional inspections of intermediate gearbox are required after tail rotor drive
system overtorque, sudden stoppage, compressor stall, etc. (Refer to
E-AB412-PT6T-6).
9. INTERMEDIATE GEARBOX - REPAIR
1. Repair intermediate gearbox in accordance with E-AB412-PT6T-3 manual.
65-21-01
Page 6 Rev. 3
E-AB412-PT6T-2
2. Repair faulty filler cap by same procedure outlined for tail rotor gearbox filler cap (module 65-22-05 paragraph "4. Oil
filler cap - repair").
3. Replace sight glass and/or oil level indicator that fails to pass inspection (module 65-21-02 "INTERMEDIATE
GEARBOX - SIGHT GLASS").
4. Replace chip detector and/or self-closing valve which fails to pass inspection (module 65-21-03 paragraph "4.
Electrical chip detector - inspection").
5. Replace overtemperature indicators (TEMP-PLATE) (2, figure 1) on couplings (6, 11) if mutilated or discolored
(E-AB412-PT6T-3).
10. INTERMEDIATE GEARBOX - ALTERNATE RUN-IN TEST
NOTE
It is desirable that intermediate gearbox be test run and inspected after overhaul in
accordance with publication furnished with run-in stand for qualification for flight.
In the event a run-in stand is not available, the following functional test may be
accomplished as a minimum acceptable alternate run-in test.
1. Install sufficient ballast in cabin to obtain maximum allowable gross weight (E-AB412-PT6T-1).
2. Verify helicopter is properly serviced and lubricated (Chapter 12).
3. Start engines (E-AB412-PT6T-1) and operate at 60% RPM for 5 minutes.
4. Gradually increase RPM to 88% at a rate of 7% each six minutes.
5. Hold at 88% RPM for two minutes with collective pitch applied to maximum which can be maintained without
becoming airborne or exceeding 100% torque.
6. Shut down engines.
7. Remove, inspect, clean and install chip detector on intermediate gearbox.
8. Start engines and slowly increase to 88% RPM. Run at 88% RPM for six minutes. Apply collective pitch to the
maximum position that can be maintained without becoming airborne or exceeding 100% torque. Gradually increase
RPM to 100% without becoming airborne or exceeding 100% torque, at a rate of 3% each six minutes.
9. Run at 100% RPM for 30 minutes with collective pitch in maximum up position which can be maintained without
becoming airborne or exceeding 100% torque.
10. Stop engines and drain oil from intermediate gearbox. Check gearbox oil and chip detector for an excessive amount of
metal particles which may indicate internal failure (Chapter 63). Service the intermediate gearbox (Chapter 12).
11. Inspect input and output quill couplings and surrounding area for evidence of grease leakage. If there is evidence of
grease leakage, remove couplings and replace defective parts. Verify the servicing of the gearbox (Chapter 12.) Repeat
test run.
12. Check visual overtemperature indicators (TEMP-PLATE) for discoloration and overheat condition. A change in color
of TEMP-PLATE dots (from white to black) will indicate a possible overheat condition and/or component degradation.
The cause of indicators discoloration shall be determined and corrected prior to continued operation.
Refer to module 65-11-02 paragraph "5. Driveshaft hanger assemblies - inspection".
13. Replace visual over-temperature indicators (TEMP-PLATE) if mutilated or discolored (E-AB412-PT6T-3).
14. Install chip detector and service intermediate gearbox (Chapter 12).
65-21-01
Rev. 3 Page 7
E-AB412-PT6T-2
65-21-01
Page 8 Rev. 3
E-AB412-PT6T-2
65-21-02
INTERMEDIATE GEARBOX - SIGHT GLASS
1. SIGHT GLASS - REMOVAL
NUMBER NOMENCLATURE
T90 DRAIN LINE
1. Remove chip detector (module 65-21-03 paragraph "1. Electrical chip detector - removal").
2. Insert one end of drain line (T90) into container. Insert other end in hole where detector was installed. Oil will
automatically drain.
3. Remove retaining ring (1, figure 1) from gearbox (5).
4. Remove sight glass (3) and packing (2). Discard packing.
5. Remove oil level indicator (4).
6. Remove drain line (T90).
2. SIGHT GLASS - INSTALLATION
1. Install oil level indicator (4, figure 1) in gearbox (5).
2. Install packing (2) on sight glass (3). Coat packing with gearbox oil (Chapter 12). Install glass (3).
3. Install retaining ring (1).
5. Service the gearbox (Chapter 12).
65-21-02
Rev. 2 Page 1
E-AB412-PT6T-2
1. Retaining ring
2. Packing
3. Sight glass
4. Oil level indicator
5. Gearbox
G6AB0526B
Figure 1. Intermediate gearbox sight glass
65-21-02
Page 2 Rev. 2
E-AB412-PT6T-2
65-21-03
INTERMEDIATE GEARBOX - ELECTRICAL CHIP DETECTOR
1. ELECTRICAL CHIP DETECTOR - REMOVAL
NUMBER NOMENCLATURE
T90 DRAIN LIFE
NOTE
Chip detector element (3, figure 1) may be removed for inspection without draining
gearbox oil.
1. Move nipple (8) back on electrical wire terminal (2) to expose nut (1). Remove nut (1) and electrical wire (2).
2. Press in on knurled body of chip detector (3), turn counterclockwise to disengage locking detent and withdraw chip
detector (3) from self-closing valve (5). Remove packing (4) and discard.
NOTE
If self-closing valve (5) is to be removed, install oil drain line (T90) in self-closing
valve (5) and allow oil to drain from gearbox.
3. Cut and remove lockwire from self-closing valve (5). Remove self-closing valve (5) from intermediate gearbox (7).
Remove gasket (6) from self-closing valve (5). Discard gasket.
2. ELECTRICAL CHIP DETECTOR - INSTALLATION
MATERIALS REQUIRED
NUMBER NOMENCLATURE
C-405 LOCKWIRE
1. Lubricate new gasket (6, figure 1) with gearbox lubricating oil (Chapter 12) and install gasket on valve (5).
2. Install self-closing valve (5) on gearbox case (7). Torque valve (5) 120 to 150 in.-lbs. (13,56 to 16,95 Nm). Apply
lockwire (C-405) to secure valve (5) to gearbox case (7).
3. Lubricate new packing (4) with gearbox lubricating oil (Chapter 12) and install packing on chip detector (3). Insert
chip detector (3) into valve (5). Push and twist clockwise to engage locking detents.
4. Position electrical wire (2) on chip detector (3) and install nut (1). Do not exceed 4 in.-lbs. (0,45 Nm) torque on nut.
Position nipple (8) over nut (1).
5. Service gearbox (Chapter 12) if self-closing valve (5) was removed.
65-21-03
Page 1
E-AB412-PT6T-2
3. ELECTRICAL CHIP DETECTOR - CLEANING
MATERIALS REQUIRED
NUMBER NOMENCLATURE
4. ELECTRICAL CHIP DETECTOR - INSPECTION
1. Refer to Chapter 63 for procedure to inspect electrical chip detector for metal particles.
2. Inspect electrical chip detector, in accordance with figure 2.
3. Perform an operational check on chip detector (Chapter 96).
5. ELECTRICAL CHIP DETECTOR - REPAIR
Repair of the electrical chip detector assembly (9, figure 1) is restricted to replacement of defective parts.
65-21-03
Page 2
E-AB412-PT6T-2
G6AB0527A
Figure 1. Intermediate gearbox electrical chip detector
65-21-03
Page 3
E-AB412-PT6T-2
AREA LIMITS
All No cracks allowed.
A Maximum depth of pitting is 0.762 mm (0.030 in) with no more than 40% of any
25.4 mm (1.0 in) square or 20% of total area of any surface to be pitted.
B Maximum depth of pitting is 0.508 mm (0.020 in) with no more than 40% of any
square or 20% of total area of any surface to be pitted. Thread damage is
not permitted.
G6AB0830A
Figure 2. Intermediate gearbox chip detector (P/N B3703) - damage limits
65-21-03
Page 4
E-AB412-PT6T-2
65-21-04
INTERMEDIATE GEARBOX - OIL FILLER CAP
1. OIL FILLER CAP - REMOVAL
1. Push down on cap (6, figure 1) and twist to disengage pin (7) from gearbox (4).
2. Unsnap safety pin (1) from gearbox (4).
2. OIL FILLER CAP - INSTALLATION
1. Position cap assembly on gearbox (4, figure 1). Push down on cap (6) and twist clockwise to engage pin (7) in gearbox
adapter.
2. Secure chain (3) to gearbox (4) with safety pin (1).
3. OIL FILLER CAP - INSPECTION
1. Inspect cap for distortion of pin (7, figure 1) or other damage which may affect function.
2. Invert filler cap to expose washer (11). Press washer approximately 0,06 in. (1,52 mm) and release. Washer should
spring back against ring (12). If washer does not return to original position, aluminum wool packing is dirty or an
insufficient amount of aluminum wool is installed.
4. OIL FILLER CAP - REPAIR
Repair intermediate gearbox filler cap assembly by same procedure outlined for tail rotor gearbox filler cap
(module 65-22-05 paragraph "4. Oil filler cap - repair").
65-21-04
Page 1
E-AB412-PT6T-2
G6AB0528A
Figure 1. Intermediate gearbox oil filler cap
65-21-04
Page 2
E-AB412-PT6T-2
65-21-05
INTERMEDIATE GEARBOX - FLEXIBLE COUPLINGS (P/N 212-040-004)
1. FLEXIBLE COUPLINGS (P/N 212-040-004) - INSPECTION AND LUBRICATION
MATERIALS REQUIRED
NUMBER NOMENCLATURE
C-015 LUBRICANT (TUBE PACK)
1. Remove tail rotor driveshaft sections (1 and 12, figure 1) attached to intermediate gearbox (module 65-11-01
paragraph "2. Tail rotor driveshaft - removal" or module 65-12-01 paragraph "2. Tail rotor driveshafts and hanger -
removal").
NOTE
Instructions to lubricate the intermediate gearbox input quill flexible coupling (13)
are given. The procedure to lubricate the output quill flexible coupling (10) is the
same.
2. While holding coupling seal plate assembly (4) against spring (5), remove retainer ring (3). Remove coupling seal plate
assembly and spring (5).
CAUTION
DO NOT USE SOLVENT TO CLEAN COUPLING SPLINES. SOLVENT MAY

LEAVE RESIDUE THAT PREVENTS LUBRICANT FROM ADHERING TO
COUPLING.
3. Hold outer coupling (7) at full inboard position and use clean, lint-free cloths to remove all old grease. Clean splines
thoroughly.
NOTE
For detailed disassembly, inspection, and assembly instructions, refer to the
E-AB412-PT6T-3.
4. Visually inspect splines of inner coupling (6) and outer coupling (7) for unusual wear patterns, nicks, dents, and cracks.
Maximum acceptable wear is 0.005 in (0.127 mm). Refer to the E-AB412-PT6T-3 for detailed damages limits for
coupling splines.
5. Inspect coupling seal plate assembly (4) for damage which could cause leakage of lubricant.
6. Inspect seal (8) in outer coupling (7) for protrusion or other damage which could cause leakage of lubricant.
7. Move outer coupling (7) on inner coupling (6) forward and aft with clockwise and counterclockwise preload and feel
for roughness. If any roughness or resistance is left, reinspect coupling splines for damage.
65-21-05
Rev. 3 Page 1
E-AB412-PT6T-2
8. Hold outer coupling (7) at full outboard position. Hand pack lubricant (tube pack) (C-015) 0.12 in (3.5 mm) over top
of coupling spline teeth. A workaid may be fabricated, as shown in figure 2, to obtain depth of grease (Chapter 63).
9. Hold outer coupling (7) at full outboard position. Install spring (5), coupling seal plate assembly (4), and retainer ring
(3).
10. Lubricate output quill flexible coupling (10) in same manner outlined in step 2. through 9.
11. Install tail rotor driveshaft sections (1 and 12) (module 65-11-01 paragraph "3. Tail rotor driveshaft - installation" or
module 65-12-01 paragraph "2. Tail rotor driveshafts and hanger - removal").
NOTE
repaired, or re-lubricated flexible couplings.
12. After flexible couplings are lubricated, perform the following test to ensure coupling is not leaking:
a. Clean all lubricant from exterior surfaces of coupling and clamp set securing tail rotor driveshaft to coupling.
Clean all lubricant from surrounding helicopter structure.
b. Operate helicopter for 5 minutes at 100% RPM.
c. After shutdown, inspect coupling and surrounding structure for evidence of grease leakage. If there is evidence
of grease leakage, remove coupling and replace defective parts. Repeat leak test run.
13. Inspect input quill coupling and surrounding area for grease leakage (E-AB412-PT6T-3) . If there is evidence of grease
leakage, remove coupling and replace defective parts. Repeat leak test run.
14. Check visual overtemperature indicators (TEMP-PLATES) for discoloration and overheat condition. A change in color
of TEMP-PLATES dots (from withe to black) indicates a possible overheat condition and/or component degradation.
The cause of overtemperature indicator discoloration shall be determined and corrected prior to continued operation
(module 65-11-02 paragraph "5. Driveshaft hanger assemblies - inspection" or module 65-12-01 paragraph "5. Tail
rotor driveshafts and hanger - cleaning").
15. Replace visual overtemperature indicators if mutilated or discolored (E-AB412-PT6T-3)
16. Make an entry in helicopter log and in flexible couplings lubrication log of date lubricated, date grease manufactured,
and helicopter hours (Chapter 12).
65-21-05
Page 2 Rev. 3
E-AB412-PT6T-2

2. Clamp assembly
3. Retainer ring
4. Coupling seal plate assembly
5. Spring
6. Inner coupling
7. Outer coupling
8. Seal
10. Output quill flexible coupling
11. Clamp assembly
13. Input quill flexible coupling assembly
G6AB0529B
Figure 1. Intermediate gearbox flexible couplings (P/N 212-040-004)
65-21-05
Rev. 3 Page 3
E-AB412-PT6T-2
G6AB0831A
Figure 2. Workaid for lubrication of tail rotor drive couplings
65-21-05
Page 4 Rev. 3
E-AB412-PT6T-2
65-21-06
65-21-06
INTERMEDIATE GEARBOX - FLEXIBLE COUPLINGS (P/N 412-040-006)
1. FLEXIBLE COUPLINGS (P/N 412-040-006) - LUBRICATION
MATERIALS REQUIRED
NUMBER NOMENCLATURE
1. Remove tail rotor driveshaft (7, figure 1) from gearbox output quill (module 65-12-01 paragraph "2. Tail rotor
driveshafts and hanger - removal").
2. Remove retainer ring (1), plate (2) and packing (3). Discard packing.
CAUTION

COUPLING.
thoroughly.
NOTE
For detailed disassembly, inspection and assembly instructions, refer to the
E-AB412-PT6T-3.
4. Visually inspect splines of inner coupling (5) for unusual wear patterns, nicks, dents or cracks. Refer to
E-AB412-PT6T-3 for detailed damages limits for coupling splines.
5. Inspect plate (2) for damage that could cause leakage of lubricant.
6. Inspect the nut and seal assembly (6) in outer coupling (4) for damage that could cause leakage of lubricant
7. Hold outer coupling (4) at full outboard position. Hand-pack lubricant (tube pack) (C-015) over top of outer coupling
to a depth of 0.20 in (5.1 mm) over top of spline teeth.
8. Hold outer coupling (4) at full outboard position. Install new packing (3) on plate (2). Install plate and retainer ring (1)
in outer coupling.
9. Install tail rotor driveshaft (7) (module 65-12-01 paragraph "3. Tail rotor driveshafts and hanger - installation").
NOTE
65-21-06
Rev. 3 Page 1
E-AB412-PT6T-2
10. After flexible coupling is lubricated, perform the following test to ensure coupling is not leaking.
a. Clean all lubricant from exterior surfaces of coupling and clamp set securing tail rotor driveshaft to coupling.
Clean all lubricant from surrounding helicopter structure.
b. Operate helicopter for 5 minutes at 100%.
c. After shutdown, inspect coupling and surrounding structure for evidence of grease leakage (E-AB412-PT6T-3).
If there is evidence of grease leakage, remove coupling and replace defective parts. Repeat leak test run.
11. Inspect input quill coupling and surrounding area for grease leakage (E-AB412-PT6T-3). If there is evidence of grease
leakage, remove coupling and replace defective parts. Repeat leak test run.
of TEMP-PLATES dots (from white to black) indicates a possible overheat condition and/or component degradation.
The cause of overtemperature indicators discoloration shall be determined and corrected prior to continued operation.
Refer to module 65-12-01 paragraph "5. Tail rotor driveshafts and hanger - cleaning".
13. Replace visual overtemperature indicators if mutilated or discolored (E-AB412-PT6T-3).
65-21-06
Page 2 Rev. 3
E-AB412-PT6T-2
1. Retainer ring
2. Plate
3. Packing
4. Outer coupling
5. Inner coupling
6. Nut and seal assembly
7. Driveshaft
G6AB1069A
Figure 1. Intermediate gearbox flexible coupling (P/N 412-040-006)
65-21-06
Rev. 3 Page 3
E-AB412-PT6T-2
65-21-06
Page 4 Rev. 3
E-AB412-PT6T-2
65-2 -01 TAIL ROTOR GEARBOX [A] [B] [C]
65-22-01
TAIL ROTOR GEARBOX [A] [B] [C]
1. TAIL ROTOR GEARBOX - DESCRIPTION
The tail rotor gearbox is located at the top of the vertical fin and provides at 90° change in direction of drive. The gearbox
has a vented oil filler cap located at the top of the gearbox case. The gearbox has an electric chip detector and oil level sight
gage on the lower left side of the gearbox case. The input quill has a flexible crownedtooth coupling for attachment to the
driveshafts. Control linkage is attached on the left side with a control rod extending through the rotor shaft for control of tail
rotor pitch angle.
The maintenance procedures contained within the following paragraphs consist of troubleshooting, inspection (installed and
removed from helicopter as well as a conditional inspection), removal, cleaning, limited repair, and installation. When any
doubt exists as to the serviceability of a gearbox, perform serviceability checks defined in Chapter 63.
2. TAIL ROTOR GEARBOX - REMOVAL
MATERIALS REQUIRED
NUMBER NOMENCLATURE
NUMBER NOMENCLATURE
T23-1 TAIL ROTOR GEARBOX PUSHER
T90 DRAIN LINE
1. If tail rotor gearbox is to be replaced, accomplish preservation by one of the following methods:
a. If the operation is practical, perform a ten minute ground run-up and drain oil using drain line (T90).
b. If run-up is not practical, remove tail rotor gearbox and spray inside through opening with approximately one
liter of applicable lubricating oil mixed with corrosion preventive compound (C-124). Use 150cc of corrosion
preventive compound (C-124) per liter of lubricating oil if the gearbox is serviced with lubricating oil
MIL-PRF-23699 (C-011) (15% concentration). Use 45cc of corrosion preventive compound (C-124) per liter of
lubricating oil if the gearbox is serviced with lubricating oil DOD-PRF-85734 (C-030) (5% concentration).
While spraying manually rotate internal gears and bearings with input drive quill. Ensure all gears, bearings and
surfaces are coated. Drain the gearbox.
c. Finally, attach tag to tail rotor gearbox stating: “PRESERVED WITH OPERATING LUBRICANT”.
2. Remove tail rotor assembly (Chapter 64).
65-22-01
Rev. 3 Page 1
E-AB412-PT6T-2
3. Remove cotter pin (9, figure 1), nut (4), and washer (5). Remove bolt (7) and washer (6) and disconnect link assembly
(8) from lever (3).
4. Disconnect electrical wire and remove chip detector (module 65-22-04 paragraph "1. Electrical chip detector -
removal").
5. Open vertical fin cover (12) and remove intermediate gearbox fairing.
6. Remove driveshaft (13) (module 65-11-01 paragraph "2. Tail rotor driveshaft - removal".
7. Remove nuts (11) with thin steel washers (10).
8. Remove gearbox (1) from support fitting (14) using tail rotor gearbox pusher (T23-1) (figure 2).
NOTE
Install two spacers (15, figure 1) and nut (11) with thin steel washer (10) on gearbox
studs (17) to hold input quill in gearbox (1) while gearbox is removed from
helicopter.
3. TAIL ROTOR GEARBOX - INSTALLATION
MATERIALS REQUIRED
NUMBER NOMENCLATURE
C-251 SEALANT
CAUTION
PRIOR TO INSTALLATION OF TAIL ROTOR GEARBOX, ACCOMPLISH THE

FOLLOWING:
ENSURE GEARBOX FLEXIBLE COUPLING IS PROPERLY LUBRICATED

(E-AB412-PT6T-3).
ROTATE FLEXIBLE COUPLING AND CHECK FOR BINDING AND FOR

PRESENCE OF BACKLASH BETWEEN PINION ON INPUT QUILL AND
GEAR ON OUTPUT SHAFT.
DRAIN PRESERVATIVE OIL (IF ANY) FROM GEARBOX AND SERVICE

WITH APPROVED OIL (CHAPTER 12).
1. Check mounting flange of gearbox (1, figure 1) for sealant protruding from the three jackscrew holes. Trim off sealant
flush to allow proper seating of tail rotor gearbox (1) flange on support fitting (14).
2. Remove nuts (11), spacers (15), and thin steel washers (10) from studs (17) around input drive quill.
65-22-01
Page 2 Rev. 3
E-AB412-PT6T-2
3. Using MEK (C-309) and a non-metallic scraper, clean mating surfaces of gearbox (1) and tailboom support fitting (14).
4. Coat all faying surfaces of gearbox, studs, tailboom mount fitting, holes for studs in mount, and washers with epoxy
polyamide primer (C-204). Do not apply primer to the threads of the studs. Install the gearbox while primer is wet.
CAUTION
ENSURE A MINIMUM OF TWO THREAD PITCHES, INCLUDING CHAMFER,

EXTEND THROUGH NUTS (11). ENSURE NUTS DO NOT BOTTOM ON GRIP
PORTION OF STUDS. USE ADDITIONAL THIN STEEL WASHERS (10) IF
REQUIRED.
NOTE
Perform special inspection after installation (between 1 and 10 hours of flight after
each installation) of tail rotor gearbox (E-AB412-PT6T-6).
5. Position tail rotor gearbox (1) on support fitting (14) with coupling (16) and studs (17) through holes in support fitting
(14).
6. Install thin steel washers (10) and nuts (11). Torque evenly in a star pattern 200 to 235 in-lbs (22.60 to 26.55 Nm).
Repeat torque pattern until all nuts retain torque initially applied to first nut in pattern. Torque value of first nut will
decrease as other nuts are torqued. Use a 0.005 in (0.127 mm) feeler gauge to verify that no gap exists between shim
plate installed between gearbox input quill and gearbox.
7. Apply a fillet of sealant (C-251) around the periphery of the mating surface of the tail rotor gearbox (1) and support
fitting (14).
8. Connect link assembly (8) to lever (3). Install bolt (7) with washer (6) under bolt head and washer (5) under nut (4).
Additional washers (5) may be used to align nut (4) for cotter pin installation. Install cotter pin (9).
10. Verify actual presence of oil in sight gauge and check oil level to full mark on indicator.
11. Close vertical fin cover (12) and install intermediate gearbox fairing.
12. Install and rig tail rotor (Chapter 67).
13. If gearbox has not been previously qualified on run-in test stand, accomplish alternate run-in and test (paragraph "10.
Tail rotor gearbox - alternate run-in test").
65-22-01
Rev. 3 Page 3
E-AB412-PT6T-2
4. TAIL ROTOR GEARBOX - TROUBLESHOOTING
Refer to table 1.
Table 1. Tail rotor gearbox - troubleshooting
CHIP 42/90 BOX caution segment Metal chips have accumulated on chip Remove electric chip detector and
illuminated. detector. inspect for metal chips. If chips are
found, retain them in a clean container
for subsequent investigation
(module 65-22-04 TAIL ROTOR
GEARBOX - ELECTRICAL CHIP
DETECTOR and Chapter 63).
Faulty wiring or faulty chip Check wiring to electric chip detector

detector. for continuity and grounding. Repair
faulty wiring or replace electric chip
detector as required. (Chapter 96).
Oil leakage from tail rotor gearbox. Faulty seals, packings, or wear Clean gearbox and recheck for oil leak
sleeves. both static and dynamic (helicopter
running). Measure and record rate of
leakage. Maximum allowable static or
dynamic leakage at input drive quill is
two drops per minute. Total allowable
leakage from all sources on gearbox is
six drops per minute.
Replace gearbox seals, packings, or

wear sleeves if maximum allowable
leakage rate is exceeded
(E-AB412-PT6T-3).
Cracked gearbox housing. Inspect gearbox for cracks in housing.

Replace gearbox if cracks are found.
65-22-01
Page 4 Rev. 3
E-AB412-PT6T-2
TORQUE
200 TO 235 IN-LBS
(22.60 TO 26.55 Nm)

2. Cap assembly
3. Lever
4. Nut
5. Washer
6. Washer
7. Bolt
8. Link assembly
9. Cotter pin
11. Nut
12. Vertical fin cover
13. Driveshaft
14. Support fitting
15. Spacer (NAS 43DD6-49)
(2 reqd - removed prior to installation)
16. Coupling
17. Stud
G6AB0530C
Figure 1. Tail rotor gearbox
65-22-01
Rev. 3 Page 5
E-AB412-PT6T-2
1. Tail rotor gearbox pusher (T101264-103)

2. Adapter assembly (T101264-109)
3. Tail rotor gearbox assembly
4. Tail rotor gearbox support
5. Clamp assembly (T101264-107)
6. Screw assembly (T101264-105)
7. Adapter retainer (T101264-121)
NOTES:
1. If not previously accomplished, thread screw assembly (6) into clamp assembly (5). Allow sufficient clearance for posi-
tioning on support (4) and adapter assembly (2).
2. Position both halves of adapter assembly (2) on tail rotor gearbox (3) against input quill as shown.
3. Position tail rotor gearbox pusher (1) on gearbox and support with hooks of clamp assembly (5) centered securely over
shoulders of support (4) and adapter retainer (7) over both halves of adapter assembly (2).
4. Tighten screw assembly (6) clockwise with a suitable wrench until tail rotor gearbox (3) separates from support (4).
Remove tools and lift gearbox from support.
G6AB0531B
Figure 2. Tail rotor gearbox pusher T23-1 (T101264-103) - tool application
65-22-01
Page 6 Rev. 3
E-AB412-PT6T-2
5. TAIL ROTOR GEARBOX - INSPECTION (INSTALLED)
1. Open vertical fin cover (12, figure 1).
2. Shake tail rotor gearbox (1) and check for looseness on tail rotor gearbox support fitting (14).
3. Inspect for evidence of fretting corrosion at mating surface between gearbox (1) and support fitting (14) that could be
caused by movement of gearbox on support. A gray residue is an indication of fretting corrosion. If residue is present,
remove gearbox and inspect in accordance with E-AB412-PT6T-3 and inspect support fitting in accordance with
Chapter 53.
NOTE
Inspection steps 4. through 9. are not applicable if gearbox is removed at step 3.
4. Inspect six nuts (11) for correct torque and thread engagement (paragraph "3. Tail rotor gearbox - installation").
5. Inspect link assembly (8) and lever (3) for secure installation.
6. Inspect coupling (16) for grease leakage and visual overtemperature indicators (TEMP-PLATES) for discoloration and
overheat condition. A change in color of TEMP-PLATES dots (from white to black) will indicate a possible overheat
condition and/or component degradation. The cause of indicators discoloration shall be determined and corrected prior
to continued operation. Refer to module 65-11-02 paragraph "5. Driveshaft hanger assemblies - inspection".
7. Inspect oil filler cap assembly (2) for damage and for correct amount of aluminum wool (module 65-22-05
paragraph "3. Oil filler cap - inspection").
8. Inspect oil sight glass for correct oil level. Inspect sight glass and indicator for staining and for cracks and crazing.
Damage which could cause oil leakage or make oil level difficult to determine is not acceptable.
9. Inspect electrical chip detector for metal particles (module 65-22-04 paragraph "4. Electrical chip detector -
inspection"). Refer to Chapter 63 for serviceability check required if metal particles are found.
6. TAIL ROTOR GEARBOX - CLEANING
MATERIALS REQUIRED
NUMBER NOMENCLATURE
1. Clean gearbox with clean cloths damp with drycleaning solvent (C-304).
CAUTION
DO NOT FORCE SOLVENT AND/OR DIRT INTO FLEXIBLE COUPLING

7. TAIL ROTOR GEARBOX - INSPECTION (NOT INSTALLED)
Inspect gearbox in accordance with E-AB412-PT6T-3 manual.
65-22-01
Rev. 3 Page 7
E-AB412-PT6T-2
8. TAIL ROTOR GEARBOX - INSPECTION (CONDITIONAL)
For conditional inspection of the tail rotor gearbox, refer to E-AB412-PT6T-3 manual.
9. TAIL ROTOR GEARBOX - REPAIR
1. Polish out mechanical and corrosion damage within limits (E-AB412-PT6T-3).
2. Repair defective filler cap (module 65-22-05 paragraph "4. Oil filler cap - repair").
3. Replace defective sight glass (module 65-22-03 "TAIL ROTOR GEARBOX - SIGHT GLASS").
4. Replace chip detector and/or self-closing valve which failed to pass inspection (module 65-22-04 "TAIL ROTOR
GEARBOX - ELECTRICAL CHIP DETECTOR").
10. TAIL ROTOR GEARBOX - ALTERNATE RUN-IN TEST
NOTE
It is desirable that tail rotor gearbox be test run and inspected after overhaul in
In the event a run-in stand is not available, the following function test may be
accomplished as a minimum acceptable alternate test.
1. Install sufficient ballast in cabin to obtain gross weight (E-AB412-PT6T-1).
2. Start engines and run at 60% RPM for five minutes.
3. Gradually increase RPM to 88% at rate of 7% each six minutes.
4. Hold at 88% for two minutes with collective pitch applied to the maximum up position which can be maintained
without becoming airborne or exceeding 100% torque.
6. Remove, inspect, clean, and reinstall chip detector.
7. Start engines and gradually increase to 88% RPM. Run at 88% RPM for six minutes. Apply collective pitch to the
maximum up position which can be maintained without becoming airborne or exceeding 100% torque. Gradually
increase RPM to 100%, without becoming airborne or exceeding 100% torque at the rate of 3% each six minutes.
8. Run at 100% for 30 minutes with collective pitch in maximum up position which can be maintained without becoming
airborne or exceeding 100% torque.
9. Shut down engines and drain oil from gearbox. Check gearbox electrical chip detector for an excessive amount of
metal particles which may indicate internal failure. Refer to Chapter 63 for required action if metal particles are found.
10. Inspect tail rotor gearbox input quill coupling and surrounding area for grease leakage. If there is evidence of grease
leakage, remove coupling and replace defective parts (E-AB412-PT6T-3). Verify the servicing of the gearbox (Chapter
12). Repeat leak test run.
Cause of dots discoloration shall be determined and corrected prior to continued operation. Refer to module 65-11-02
paragraph "5. Driveshaft hanger assemblies - inspection".
65-22-01
Page 8 Rev. 3
E-AB412-PT6T-2
13. Install electrical chip detector (module 65-22-04 paragraph "2. Electrical chip detector - installation") and service
gearbox (Chapter 12).
65-22-01
Rev. 3 Page 9
E-AB412-PT6T-2
65-22-01
Page 10 Rev. 3
E-AB412-PT6T-2
65-2 -02 TAIL ROTOR GEARBOX [D]
65-22-02
TAIL ROTOR GEARBOX [D]
1. TAIL ROTOR GEARBOX - DESCRIPTION
The maintenance procedures contained within the following paragraphs consist of troubleshooting, inspection (installed and
removed from helicopter as well as a conditional inspection), removal, cleaning, limited repair, and installation. When any
doubt exists as to the serviceability of a gearbox, perform serviceability checks defined in Chapter 63.
2. TAIL ROTOR GEARBOX - REMOVAL
MATERIALS REQUIRED
NUMBER NOMENCLATURE
NUMBER NOMENCLATURE
T23-1 TAIL ROTOR GEARBOX PUSHER
T62-2 HOLDING FIXTURE
T90 DRAIN LINE
1. If tail rotor gearbox is to be replaced, accomplish preservation by one of the following methods:
a. If the operation is practical, perform a ten minute ground run-up and drain oil using drain line (T90).
b. If run-up is not practical, remove tail rotor gearbox and spray inside through opening with approximately one
liter of applicable lubricating oil (C-030) mixed with corrosion preventive compound (C-124). Use 45cc of
corrosion preventive compound (C-124) per liter of lubricating oil (5% concentration). While spraying manually
rotate internal gears and bearings with input drive quill. Ensure all gears, bearings and surfaces are coated. Drain
the gearbox.
c. Finally, attach tag to tail rotor gearbox stating: “PRESERVED WITH OPERATING LUBRICANT”.
2. Remove tail rotor assembly (Chapter 64).
3. Remove cotter pin (9, figure 1), nut (4), and washer (5). Remove bolt (7) and washer (6) and disconnect link assembly
(8) from lever (3).
4. Disconnect electrical wire and remove chip detector (module 65-22-04 paragraph "1. Electrical chip detector -
removal").
5. Open vertical fin cover (12) and remove intermediate gearbox fairing.
65-22-02
Rev. 3 Page 1
E-AB412-PT6T-2
6. Remove driveshaft (13) (module 65-12-01 paragraph "2. Tail rotor driveshafts and hanger - removal".
7. Remove tail rotor gearbox adapter (24) as follows:
a. Remove retaining ring (18) and lock spring (19).
b. Insert 1/4 inch X 20 UNF bolt into retainer (20) and remove retainer with packing (21). Discard packing.
c. While holding adapter with holding fixture (T62-2), loosen bolt (22). Remove bolt (22), washer (23), and adapter
(24) from gearbox.
8. Remove nuts (11) with thin steel washers (10).
9. Remove gearbox (1) from support fitting (14) using tail rotor gearbox pusher (T23-1) (figure 2).
NOTE
Install two spacers (15, figure 1) and nut (11) with thin steel washer (10) on gearbox
studs (17) to hold input quill in gearbox (1) while gearbox is removed from
helicopter.
3. TAIL ROTOR GEARBOX - INSTALLATION
MATERIALS REQUIRED
NUMBER NOMENCLATURE
C-251 SEALANT
NUMBER NOMENCLATURE
T62-2 HOLDING FIXTURE
CAUTION
PRIOR TO INSTALLATION OF TAIL ROTOR GEARBOX, ACCOMPLISH THE

FOLLOWING:
ROTATE FLEXIBLE COUPLING AND CHECK FOR BINDING AND FOR

PRESENCE OF BACKLASH BETWEEN PINION ON INPUT QUILL AND
GEAR ON OUTPUT SHAFT.
DRAIN PRESERVATIVE OIL (IF ANY) FROM GEARBOX AND SERVICE

WITH APPROVED OIL (CHAPTER 12).
65-22-02
Page 2 Rev. 3
E-AB412-PT6T-2
1. Check mounting flange of gearbox (1, figure 1) for sealant protruding from the three jackscrew holes. Trim off sealant
flush to allow proper seating of tail rotor gearbox (1) flange on support fitting (14).
2. Remove nuts (11), spacers (15), and thin steel washers (10) from studs (17) around input drive quill.
3. Using MEK (C-309) and a non-metallic scraper, clean mating surfaces of gearbox (1) and tailboom support fitting (14).
4. Coat all faying surfaces of gearbox, studs, tailboom mount fitting, holes for studs in mount, and washers with epoxy
polyamide primer (C-204). Do not apply primer to the threads of the studs. Install the gearbox while primer is wet.
CAUTION
ENSURE A MINIMUM OF TWO THREAD PITCHES, INCLUDING CHAMFER,

EXTEND THROUGH NUTS (11). ENSURE NUTS DO NOT BOTTOM ON GRIP
PORTION OF STUDS. USE ADDITIONAL THIN STEEL WASHERS (10) IF
REQUIRED.
NOTE
Perform special inspection after installation (between 1 and 10 hours of flight after
each installation) of tail rotor gearbox (E-AB412-PT6T-6).
5. Position tail rotor gearbox (1) on support fitting (14) with studs (17) through holes in support fitting (14).
6. Install thin steel washers (10) and nuts (11). Torque evenly in a star pattern 200 to 235 in-lbs (22,60 to 26,55 Nm).
Repeat torque pattern until all nuts retain torque initially applied to first nut in pattern. Torque value of first nut will
decrease as other nuts are torqued. Use a 0,005 in. (0,127 mm) feeler gauge to verify that no gap exists between shim
plate installed between gearbox input quill and gearbox.
7. Apply a fillet of sealant (C-251) around the periphery of the mating surface of the tail rotor gearbox (1) and support
fitting (14).
8. Install adapter (24) to tail rotor gearbox input pinion as follows:
CAUTION
DO NOT ALLOW MEK TO CONTACT LIP SEAL.
a. Clean inboard end of adapter (24) and mating face of spacer (16) with a cotton swab dampened with MEK
(C-309).
b. Install adapter (24), washer (23), and bolt (22). Tighten bolt to where a gap of approximately 0,10 in. (2,54 mm)
remains between inboard end of adapter (24) and mating face of spacer (16).
c. Apply a small amount of adhesive sealant (C-308) between inboard end of adapter (24) and mating face of spacer
(16) at the location of the three slots in inboard end of adapter (24).
d. Within five minutes after sealant application, torque bolt (22) 80 to 100 ft.-lbs. (108,46 to 135,58 Nm).
e. Wipe all sealant from outside diameter of adapter (24) and spacer (16). No sealant residue is permitted on lip of
seal or mating wear sleeve.
f. Install retainer (20), with new packing (21), so square extension engages bolt (22).
g. Install lock spring (19) in groove of retainer (20) so tang extends through a hole in retainer and engages a slot in
adapter (24).
65-22-02
Rev. 3 Page 3
E-AB412-PT6T-2
h. Install retaining ring (18).
i. Install driveshaft (13) (module 65-12-01 paragraph "3. Tail rotor driveshafts and hanger - installation").
9. Connect link assembly (8) to lever (3). Install bolt (7) with washer (6) under bolt head and washer (5) under nut (4).
Additional washers (5) may be used to align nut (4) for cotter pin installation. Install cotter pin (9).
11. Verify actual presence of oil in sight gauge and check oil level to full mark on indicator.
12. Close vertical fin cover (12) and install intermediate gearbox fairing.
13. Install and rig tail rotor (Chapter 67).
14. If gearbox has not been previously qualified on run-in test stand, accomplish alternate run-in and test (paragraph "10.
Tail rotor gearbox - alternate run-in test").
4. TAIL ROTOR GEARBOX - TROUBLESHOOTING
Refer to module 65-21-01 paragraph "4. Intermediate gearbox - troubleshooting".
65-22-02
Page 4 Rev. 3
E-AB412-PT6T-2
TORQUE
80 TO 100 FT-LBS
(108.46 TO 135.58 Nm)
TORQUE
200 TO 235 FT-LBS
(22.60 TO 26.55 Nm)
13
1. Tail rotor gearbox 13. Driveshaft

2. Cap assembly 14. Support fitting
3. Lever 15. Spacer
4. Nut 16. Spacer
5. Washer 17. Stud
6. Washer 18. Retaining ring
7. Bolt 19. Lock spring
8. Link assembly 20. Retainer
9. Cotter pin 21. Packing
10. Thin steel washer 22. Bolt
11. Nut 23. Washer
12. Vertical fin cover 24. Adapter
G6AB0826B
Figure 1. Tail rotor gearbox
65-22-02
Rev. 3 Page 5
E-AB412-PT6T-2
1. Tail rotor gearbox pusher (T101264-103)

2. Adapter assembly (T101264-109)
3. Tail rotor gearbox assembly
4. Tail rotor gearbox support
5. Clamp assembly (T101264-107)
6. Screw assembly (T101264-105)
7. Adapter retainer (T101264-121)
NOTES:
1. If not previously accomplished, thread screw assembly (6) into clamp assembly (5). Allow sufficient clearance for posi-
tioning on support (4) and adapter assembly (2).
2. Position both halves of adapter assembly (2) on tail rotor gearbox (3) against input quill as shown.
3. Position tail rotor gearbox pusher (1) on gearbox and support with hooks of clamp assembly (5) centered securely over
shoulders of support (4) and adapter retainer (7) over both halves of adapter assembly (2).
4. Tighten screw assembly (6) clockwise with a suitable wrench until tail rotor gearbox (3) separates from support (4).
Remove tools and lift gearbox from support.
G6AB0531B
Figure 2. Tail rotor gearbox pusher T23-1 (T101264-103) - tool application
65-22-02
Page 6 Rev. 3
E-AB412-PT6T-2
5. TAIL ROTOR GEARBOX - INSPECTION (INSTALLED)
1. Open vertical fin cover (12, figure 1).
2. Shake tail rotor gearbox (1) and check for looseness on tail rotor gearbox support fitting (14).
3. Inspect for evidence of fretting corrosion at mating surface between gearbox (1) and support fitting (14) that could be
caused by movement of gearbox on support. A gray residue is an indication of fretting corrosion. If residue is present,
remove gearbox and inspect in accordance with E-AB412-PT6T-3 and inspect support fitting in accordance with
Chapter 53.
NOTE
Inspection steps 4. through 9. are not applicable if gearbox is removed at step 3.
4. Inspect six nuts (11) for correct torque and thread engagement (paragraph "3. Tail rotor gearbox - installation").
5. Inspect link assembly (8) and lever (3) for secure installation.
6. Inspect visual overtemperature indicators (TEMP-PLATES) for discoloration and overheat condition. A change in
color of TEMP-PLATES dots (from white to black) will indicate a possible overheat condition and/or component
degradation. The cause of indicators discoloration shall be determined and corrected prior to continued operation.
Refer to module 65-12-01 paragraph "5. Tail rotor driveshafts and hanger - cleaning".
7. Inspect oil filler cap assembly (2) for damage and for correct amount of aluminum wool (module 65-22-05
paragraph "3. Oil filler cap - inspection").
8. Inspect oil sight glass for correct oil level. Inspect sight glass and indicator for staining and for cracks and crazing.
Damage which could cause oil leakage or make oil level difficult to determine is not acceptable.
9. Inspect electrical chip detector for metal particles (module 65-22-04 paragraph "3. Oil filler cap - inspection"). Refer
to Chapter 63 for serviceability check required if metal particles are found.
6. TAIL ROTOR GEARBOX - CLEANING
MATERIALS REQUIRED
NUMBER NOMENCLATURE
1. Clean gearbox with clean cloths damp with drycleaning solvent (C-304).
CAUTION
DO NOT FORCE SOLVENT AND/OR DIRT INTO FLEXIBLE COUPLING

7. TAIL ROTOR GEARBOX - INSPECTION (NOT INSTALLED)
Inspect gearbox in accordance with E-AB412-PT6T-3 manual.
65-22-02
Rev. 3 Page 7
E-AB412-PT6T-2
8. TAIL ROTOR GEARBOX - INSPECTION (CONDITIONAL)
For conditional inspection of the tail rotor gearbox, refer to E-AB412-PT6T-3 manual.
9. TAIL ROTOR GEARBOX - REPAIR
1. Polish out mechanical and corrosion damage within limits. Refer to E-AB412-PT6T-3.
2. Repair defective filler cap (module 65-22-05 paragraph "4. Oil filler cap - repair").
3. Replace defective sight glass (module 65-22-03 TAIL ROTOR GEARBOX - SIGHT GLASS).
4. Replace chip detector and/or self-closing valve which failed to pass inspection (module 65-22-04 TAIL ROTOR
GEARBOX - ELECTRICAL CHIP DETECTOR).
10. TAIL ROTOR GEARBOX - ALTERNATE RUN-IN TEST
NOTE
It is desirable that tail rotor gearbox be test run and inspected after overhaul in
In the event a run-in stand is not available, the following function test may be
accomplished as a minimum acceptable alternate test.
1. Install sufficient ballast in cabin to obtain gross weight (E-AB412-PT6T-1).
2. Start engines and run at 60% RPM for five minutes.
3. Gradually increase RPM to 88% at rate of 7% each six minutes.
4. Hold at 88% for two minutes with collective pitch applied to the maximum up position which can be maintained
without becoming airborne or exceeding 100% torque.
6. Remove, inspect, clean, and reinstall chip detector.
7. Start engines and gradually increase to 88% RPM. Run at 88% RPM for six minutes. Apply collective pitch to the
maximum up position which can be maintained without becoming airborne or exceeding 100% torque. Gradually
increase RPM to 100%, without becoming airborne or exceeding 100% torque at the rate of 3% each six minutes.
8. Run at 100% for 30 minutes with collective pitch in maximum up position which can be maintained without becoming
airborne or exceeding 100% torque.
9. Shut down engines and drain oil from gearbox. Check gearbox electrical chip detector for an excessive amount of
metal particles which may indicate internal failure. Refer to Chapter 63 for required action if metal particles are found.
10. Inspect tail rotor gearbox input quill coupling and surrounding area for grease leakage. If there is evidence of grease
leakage, remove coupling and replace defective parts (E-AB412-PT6T-3). Verify the servicing of the gearbox (Chapter
12). Repeat leak test run.
Cause of dots discoloration shall be determined and corrected prior to continued operation. Refer to module 65-12-01
paragraph "6. Tail rotor driveshafts and hanger - inspection".
65-22-02
Page 8 Rev. 3
E-AB412-PT6T-2
13. Install electrical chip detector (module 65-22-04 paragraph "2. Electrical chip detector - installation") and service
gearbox (Chapter 12).
65-22-02
Rev. 3 Page 9
E-AB412-PT6T-2
65-22-02
Page 10 Rev. 3
E-AB412-PT6T-2
65-2 -03 TAIL ROTOR GEARBOX - SIGHT GLASS
65-22-03
TAIL ROTOR GEARBOX - SIGHT GLASS
1. SIGHT GLASS - REMOVAL
NUMBER NOMENCLATURE
T90 DRAIN LINE
1. Remove electrical chip detector (6, figure 1) (module 65-22-04 paragraph "1. Electrical chip detector - removal") from
tail rotor gearbox (1).
2. Insert one end of drain line (T90) into container. Insert one end in hole where chip detector (6) was installed. Oil will
automatically drain.
3. Remove retaining ring (5).
4. Remove sight glass (4) and packing (3). Discard packing.
5. Remove oil level indicator (2).
6. Remove drain line (T90).
2. SIGHT GLASS - INSTALLATION
1. Install oil level indicator (2, figure 1).
2. Lubricate new packing (3) with gearbox oil (Chapter 12) and install packing on sight glass (4). Install glass.
3. Install retaining ring (5).
4. Install electrical chip detector (6) (module 65-22-04 paragraph "2. Electrical chip detector - installation").
5. Service gearbox (Chapter 12).
65-22-03
Page 1
E-AB412-PT6T-2
G6AB0532A
Figure 1. Tail rotor gearbox sight glass
65-22-03
Page 2
E-AB412-PT6T-2
65-2 -04 TAIL ROTOR GEARBOX - ELECTRICAL CHIP DETECTOR
65-22-04
TAIL ROTOR GEARBOX - ELECTRICAL CHIP DETECTOR
1. ELECTRICAL CHIP DETECTOR - REMOVAL
NUMBER NOMENCLATURE
T90 DRAIN LINE
NOTE
Electrical chip detector element (5, figure 1) may be removed for inspection without
draining gearbox oil.
1. Move nipple (8) back on electrical wire (6) to expose nut (7). Remove nut (7) and wire (6).
2. Press in on knurled body of electrical chip detector element (5), turn counterclockwise to disengage locking
mechanism, and withdraw element from electrical chip detector self-closing valve (3).
NOTE
If self-closing valve (3) is to be removed, drain gearbox oil into container with drain
line (T90) installed in valve (3).
3. Cut and remove lockwire from valve (3). Remove valve (3). Remove packing (2) from valve.
2. ELECTRICAL CHIP DETECTOR - INSTALLATION
MATERIALS REQUIRED
NUMBER NOMENCLATURE
C-405 LOCKWIRE
1. Lubricate new packing (2, figure 1) with gearbox oil (Chapter 12). Install packing on self-closing valve (3).
2. Install self-closing valve (3) on gearbox (1). Torque valve 120 to 150 in.-lbs. (13,56 to 16,95 Nm). Secure valve to
gearbox (1) with lockwire (C-405).
3. Lubricate new packing (4) with gearbox oil (Chapter 12). Install packing on chip detector element (5). Insert element
(5) into self-closing valve (3). Push down and twist element until locking detents engage.
CAUTION
DO NOT EXCEED 4,0 IN.-LBS. (0,45 NM) TORQUE ON NUT (7).
65-22-04
Page 1
E-AB412-PT6T-2
4. Position electrical wire (6) on element (5) and install nut (7). Torque nut to a maximum of 4,0 in.-lbs. (0,45 Nm).
Position nipple (8) over nut (7).
NOTE
Service gearbox (Chapter 12) if self-closing valve (3) was removed.
3. ELECTRICAL CHIP DETECTOR - CLEANING
MATERIALS REQUIRED
NUMBER NOMENCLATURE
4. ELECTRICAL CHIP DETECTOR - INSPECTION
1. Inspect electrical chip detector for metal particles (Chapter 63).
2. Inspect electrical chip detector components for damage (figure 2).
3. Perform an operational check on electrical chip detector (Chapter 96).
5. ELECTRICAL CHIP DETECTOR - REPAIR
Repair of electrical chip detector is restricted to replacement of defective parts.
65-22-04
Page 2
E-AB412-PT6T-2
G6AB0533A
Figure 1. Tail rotor gearbox electrical chip detector
65-22-04
Page 3
E-AB412-PT6T-2
G6AB0534A
Figure 2. Tail rotor gearbox electrical chip detector - damage limits
65-22-04
Page 4
E-AB412-PT6T-2
65-2 -05 TAIL ROTOR GEARBOX - OIL FILLER CAP
65-22-05
TAIL ROTOR GEARBOX - OIL FILLER CAP
1. OIL FILLER CAP - REMOVAL
1. Push down on cap assembly (6 or 14, figure 1) and twist to disengage pin (7, detail A) from gearbox (1). New cap (14)
does not have pin (7). Pins to engage the gearbox adapter are part of the cap assembly.
2. Unsnap safety pin (4) from gearbox (1).
2. OIL FILLER CAP - INSTALLATION
1. Position cap assembly on gearbox (1, figure 1). Push down on cap (6 or 14) and twist clockwise to engage in gearbox
adapter.
2. Secure chain (2 or 16) to gearbox (1) with safety pin (4).
3. OIL FILLER CAP - INSPECTION
1. Inspect filler cap for distortion of pin (7, figure 1) or other damage which would affect serviceability.
2. Invert filler cap to expose washer (9 or 23). Depress washer approximately 0,06 in. (1,52 mm) and release. Washer
should spring back against ring (8 or 24). If spring back is not present, aluminum wool filter (10 or 22) is dirty or an
insufficient amount of aluminum wool is installed.
4. OIL FILLER CAP - REPAIR
MATERIALS REQUIRED
NUMBER NOMENCLATURE
C-304 SOLVENT
C-422 ALUMINIUM WOOL
1. Repair is restricted to replacement of aluminum wool filter (10 or 22, figure 1) as outlined in steps 2. through 10.
NOTE
Screw (13) and plug (20, detail B) are bonded to cap (14). It is not necessary to
remove either to replace filter (22).
2. Remove pin (7, detail A).
3. Remove ring (5), cap (6), and spring assembly (12) from plug (11).
4. Remove ring (8 or 24) and washer (9 or 23).
65-22-05
Page 1
E-AB412-PT6T-2
5. Remove aluminum wool filter (10 or 22) and discard.
6. Clean parts with solvent (C-304).
7. Fill plug (11 or 20) with new aluminum wool (C-422) until washer (9 or 23) will spring back to original position after
being pressed in 0,06 in. (1,52 mm). Add or remove aluminum wool as required.
8. Install washer (9 or 23) and ring (8 or 24).
9. Ensure packing (3 or 21) is in place and install spring assembly (12, detail A), cap (6), and ring (5) on plug (11).
10. Insert pin (7, detail A) through cap (6) and bend end of pin to secure.
65-22-05
Page 2
E-AB412-PT6T-2
G6AB0535A
Figure 1. Tail rotor gearbox oil filler cap
65-22-05
Page 3
E-AB412-PT6T-2
65-22-05
Page 4
E-AB412-PT6T-2
65-2 -06 TAIL ROTOR GEARBOX - FLEXIBLE COUPLINGS
65-22-06
TAIL ROTOR GEARBOX - FLEXIBLE COUPLINGS
1. FLEXIBLE COUPLINGS - LUBRICATION
MATERIALS REQUIRED
NUMBER NOMENCLATURE
1. Remove tail rotor driveshaft section between tail rotor gearbox and intermediate gearbox (module 65-11-01
paragraph "2. Tail rotor driveshaft - removal" or module 65-12-01 "TAIL ROTOR DRIVESHAFTS AND HANGERS
[D]").
2. Remove retaining ring (1, figure 1) and at same time hold plate (2) against spring (3). Remove plate (2) and spring (3).
CAUTION

COUPLING.
thoroughly.
NOTE
For detailed disassembly, inspection, and assembly instructions, refer to the
E-AB412-PT6T-3.
4. Visually inspect splines of inner coupling (4) and outer coupling (5) for unusual wear patterns, nicks, dents, and cracks.
Refer to the E-AB412-PT6T-3 for detailed damages limits for coupling splines.
5. Inspect plate (2) for damage that could cause leakage of lubricant.
6. Inspect seal (6) in coupling (5) for protrusion or other damage which could cause leakage of lubricant. Replace seal as
required (E-AB412-PT6T-3).
7. Move outer coupling (5) on inner coupling (4) forward and aft with clockwise and counterclockwise preload and feel
for roughness. If any roughness or resistance is felt, reinspect coupling splines for damage.
8. Hold coupling (5) at full outboard position. Hand-pack lubricant (tube pack) (C-015) 0.12 in (3.05 mm) over top of
coupling (5) spline teeth. A workaid may be fabricated as shown in figure 2, to obtain depth of grease.
9. Hold coupling (5) at full outboard position. Install spring (3), plate (2), and retainer ring (1).
10. Install tail rotor driveshaft section between intermediate gearbox and tail rotor gearbox (module 65-11-01
paragraph "3. Tail rotor driveshaft - installation" or module 65-12-01 paragraph "3. Tail rotor driveshafts and hanger
- installation").
65-22-06
Rev. 2 Page 1
E-AB412-PT6T-2
NOTE
11. After flexible coupling is lubricated, perform the following test to ensure coupling is not leaking.
a. Clean all lubricant from exterior surfaces of coupling and clamp set that secures tail rotor driveshaft to coupling.
Also, clean all lubricant from surrounding helicopter structure.
b. Operate helicopter (E-AB412-PT6T-1) for five minutes at 100%.
c. Shut down helicopter and inspect coupling and surrounding structure for evidence of grease leakage. If there is
any evidence of grease leakage, wipe surface clean and rerun test to ensure leakage is not from excessive grease
applied at build up. If test indicates coupling is leaking, remove coupling and replace defective parts. Repeat leak
test run.
d. Inspect input quill coupling (E-AB412-PT6T-3) and surrounding area for grease leakage. If there is evidence of
grease leakage, remove coupling and replace defective parts. Repeat leak test run.
e. Check visual overtemperature indicators (TEMP-PLATES) for discoloration and overheat condition. A change
in color of TEMP-PLATES dots (from white to black) indicates a possible overheat condition and/or component
degradation. The cause of indicators discoloration shall be determined and corrected prior to continued
operation. Refer to module 65-11-02 paragraph "5. Driveshaft hanger assemblies - inspection".
f. Replace visual overtemperature indicators if mutilated or discolored (E-AB412-PT6T-3).
65-22-06
Page 2 Rev. 2
E-AB412-PT6T-2
1. Retaining ring
2. Coupling seal plate assembly
3. Spring
4. Inner coupling
5. Outer coupling
6. Seal
7. Gearbox
G6AB0536B
Figure 1. Tail rotor gearbox flexible coupling
65-22-06
Rev. 2 Page 3
E-AB412-PT6T-2
G6AB0537A
Figure 2. Workaid for lubrication of tail rotor drive couplings
65-22-06
Page 4 Rev. 2
E-AB412-PT6T-2
CHAPTER 67 - ROTORS FLIGHT CONTROL

Module Page
Number Title Number
67-00-00 FLIGHT CONTROL SYSTEMS
1. Flight control systems - general .............................................................................................................. 1

2. Flight control systems - troubleshooting ................................................................................................ 2
67-11-01 FLIGHT CONTROLS RIGGING - COLLECTIVE CONTROLS
1. Collective controls - description ............................................................................................................. 1
67-11-02 FLIGHT CONTROLS RIGGING - CYCLIC CONTROLS
1. Cyclic controls - description ................................................................................................................... 1

2. Cyclic controls - primary method ........................................................................................................... 1
3. Cyclic controls - alternate method ........................................................................................................ 18
4. Cyclic controls - cyclic position sensor ................................................................................................ 28
67-11-03 FLIGHT CONTROLS RIGGING - ANTI-TORQUE CONTROLS
1. Anti-torque controls - description ........................................................................................................... 1
67-11-04 FLIGHT CONTROLS RIGGING - AERODINAMICALLY ACTUATED ELEVATOR
1. Aerodynamically actuated elevator - description ................................................................................... 1
67-12-01 COLLECTIVE CONTROLS
1. Collective controls - description ............................................................................................................. 1
67-12-02 1COLLECTIVE CONTROLS - HYDRAULIC SERVO CYLINDER BOOT
1. Hydraulic servo cylinder boot - removal ................................................................................................ 1

2. Hydraulic servo cylinder boot - installation ........................................................................................... 1
3. Hydraulic servo cylinder boot - inspection ............................................................................................. 1
67-12-03 COLLECTIVE CONTROLS - HYDRAULIC CYLINDER EXTENSION TUBE
1. Hydraulic cylinder extension tube - removal .......................................................................................... 1

2. Hydraulic cylinder extension tube - installation ..................................................................................... 1
3. Hydraulic cylinder extension tube - inspection ...................................................................................... 1
67-12-04 COLLECTIVE CONTROLS - HYDRAULIC CYLINDER EXTENSION UNIVERSAL
1. Hydraulic cylinder extension universal - removal .................................................................................. 1

2. Hydraulic cylinder extension universal - installation ............................................................................. 1
3. Hydraulic cylinder extension universal - inspection ............................................................................... 1
67-12-05 COLLECTIVE CONTROLS - PISTON ROD CLEVIS
1. Piston rod clevis - removal ..................................................................................................................... 1
67-Index
Rev. 3 Page 1
E-AB412-PT6T-2

Module Page
Number Title Number
2. Piston rod clevis - installation .................................................................................................................1

3. Piston rod clevis - inspection ..................................................................................................................2
67-12-06 COLLECTIVE CONTROLS - SERVO VALVE BALANCE SPRING
1. Servo valve balance spring - description .................................................................................................1

2. Servo valve balance spring - removal .....................................................................................................1
3. Servo valve balance spring - installation .................................................................................................1
4. Servo valve balance spring - inspection ..................................................................................................1
67-12-07 COLLECTIVE CONTROLS - COLLECTIVE FLIGHT CONTROL CYLINDER
1. Collective flight control cylinder - removal ............................................................................................1

2. Collective flight control cylinder - installation .......................................................................................1
3. Collective flight control cylinder - inspection .........................................................................................3
67-12-08 COLLECTIVE CONTROLS - LEFT CYCLIC AND COLLECTIVE BOOST SUPPORT
1. Left cyclic and collective boost support - removal .................................................................................1

2. Left cyclic and collective boost support - installation .............................................................................1
3. Left cyclic and collective boost support - inspection ..............................................................................1
67-12-09 COLLECTIVE CONTROLS - ADJUSTABLE ROD END TUBE
1. Adjustable rod end tube - removal ..........................................................................................................1

2. Adjustable rod end tube - installation .....................................................................................................1
3. Adjustable rod end tube - inspection .......................................................................................................1
67-12-10 COLLECTIVE CONTROLS - PITCH CONTROL BELLCRANK
1. Pitch control bellcrank - removal ............................................................................................................1

2. Pitch control bellcrank - installation .......................................................................................................1
3. Pitch control bellcrank - inspection .........................................................................................................1
67-12-11 COLLECTIVE CONTROLS - COLLECTIVE FORCE GRADIENT
1. Collective force gradient - description ....................................................................................................1

2. Collective force gradient - removal .........................................................................................................1
3. Collective force gradient - installation ....................................................................................................1
4. Collective force gradient - inspection .....................................................................................................2
5. Collective force gradient - repair ............................................................................................................2
67-12-12 COLLECTIVE CONTROLS - COLLECTIVE BELLCRANK
1. Collective bellcrank - description ...........................................................................................................1

2. Collective bellcrank - removal ................................................................................................................1
3. Collective bellcrank - installation ...........................................................................................................1
4. Collective bellcrank - inspection .............................................................................................................1
67-12-13 COLLECTIVE CONTROLS - COLLECTIVE LINK
1. Collective link - description ....................................................................................................................1

2. Collective link - removal .........................................................................................................................1
67-Index
Page 2 Rev. 3
E-AB412-PT6T-2

Module Page
Number Title Number
3. Collective link - installation .................................................................................................................... 1

4. Collective link - inspection ..................................................................................................................... 1
67-12-14 COLLECTIVE CONTROLS - COLLECTIVE ROTARY ACTUATOR
1. Collective rotary actuator - description .................................................................................................. 1

2. Collective rotary actuator - removal ....................................................................................................... 1
3. Collective rotary actuator - installation .................................................................................................. 1
4. Collective rotary actuator - inspection .................................................................................................... 1
5. Collective rotary actuator - repair ........................................................................................................... 1
67-12-15 COLLECTIVE CONTROLS - ADJUSTABLE COLLECTIVE CONTROL TUBE
1. Adjustable collective control tube - removal .......................................................................................... 1

2. Adjustable collective control tube - installation ..................................................................................... 1
3. Adjustable collective control tube - inspection ....................................................................................... 1
67-12-16 COLLECTIVE CONTROLS - CONTROL LEVER AND STOP ASSEMBLY
1. Control lever and stop assembly - removal ............................................................................................ 1

2. Control lever and stop assembly - installation ........................................................................................ 1
3. Control lever and stop assembly - inspection ......................................................................................... 1
67-12-17 COLLECTIVE CONTROLS - PILOT COLLECTIVE BOOT
1. Pilot collective boot - description ........................................................................................................... 1

2. Pilot collective boot - removal ................................................................................................................ 1
3. Pilot collective boot - installation ........................................................................................................... 1
4. Pilot collective boot - inspection ............................................................................................................ 1
67-12-18 COLLECTIVE CONTROLS - COLLECTIVE JACKSHAFT
1. Collective jackshaft - description ........................................................................................................... 1

2. Collective jackshaft - removal ................................................................................................................ 1
3. Collective jackshaft - installation ........................................................................................................... 5
4. Collective jackshaft - inspection.............................................................................................................. 8
67-12-19 COLLECTIVE CONTROLS - FRICTION CLAMP
1. Friction clamp - removal ......................................................................................................................... 1

2. Friction clamp - installation .................................................................................................................... 1
3. Friction clamp - inspection ..................................................................................................................... 1
4. Friction clamp - repair ............................................................................................................................ 1
67-13-01 CYCLIC CONTROLS
1. Cyclic controls - description ................................................................................................................... 1
67-13-02 CYCLIC CONTROLS - HYDRAULIC CYLINDER EXTENSION TUBE
1. Hydraulic cylinder extension tube - removal .......................................................................................... 1

2. Hydraulic cylinder extension tube - installation ..................................................................................... 1
3. Hydraulic cylinder extension tube - inspection ...................................................................................... 1
67-Index
Rev. 3 Page 3
E-AB412-PT6T-2

Module Page
Number Title Number
67-13-03 CYCLIC CONTROLS - HYDRAULIC SERVO CYLINDER BOOT
1. Hydraulic servo cylinder boot - description ............................................................................................1

2. Hydraulic servo cylinder boot - removal .................................................................................................1
3. Hydraulic servo cylinder boot - installation ............................................................................................1
4. Hydraulic servo cylinder boot - inspection .............................................................................................1
67-13-04 CYCLIC CONTROLS - HYDRAULIC CYLINDER EXTENSION UNIVERSAL
1. Hydraulic cylinder extension universal - description ..............................................................................1

2. Hydraulic cylinder extension universal - removal ..................................................................................1
3. Hydraulic cylinder extension universal - installation ..............................................................................1
4. Hydraulic cylinder extension universal - inspection ...............................................................................1
5. Hydraulic cylinder extension universal - bearing replacement ...............................................................1
67-13-05 CYCLIC CONTROLS - LEFT CYCLIC PISTON ROD CLEVIS
1. Left cyclic piston rod clevis - removal ....................................................................................................1

2. Left cyclic piston rod clevis - installation ...............................................................................................1
3. Left cyclic piston rod clevis - inspection ................................................................................................2
4. Left cyclic piston rod clevis - repair ........................................................................................................2
67-13-06 CYCLIC CONTROLS - RIGHT CYCLIC PISTON ROD CLEVIS
1. Right cyclic piston rod clevis - removal ..................................................................................................1

2. Right cyclic piston rod clevis - installation .............................................................................................1
3. Right cyclic piston rod clevis - inspection ..............................................................................................2
67-13-07 CYCLIC CONTROLS - LEFT CYCLIC FLIGHT CONTROL CYLINDER
1. Left cyclic flight control cylinder - removal ...........................................................................................1

2. Left cyclic flight control cylinder - installation ......................................................................................1
3. Left cyclic flight control cylinder - inspection ........................................................................................3
67-13-08 CYCLIC CONTROLS - RIGHT CYCLIC FLIGHT CONTROL CYLINDER
1. Right cyclic flight control cylinder - removal .........................................................................................1

2. Right cyclic flight control cylinder - installation ....................................................................................1
3. Right cyclic flight control cylinder - inspection ......................................................................................3
67-13-09 CYCLIC CONTROLS - RIGHT CYCLIC BOOST CYLINDER SUPPORT
1. Right cyclic boost cylinder support - description ....................................................................................1

2. Right cyclic boost cylinder support - removal ........................................................................................1
3. Right cyclic boost cylinder support - installation ....................................................................................1
4. Right cyclic boost cylinder support - inspection .....................................................................................2
67-13-10 CYCLIC CONTROLS - CYCLIC CONTROL TUBES
1. Cyclic control tubes - removal ................................................................................................................1

2. Cyclic control tubes - installation ............................................................................................................1
3. Cyclic control tubes - inspection .............................................................................................................2
67-Index
Page 4 Rev. 3
E-AB412-PT6T-2

Module Page
Number Title Number
4. Cyclic control tubes - repair .................................................................................................................... 2
67-13-11 CYCLIC CONTROLS - MIXING LEVER ASSEMBLY
1. Mixing lever assembly - removal ........................................................................................................... 1

2. Mixing lever assembly - installation ....................................................................................................... 1
3. Mixing lever assembly - inspection ........................................................................................................ 1
4. Mixing lever assembly - repair ............................................................................................................... 1
67-13-12 CYCLIC CONTROLS - FORE AND AFT PROXIMITY SWITCH
1. For and aft proximity switch - removal .................................................................................................. 1

2. For and aft proximity switch - installation .............................................................................................. 1
3. For and aft proximity switch - inspection ............................................................................................... 1
4. For and aft proximity switch - repair ...................................................................................................... 1
67-13-13 CYCLIC CONTROLS - LATERAL PROXIMITY
1. Lateral proximity - removal .................................................................................................................... 1

2. Lateral proximity - installation ............................................................................................................... 1
3. Lateral proximity - inspection ................................................................................................................. 1
4. Lateral proximity - repair ........................................................................................................................ 1
67-13-14 CYCLIC CONTROLS - LATERAL SERIES ACTUATOR
1. Lateral series actuator - removal ............................................................................................................. 1

2. Lateral series actuator - installation ........................................................................................................ 1
3. Lateral series actuator - inspection ......................................................................................................... 1
4. Lateral series actuator - repair ................................................................................................................. 2
67-13-15 CYCLIC CONTROLS - LONGITUDINAL SERIES ACTUATOR
1. Longitudinal series actuator - removal ................................................................................................... 1

2. Longitudinal series actuator - installation ............................................................................................... 1
3. Longitudinal series actuator - inspection ................................................................................................ 1
4. Longitudinal series actuator - repair ....................................................................................................... 2
67-13-16 CYCLIC CONTROLS - ROTARY ACTUATOR (LATERAL CYCLIC)
1. Rotary actuator (lateral cyclic) - removal ............................................................................................... 1

2. Rotary actuator (lateral cyclic) - installation .......................................................................................... 1
3. Rotary actuator (lateral cyclic) - inspection ............................................................................................ 1
67-13-17 CYCLIC CONTROLS - ROTARY ACTUATOR (FORE AND AFT CYCLIC)
1. Rotary actuator (fore and aft cyclic) - removal ....................................................................................... 1

2. Rotary actuator (fore and aft cyclic) - installation .................................................................................. 1
3. Rotary actuator (fore and aft cyclic) - inspection ................................................................................... 2
67-13-18 CYCLIC CONTROLS - FORCE GRADIENT (FORE AND AFT CYCLIC)
1. Force gradient (fore and aft cyclic) - removal ........................................................................................ 1

2. Force gradient (fore and aft cyclic) - installation ................................................................................... 1
67-Index
Rev. 3 Page 5
E-AB412-PT6T-2

Module Page
Number Title Number
3. Force gradient (fore and aft cyclic) - inspection .....................................................................................3

4. Force gradient (fore and aft cyclic) - repair ............................................................................................3
67-13-19 CYCLIC CONTROLS - FORCE GRADIENT (LATERAL CYCLIC)
1. Force gradient (lateral cyclic) - removal .................................................................................................1

2. Force gradient (lateral cyclic) - installation ............................................................................................1
3. Force gradient (lateral cyclic) - inspection ..............................................................................................4
4. Force gradient (lateral cyclic) - repair .....................................................................................................4
67-13-20 CYCLIC CONTROLS - TRANSDUCERS (FORE AND AFT CYCLIC)
1. Transducers (fore and aft cyclic) - removal ............................................................................................1

2. Transducers (fore and aft cyclic) - installation ........................................................................................1
3. Transducers (fore and aft cyclic) - inspection .........................................................................................1
4. Transducers (fore and aft cyclic) - repair ................................................................................................2
67-13-21 CYCLIC CONTROLS - JACKSHAFT (FORE AND AFT) TUBE AND LEVER ASSEMBLY
(RIGHT SIDE)
1. Jackshaft (fore and aft) tube and lever assembly (right side) - removal .................................................1
2. Jackshaft (fore and aft) tube and lever assembly (right side) - installation .............................................1
3. Jackshaft (fore and aft) tube and lever assembly (right side) - inspection ..............................................3
(LEFT SIDE)
1. Jackshaft (fore and aft) tube and lever assembly (left side) - removal ....................................................1
2. Jackshaft (fore and aft) tube and lever assembly (left side) - installation ...............................................1
3. Jackshaft (fore and aft) tube and lever assembly (left side) - inspection ................................................3
67-13-23 CYCLIC CONTROLS - JACKSHAFT HOUSING
1. Jackshaft housing - removal ....................................................................................................................1

2. Jackshaft housing - installation ...............................................................................................................1
3. Jackshaft housing - inspection .................................................................................................................1
67-13-24 CYCLIC CONTROLS - ARM ASSEMBLY
1. Arm assembly - removal .........................................................................................................................1

2. Arm assembly - installation .....................................................................................................................1
3. Arm assembly - inspection ......................................................................................................................2
67-13-25 CYCLIC CONTROLS - LATERAL TRANSDUCERS
1. Lateral transducers - removal ..................................................................................................................1

2. Lateral transducers - installation .............................................................................................................1
3. Lateral transducers - inspection ...............................................................................................................1
4. Lateral transducers - repair.......................................................................................................................2
67-13-26 CYCLIC CONTROLS - CYCLIC STICK BOOT
1. Cyclic stick boot - removal .....................................................................................................................1
67-Index
Page 6 Rev. 3
E-AB412-PT6T-2

Module Page
Number Title Number
2. Cyclic stick boot - installation ................................................................................................................ 1

3. Cyclic stick boot - inspection .................................................................................................................. 1
67-13-27 CYCLIC CONTROLS - PILOT CYCLIC CONTROL STICK ASSEMBLY
1. Pilot cyclic control stick assembly - removal ......................................................................................... 1

2. Pilot cyclic control stick assembly - installation .................................................................................... 1
3. Pilot cyclic control stick assembly - inspection ...................................................................................... 1
67-21-01 ANTI-TORQUE CONTROLS
1. Anti-torque controls - description ........................................................................................................... 1
67-21-02 ANTI-TORQUE CONTROLS - PITCH CHANGE CONTROL BELLCRANK
1. Pitch change control bellcrank - removal ............................................................................................... 1

2. Pitch change control bellcrank - installation ........................................................................................... 1
3. Pitch change control bellcrank - inspection ............................................................................................ 1
4. Pitch change control bellcrank - repair ................................................................................................... 1
67-21-03 ANTI-TORQUE CONTROLS - TUBE GUIDES
1. Tube guides - removal ............................................................................................................................ 1

2. Tube guides - installation ........................................................................................................................ 1
3. Tube guides - inspection ......................................................................................................................... 1
67-21-04 ANTI-TORQUE CONTROLS - FLIGHT CONTROL TUBES AND BELLCRANKS
1. Flight control tubes and bellcranks - description .................................................................................... 1

2. Flight control tubes and bellcranks - removal ........................................................................................ 1
3. Flight control tubes and bellcranks - installation .................................................................................... 1
4. Flight control tubes and bellcranks - inspection ..................................................................................... 1
67-21-05 ANTI-TORQUE CONTROLS - WALKING BEAM SUPPORT ASSEMBLY
1. Walking beam support assembly - removal ............................................................................................ 1

2. Walking beam support assembly - installation ....................................................................................... 1
3. Walking beam support assembly - inspection and repair ....................................................................... 1
67-21-06 ANTI-TORQUE CONTROLS - CONTROL CYLINDER
1. Control cylinder - removal ...................................................................................................................... 1

2. Control cylinder - installation ................................................................................................................. 1
3. Control cylinder - inspection .................................................................................................................. 2
4. Control cylinder - repair ......................................................................................................................... 2
67-21-07 ANTI-TORQUE CONTROLS - SERIES ACTUATOR
1. Series actuator - general .......................................................................................................................... 1

2. Series actuator - removal ........................................................................................................................ 1
3. Series actuator - installation .................................................................................................................... 1
4. Series actuator - inspection ..................................................................................................................... 2
67-Index
Rev. 3 Page 7
E-AB412-PT6T-2

Module Page
Number Title Number
67-21-08 ANTI-TORQUE CONTROLS - WALKING BEAM AND FRICTION CLAMP
1. Walking beam and friction clamp - removal ...........................................................................................1

2. Walking beam and friction clamp - installation ......................................................................................1
3. Walking beam and friction clamp - inspection .......................................................................................2
4. Walking beam and friction clamp - repair ..............................................................................................2
67-21-09 ANTI-TORQUE CONTROLS - MAGNETIC BRAKE
1. Magnetic brake - removal .......................................................................................................................1

2. Magnetic brake - installation ...................................................................................................................1
3. Magnetic brake - inspection .....................................................................................................................2
4. Magnetic brake - repair ...........................................................................................................................3
67-21-10 ANTI-TORQUE CONTROLS - CONTROL TRANSDUCER
1. Control transducer - removal ...................................................................................................................1

2. Control transducer - installation ..............................................................................................................1
3. Control transducer - inspection ...............................................................................................................1
4. Control transducer - repair ......................................................................................................................1
67-21-11 ANTI-TORQUE CONTROLS - FORCE GRADIENT
1. Force gradient - removal .........................................................................................................................1

2. Force gradient - installation .....................................................................................................................1
3. Force gradient - inspection ......................................................................................................................2
4. Force gradient - repair .............................................................................................................................2
67-21-12 ANTI-TORQUE CONTROLS - PEDAL ADJUSTER ASSEMBLY
1. Pedal adjuster assembly - removal ..........................................................................................................1

2. Pedal adjuster assembly - installation .....................................................................................................1
3. Pedal adjuster assembly - inspection .......................................................................................................2
67-21-13 ANTI-TORQUE CONTROLS - PEDALS
1. Pedals - description .................................................................................................................................1

2. Pedals - removal ......................................................................................................................................1
3. Pedals - installation .................................................................................................................................1
4. Pedals - inspection ...................................................................................................................................1
67-26-01 AERODYNAMICALLY ACTUATED ELEVATOR SYSTEM
1. Aerodynamically actuated elevator system - description ........................................................................1
67-26-02 AERODYNAMICALLY ACTUATED ELEVATOR
1. Aerodynamically actuated elevator - removal .........................................................................................1

2. Aerodynamically actuated elevator - installation.....................................................................................3
3. Aerodynamically actuated elevator - inspection ......................................................................................5
4. Aerodynamically actuated elevator - repair .............................................................................................6
67-Index
Page 8 Rev. 3
E-AB412-PT6T-2

Module Page
Number Title Number
67-26-03 AERODYNAMICALLY ACTUATED ELEVATOR - ELEVATOR CONTROL TUBE
1. Elevator control tube - removal .............................................................................................................. 1

2. Elevator control tube - installation .......................................................................................................... 1
3. Elevator control tube - inspection............................................................................................................ 3
67-Index
Rev. 3 Page 9
E-AB412-PT6T-2
FIGURES
Figure Page
Number Title Number
67-11-01 FLIGHT CONTROLS RIGGING - COLLECTIVE CONTROLS
Figure 1. Collective rigging (sheet 1 of 3)......................................................................................................................3

Figure 2. Collective controls (4-axis configuration) ......................................................................................................6
67-11-02 FLIGHT CONTROLS RIGGING - CYCLIC CONTROLS
Figure 1. Cyclic rigging (sheet 1 of 3)............................................................................................................................5

Figure 2. Cyclic rigging - hydraulic cylinders................................................................................................................8
Figure 3. Cyclic rigging - bellcrank stops ......................................................................................................................9
Figure 4. Cyclic rigging - swashplate...........................................................................................................................10
Figure 5. Cyclic rigging - actuators ..............................................................................................................................13
Figure 6. Cyclic rigging - transducer (sheet 1 of 2)......................................................................................................15
Figure 7. Cyclic friction adjustment .............................................................................................................................18
Figure 8. Cyclic rigging (alternate method) (sheet 1 of 4) ...........................................................................................21
Figure 9. Position verification ......................................................................................................................................31
Figure 10. Fore and aft cyclic sensor adjustment (sheet 1 of 2).....................................................................................32
Figure 11. Lateral cyclic sensor adjustment (sheet 1 of 2).............................................................................................34
67-11-03 FLIGHT CONTROLS RIGGING - ANTI-TORQUE CONTROLS
Figure 1. Anti-torque rigging (sheet 1 of 2) ...................................................................................................................4

Figure 2. Rigging tool (T103206-101) ...........................................................................................................................6
Figure 3. Control motion transducer rigging ..................................................................................................................7
Figure 4. Tail rotor blade to yoke clearance...................................................................................................................8
67-11-04 FLIGHT CONTROLS RIGGING - AERODINAMICALLY ACTUATED ELEVATOR
Figure 1. Elevator rigging (sheet 1 of 2) ........................................................................................................................2
Figure 1. Collective controls ..........................................................................................................................................2
67-12-02 COLLECTIVE CONTROLS - HYDRAULIC SERVO CYLINDER BOOT
Figure 1. Hydraulic servo cylinder boot.........................................................................................................................2
Figure 1. Hydraulic cylinder extension tube ..................................................................................................................2

Figure 1. Hydraulic cylinder extension universal...........................................................................................................2

67-Index
Page 10 Rev. 3
E-AB412-PT6T-2
FIGURES (CONT.D)
Figure Page
Number Title Number
Figure 1. Piston rod clevis.............................................................................................................................................. 3

Figure 2. Hydraulic servo cylinder boot ........................................................................................................................ 4
Figure 1. Servo valve balance spring ............................................................................................................................. 2
Figure 1. Collective flight control cylinder (sheet 1 of 3) ............................................................................................. 4

Figure 2. Hydraulic servo cylinder boot ........................................................................................................................ 7
Figure 1. Left cyclic and collective boost support ......................................................................................................... 2
Figure 1. Adjustable rod end tube .................................................................................................................................. 2
Figure 1. Collective control bellcrank............................................................................................................................ 2
Figure 1. Collective force gradient (applicable to helicopters with 4-axis AFCS/flight director kit installed)
(sheet 1 of 2) ................................................................................................................................................... 3
Figure 1. Collective bellcrank (applicable to helicopters with 4-axis AFCS/flight director kit installed) .................... 2
Figure 1. Collective link (applicable to helicopters with 4-axis AFCS/flight director kit installed) ............................. 2
Figure 1. Collective rotary actuator (applicable to helicopters with 4-axis AFCS/flight director kit installed)............ 2
Figure 1. Adjustable collective control tube .................................................................................................................. 2
Figure 1. Collective control lever installation................................................................................................................ 2
67-Index
Rev. 3 Page 11
E-AB412-PT6T-2
FIGURES (CONT.D)
Figure Page
Number Title Number
Figure 1. Pilot collective stick boot ................................................................................................................................2
Figure 1. Collective jackshaft (sheet 1 of 2)...................................................................................................................3

Figure 2. Collective jackshaft assembly .........................................................................................................................7
Figure 1. Collective friction clamp assembly.................................................................................................................3
Figure 1. Cyclic controls ................................................................................................................................................2
Figure 1. Hydraulic cylinder extension universal...........................................................................................................2
Figure 1. Left cyclic piston rod clevis ............................................................................................................................3
Figure 1. Right cyclic piston rod clevis..........................................................................................................................3
Figure 1. Left cyclic flight cylinder (sheet 1 of 3)..........................................................................................................4
Figure 1. Right cyclic flight control cylinder (sheet 1 of 4) ...........................................................................................4
Figure 1. Cyclic controls ................................................................................................................................................3

Figure 2. Right cyclic control boost cylinder support ....................................................................................................4
67-Index
Page 12 Rev. 3
E-AB412-PT6T-2
FIGURES (CONT.D)
Figure Page
Number Title Number
Figure 1. Right cyclic control tubes and bellcranks....................................................................................................... 3
Figure 1. Mixing lever ................................................................................................................................................... 2
Figure 1. Fore and aft lateral proximity switches .......................................................................................................... 2
Figure 1. Fore and aft and lateral proximity switches.................................................................................................... 2
Figure 1. Lateral series actuator and proximity switch .................................................................................................. 3
Figure 1. Longitudinal series actuator............................................................................................................................ 3
Figure 1. Lateral cyclic rotary actuator .......................................................................................................................... 2
Figure 1. Fore and aft cyclic rotary actuator .................................................................................................................. 3
Figure 1. Fore and aft cyclic force gradient ................................................................................................................... 4

Figure 2. Fore and aft cyclic force gradient assembly ................................................................................................... 5
Figure 1. Lateral cyclic force gradient ........................................................................................................................... 3

Figure 2. Lateral cyclic force gradient assembly ........................................................................................................... 4
Figure 1. Fore and aft cyclic transducers ....................................................................................................................... 3
(RIGHT SIDE)
Figure 1. Fore and aft cyclic jackshaft tube and lever assembly (right side)................................................................. 4
Figure 2. Fore and aft cyclic jackshaft tube and lever assembly (right side) alignment................................................ 5
67-Index
Rev. 3 Page 13
E-AB412-PT6T-2
FIGURES (CONT.D)
Figure Page
Number Title Number
(LEFT SIDE)
Figure 1. Fore and aft cyclic jackshaft tube and lever assembly (left side) ...................................................................4
Figure 2. Fore and aft cyclic jackshaft tube and lever assembly (left side) alignment ..................................................5
Figure 1. Cyclic jackshaft housing .................................................................................................................................2
Figure 1. Cyclic controls arm .........................................................................................................................................3

Figure 2. Cyclic controls arm and washer positioning ...................................................................................................4
Figure 1. Lateral transducers ..........................................................................................................................................2
Figure 1. Cyclic stick boot..............................................................................................................................................2
Figure 1. Pilot cyclic stick ..............................................................................................................................................2
Figure 1. Anti-torque controls ........................................................................................................................................2
Figure 1. Pitch change control bellcrank ........................................................................................................................2
Figure 1. Control tube guides .........................................................................................................................................2
Figure 1. Anti-torque controls ........................................................................................................................................2
Figure 1. Anti-torque control support.............................................................................................................................2
Figure 1. Anti-torque hydraulic cylinder........................................................................................................................3

Figure 2. Anti-torque hydraulic cylinder bearing inspection tool ..................................................................................4
67-Index
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E-AB412-PT6T-2
FIGURES (CONT.D)
Figure Page
Number Title Number
Figure 1. Directional series actuator .............................................................................................................................. 3

Figure 2. Directional series actuator assembly .............................................................................................................. 4
Figure 1. Walking beam and friction clamp assembly................................................................................................... 3

Figure 2. Anti-torque controls........................................................................................................................................ 4
Figure 1. Magnetic brake ............................................................................................................................................... 3

Figure 2. Magnetic brake assembly P/N 204-001-376-3 ............................................................................................... 4
Figure 1. Control transducer and force gradient ............................................................................................................ 2
Figure 1. Control transducer and force gradient ............................................................................................................ 3

Figure 2. Force gradient assembly ................................................................................................................................. 4
Figure 1. Pedal adjuster.................................................................................................................................................. 3
Figure 1. Anti-torque pedals .......................................................................................................................................... 2
Figure 1. Aerodynamically actuated elevator and horn ................................................................................................. 2
Figure 1. Aerodynamically actuated elevator and horn ................................................................................................. 2

Figure 2. Elevator inspection (installed) ........................................................................................................................ 7
Figure 1. Elevator control tube ...................................................................................................................................... 2
67-Index
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67-0 -0 FLIGHT CONTROL SYSTEMS
67-00-00
FLIGHT CONTROL SYSTEMS
1. FLIGHT CONTROL SYSTEMS - GENERAL
The following paragraphs contains information and instructions for maintenance of both standard and automatic flight
control systems.
The standard flight control system includes a cyclic control stick for fore and aft and lateral controls, a collective pitch
control stick for vertical control and anti-torque pedals for directional control. An aerodynamically actuated elevator
increases stability about the longitudinal axis.
All control systems are provided with hydraulic servocontrol, and all control system except the collective pitch control sys-
tem with force gradient and magnetic brake. The control linkages are easily accessible through access doors and panels
secured by screws, therefore maintenance and inspection operations are this simplified. The pilot and copilot controls are
interconnected.
Electrically operated force trim systems consisting of electromechanical rotary actuators and force gradients (cyclic
controls) and magnetic brake and force gradient (anti-torque controls) are connected in parallel to the cyclic and anti-torque
controls, position the flight controls in response to a signal from either the pilot or AFCS system to establish a flight
reference point, provide artificial force feel and stabilization of the cyclic and anti-torque controls.
The stick centering indicator system consists of two proximity switches and two cyclic centering (CYC CTR) caution lights
(Kit 412-704-115-101). The lights are located on the pilot and copilot instrument panel. System circuitry is activated
whenever the rotor RPM warning light is illuminated. During ground operations below normal operating range, excessive
cyclic inputs will illuminate the CYC CTR caution lights. Properly positioning cyclic stick will extinguish the lights.
The Automatic Flight Control System (AFCS) consists of the standard flight control system plus added AFCS components
in the cyclic and directional control systems.
The AFCS has two modes of operation: SAS (stability augmentation system) and ATT (attitude retention). The SAS mode
acts as a damping system that stabilizes the helicopter against outside disturbances, thereby augmenting pilot effort. In this
mode, the AFCS does not interfere with attitude changes initiated by the pilot.
The ATT mode maintains a given attitude indefinitely without pilot-initiated cyclic control inputs. Small attitude changes
can be deliberately introduced by way of a momentary ATTD TRIM beep switch on the cyclic stick. More extensive changes
can be made by depressing the FORCE TRIM switch, also on the cyclic stick. This switch disengages the AFCS while
depressed and reengages it when released.
The AFCS consists of two computer-operated subsystems, either of which is capable of complete attitude control of the
helicopter. The normal procedure, however, is for both subsystems to operate simultaneously. The subsystems are identical
in their roll and pitch control capabilities, but one has short-term yaw control capability as well.
A navigation coupling system is also installed. This system adds to the AFCS the capability to intercept and follow radio
navigation systems on its own, without pilot handling of the controls. This automatic capability keeps the helicopter on a
selected heading at a given airspeed and altitude. It also permits VOR, localizer and glideslope interception and tracking.
An automatic ILS approach to minimums (with positive sensing on the front and back courses) is also possible. The coupler
provides inputs to the flight director bars on the pilot's ADI.
An AFCS mode selector unit is installed in the pedestal. This unit has five illuminated push button switches, 1 for each
subsystem (HP1, HP2), 1 for the navigation coupling system (CPL), 1 for SAS, and 1 for ATT.
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E-AB412-PT6T-2
An AFCS caution light illuminates on the master caution/warning panel when there is a loss of power to one of the
subsystems or when the two systems are not tracking together.
The AFCS cyclic control systems incorporate four electromechanical series actuators, two connected in series in the roll
system and two connected in series in the pitch system. Four transducers, two in roll system and two in pitch system are used
to convert mechanical movement to electrical signals for injection of pilot control commands to the AFCS.
AFCS anti-torque directional system incorporates a single electrical servo actuator and a transducer. The servo actuator is
located forward of the directional hydraulic actuator. The transducer is connected to the bellcrank aft of the pedals.
Forward servo actuator in each cyclic system and directional series actuators are controlled by helipilot, HP-1 system. Aft
actuators in each system are controlled by HP-2 system.
When the optional flight director kit is installed an additional transducer is added to the collective control system.
Refer to Chapter 98 for AFCS system wiring diagrams.
The following modules provide rigging instructions for the collective, cyclic, anti-torque (tail rotor), and aerodynamically
actuated elevator control systems. For engine power lever controls (throttle), refer to Chapter 76.
2. FLIGHT CONTROL SYSTEMS - TROUBLESHOOTING
Refer to Chapter 29 for flight control hydraulic systems troubleshooting.
67-00-00
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67-1 -01 FLIGHT CONTROLS RIGGING - COLLECTIVE CONTROLS
67-11-01
FLIGHT CONTROLS RIGGING - COLLECTIVE CONTROLS
1. COLLECTIVE CONTROLS - DESCRIPTION
MATERIALS REQUIRED
NUMBER NOMENCLATURE
C-405 LOCKWIRE
NUMBER NOMENCLATURE
T55-4 COLLECTIVE LEVER POSITIONING TOOL
T81 PUSH-PULL DIAL GAGE (SPRING SCALE)
1. Comply with the following general procedures when rigging collective controls:
a. When a rigging procedure requires a specific position to accomplish following steps, manually hold controls in
position or secure controls in position with pilot friction adjustment.
b. Tolerance for rigging dimensions is plus or minus 0,03 in (0,76 mm).
c. All adjustable control tubes shall have a maximum of 1,0 in (25,4 mm) of exposed threads after adjustment. If
control tubes have inspection holes, threads shall be engaged sufficiently to cover holes.
d. Apply corrosion preventive compound (C-101) to threads of all adjustable end bearings and clevises after
adjustment.
e. Torque control jam nuts 80 to 100 in-lbf (9,04 to 11,30 Nm) after adjustment unless other torque is specified.
f. Control tubes must be free to rotate several degrees about longitudinal axis. Loosen jam nuts, adjust end fittings,
and torque jam nuts if necessary. Remove and replace lockwire (C-405) as necessary.
2. Disconnect the following controls tubes:
a. Disconnect extension tube (2, figure 1) from collective lever (1) by removing cotter pin, nut, four washers, and
bolt.
b. Disconnect control tube (4) from collective hydraulic cylinder (3) by removing cotter pin, nut, two washers, bolt
and clip.
c. Disconnect control tube (7) from lever (8) by removing cotter pin, nut, two washers, and bolt.
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NOTE
The following two substeps are only applicable to helicopters with 4-axis AFCS/
Flight Director Kit installed.
d. Disconnect force gradient (1, figure 2) from control lever (6).
e. Disconnect link (3) from rotary actuator (2).
3. If available, connect hydraulic power cart to helicopter. Do not apply hydraulic power at this time.
4. Position pilot collective stick (14, figure 1) against the “UP” stop, hold in position, and tighten pilot collective friction
adjuster (13).
5. Position top edge of bellcrank (6) 0,52 in (13,21 mm) above top of support (5) as shown on detail C.
6. Adjust control tube (7) to lever (8). Tighten jam nut on tube (7) clevis. Install tube (7) on lever (8) using bolt, two
washers, nut and cotter pin.
7. Ensure pilot collective stick (14) is positioned as described in step 4.
8. Move actuator valve lever (16) up to bottom collective hydraulic cylinder (3) in “UP” position. Set actuator valve lever
0,070 in (1,778 mm) above center line neutral valve position (detail B) and hold in position.
9. Adjust control tube (4) to fit actuator valve lever (16). Shorten rod end bearing three turns. Tighten jam nut against rod
end bearing on control tube. Install control tube on actuator valve lever.
NOTE
If collective lever positioning tool (27) (T55-4) is available, skip step 10. and
perform step 11.
10. Position collective lever (1) 4,67 to 4,70 in (118,62 to 119,38 mm) above base of swashplate support (18) to center of
pin (17) (detail A).
11. Secure collective lever positioning tool (27) to pin (17) on collective lever (1) with screw (28), then pull up on
collective lever to seat collective lever positioning tool base on plate assembly (29).
12. Apply hydraulic power from hydraulic cart to helicopter.
CAUTION
WHEN PERFORMING OPERATIONAL CHECK OF COLLECTIVE

CONTROLS WITH HYDRAULIC POWER APPLIED, ENSURE CYCLIC STICK
IS IN CENTER POSITION.
NOTE
If hydraulic power cart is not available refer to Note preceding step 16.
13. With collective lever (1) set as per steps 10. or 11, position pilot collective stick (14) against DOWN stop. Tighten pilot
collective friction adjuster (13).
14. Adjust extension tube (2) to fit collective lever (1). Torque jam nut 1500 to 1800 lbf·in (169,48 to 203,37 Nm) on
extension tube (2), and apply lockwire (C-405). Apply adhesive (C-308) around nut, lockwire and threads of clevis.
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G6AB0105A
Figure 1. Collective rigging (sheet 1 of 3)
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E-AB412-PT6T-2
G6AB0106A
67-11-01
Page 4 Rev. 1
E-AB412-PT6T-2
1. Collective lever 16. Actuator valve lever

2. Extension tube 17. Pin
3. Collective hydraulic cylinder 18. Swashplate support
4. Control tube 19. Transmission
5. Support 20. Nut
6. Bellcrank 21. Elbow support
7. Control tube 22. Gear sector
8. Lever 23. Gear sector
9. Stop 24. Shim
10. Control tube 25. Control tube
11. Minimum collective friction clamp 26. Control tube
12. Collective jackshaft 27. Collective lever positioning tool (T103287-101)
13. Pilot collective friction adjuster 28. Screw
14. Pilot collective stick 29. Plate assembly
15. Piston
G6AB0107B
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E-AB412-PT6T-2
1. Force gradient
2. Rotary actuator
3. Link
4. Bellcrank
5. Control tube
6. Control lever
7. Control tube
8. Collective jackshaft
9. Pilot collective fricton adjuster
10. Pilot collective stick
G6AB0108B
Figure 2. Collective controls (4-axis configuration)
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CAUTION
DO NOT MOVE PILOT COLLECTIVE STICK (14) WITH COLLECTIVE

LEVER POSITIONING TOOL (27) INSTALLED.
15. Install extension tube (2) to collective lever (1) using bolt, washers, nut and cotter pin (module 67-12-03
paragraph "2. Hydraulic cylinder extension tube - installation").
a. If applicable, remove collective lever positioning tool (27).
NOTE
Alternate method of adjusting extension tube (2) without pressurizing hydraulic
system is outlined in steps 16. through 21.
16. Position collective lever (1) and pilot collective stick (13) as outlined in step 13.
17. Exert sufficient downward pressure on collective hydraulic cylinder (3) to hold actuator valve lever (15) at top of travel
(detail B).
CAUTION
DO NOT ALLOW COLLECTIVE CONTROLS BELOW HYDRAULIC

CYLINDER (3) TO MOVE WHILE ACCOMPLISHING THE FOLLOWING
STEP.
18. Adjust extension tube (2) to fit collective lever (1), then shorten tube by one complete turn of upper clevis.
19. Torque jam nut 1500 to 1800 lbf·in (169,48 to 203,37 Nm) on extension tube (2) and secure with lockwire (C-405).
Apply adhesive (C-308), around nut, lockwire and threads of clevis.
20. Install extension tube (2) to collective lever (1) using bolt, four washers, nut and cotter pin (module 67-12-03
paragraph "2. Hydraulic cylinder extension tube - installation")
21. Adjust stop (9) as shown in detail F. Torque jam nut 80 to 100 lbf·in (9,04 to 11,30 Nm) and secure with lockwire
(C-405).
NOTE
The following step is only applicable to helicopters with 4-axis AFCS/Flight
Director Kit installed.
22. Rig collective trim system as follows:
a. Position pilot collective stick (10, figure 2) against its down stop.
b. Connect force gradient (1) to control lever (6).
c. Position output arm of rotary actuator (2) as shown in detail A.
d. Position and hold output arm of rotary actuator (2) against its outboard left-hand stop.
e. Adjust link (3) to fit between the bellcrank (4) and rotary actuator (2) positioned per step d., then extend the rod
end bearing 2 1/2 complete turns and secure to output arm of the rotary actuator (2).
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23. Adjust minimum friction as follows:
NOTE
Steps a. and b. are applicable to helicopters without 4-axis AFCS/Flight Director kit
installed when a hydraulic power cart is not used.
a. Disconnect tube (10, figure 1) from collective jackshaft (12) by removing cotter pin, nut, two washers, and bolt.
b. Attach a spring scale at the center of upper throttle grip within 0,50 in (12,7 mm). Correct measurement is 13 to
14 lb (57,8 to 62,2 N) up-collective stick force. Proceed to step d.
NOTE
Measurement in step c. requires the use of a hydraulic power cart.
For helicopters with AFCS/4-axis Flight Director kit installed, measurement is taken
with collective force trim OFF.
c. Attach a spring scale (T81) at center of upper throttle grip within 0,50 in (12,7 mm). Correct measurement is 8
to 11 lb (35,6 to 48,9 N) (helicopters without 4-axis Flight Director kit installed) or 4,0 to 4,5 lb (17,8 to 20,0 N)
(helicopter with 4-axis AFCS/Flight Director kit installed) up-collective stick force.
d. Tighten or loosen nut (20) to adjust clamp (11) as shown in detail D to obtain correct sliding force.
e. After friction is adjusted within limits, connect tube (10) if disconnected in step a.
24. Move collective controls through full travel and check for binding and/or obstruction of control movement.
25. Turn off hydraulic power cart and disconnect from helicopter.
26. Ensure all collective control bolts are installed and cotter pins and lockwire are installed, where applicable.
27. Check throttle controls for binding or obstruction as follows:
a. Disconnect left and right adjustable throttle control tubes (24 and 25) from each bellcrank by removing nut, two
washers, and bolt.
b. Check marked tooth of flex shaft is engaged with 10th tooth space of mating gear sectors (21 and 22) on both
pilot and copilot collective elbow.
c. Roll both throttle grips on pilot (and copilot, if installed) collective sticks to full INCR position against stop.
NOTE
If binding or obstruction occurs in copilot throttle grips when rotated, adjust shims
(23) between airframe structure and elbow support (20) to minimize lateral
deflection of elbow assembly flex shafts.
d. Adjust control tubes (24 and 25) to fit, torque jam nuts and install.
e. Cycle both throttle grips through full travel and ensure each gear sector on both pilot and copilot elbow support
is within no less than one tooth of rolling off its mating pinion.
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Page 8 Rev. 1
E-AB412-PT6T-2
67-1 -02 FLIGHT CONTROLS RIGGING - CYCLIC CONTROLS
67-11-02
FLIGHT CONTROLS RIGGING - CYCLIC CONTROLS
1. CYCLIC CONTROLS - DESCRIPTION
Two methods of rigging cyclic controls are provided in the following paragraphs. The primary method is provided in
paragraph "2. Cyclic controls - primary method" and the alternate method in paragraph "3. Cyclic controls - alternate
method".
2. CYCLIC CONTROLS - PRIMARY METHOD
NUMBER NOMENCLATURE
T24-1 SWASHPLATE RIGGING TOOL
T82 INCLINOMETER
MATERIALS REQUIRED
NUMBER NOMENCLATURE
C-405 LOCKWIRE
NOTE
Rigging procedures contained herein, pertain to helicopters with dual controls
installed in basic controls systems.
1. Comply with the following general procedures when rigging cyclic controls (figure 1).
position or secure controls in position with friction adjustment.
b. Tolerance for rigging dimensions is plus or minus 0.03 in (0.76 mm).
c. All adjustable control tubes shall have no more than 1.0 in (25.40 mm) of exposed threads or less than 1,5
threads, after adjustment.
d. Apply corrosion preventive compound (C-101) to threads of all adjustable rod bearings and clevises after
adjustment.
e. Torque control jam nuts 80 to 100 in-lbs (9.04 to 11.30 Nm) after adjustment unless other torque is specified.
and torque jam nuts, if necessary.
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2. Connect hydraulic power cart to helicopter. Do not apply hydraulic power at this time.
NOTE
During rigging, care must be taken to prevent helicopter from moving. Keep
helicopter as level as possible.
3. Retract stop bolts as far as possible (figure 2 and figure 3).
4. Disconnect the following control tubes and force gradients.
a. Disconnect extension tube (2, figure 1) from swashplate (1) by removing nut, lock washer, three washers, and
bolt.
b. Disconnect extension tube (3) from swashplate (1) by removing nut, lock washer, three washers, and bolt.
c. Disconnect control tube (8) from bellcrank (7) by removing two nuts, four washers, and two bolts and from valve
arm (4) by removing two nuts, four washers, and two bolts. Remove control tube (8) and tag.
d. Disconnect control tube (9) from bellcrank (10) by removing two nuts, four washers, and two bolts and from
valve arm (13) by removing two nuts, four washers, and two bolts. Remove control tube (9) and tag.
e. Disconnect fore and aft cyclic force gradient (17) and clevis (20) from jackshaft (16) by removing nut, and
washer.
f. Disconnect fore and aft cyclic transducers (34) from jackshaft (16) by removing nut, lock washer, two washers,
and bolt.
g. Disconnect control tube (22) from jackshaft (16) by removing nut, three washers, and bolt and remove control
tube (24) from bellcrank (31) by removing nut, three washers, and bolt.
h. Disconnect cyclic lateral transducers (29) from bellcrank (31) by removing nut, two washers, two spacers, and
bolt.
i. Disconnect cyclic force gradient (26) from bellcrank (31) by removing cotter pin, nut, two washers, bushing and
bolt.
NOTE
Helicopters codes [A] [B] have control tube (30) (204-001-016-13) installed.
Helicopters codes [C] [D] use control tube (412-001-307-101) which is a
replacement for all serial number helicopters.
j. Disconnect control tube (30) from pilot cyclic stick (33) by removing nut, two washers, and bolt. Remove control
tube and tag.
5. Verify length of centered fore and aft series actuator (14, figure 1) of 27.505 to 27.555 in (698.627 to 699.897 mm).
6. Verify length of centered lateral series actuator (35) of 56.295 to 56.345 in (1429.893 to 1431.163 mm).
7. Level helicopter (Chapter 8).
8. Position pilot cyclic stick (33) with respect to deck using an inclinometer (T82), bubble protractor, or equivalent as
follows:
a. Place pilot cyclic against extreme forward stop. Measure and record angle of stick relative to deck.
b. Place pilot cyclic against extreme aft stop. Measure and record angle of stick relative to deck.
c. Place pilot cyclic against extreme right lateral stop. Measure and record angle of stick relative to deck.
d. Place pilot cyclic against extreme left lateral stop. Measure and record angle of stick relative to deck.
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E-AB412-PT6T-2
e. Position pilot cyclic at mid-position within 0.5° utilizing one-half total stick deflections as measured in steps a.
and b. (fore and aft cyclic) and steps c. and d. (lateral cyclic). Tighten pilot cyclic friction knob (32) to maintain
this position.
9. Check and adjust (if necessary) control tube (30) between pilot cyclic and bellcrank. Verify dimension A and B
between bellcrank and bulkhead are equal within 0.030 in (0.762 mm) (figure 1 detail C). Torque jam nut and install
control tube (30).
10. Adjust rod end bearing (52, detail E) on left cyclic hydraulic cylinder (5) as follows:
a. Remove cotter pin (41), nut (42), washer (43), and bolt (39) from support (40).
b. Push lower actuator body (48) full up and pull lower piston (49) full down (detail E).
c. Remove lockwire and loosen jam nut (51) and adjust rod end bearing (52) to align bolt holes in rod end bearing
(52) and support (40).
CAUTION
IMPROPER TORQUE TECHNIQUE CAN DESTROY TAB ON LOCKING

DEVICE (50). ROD END BEARING (52) MUST BE HELD SECURE TO
PREVENT DAMAGING LOCKING DEVICE.
d. Torque jam nut (51) 200 to 250 in-lbs (22.60 to 28.25 Nm) and secure to locking washer (50) with lockwire
(C-405).
e. Inspect locking device (50) to ensure tab is in groove of rod end bearing (52) and that it was not damaged when
jam nut (51) was tightened. Replace locking device if tab is twisted or damaged.
NOTE
Alignment procedures are applicable to all three cylinders.
11. Align left cyclic cylinder (5, figure 1) to support (40) as follows:
a. Ensure extension tube (2) is disconnected from swashplate (1).
b. Move lower piston rod up and clear of support (40). Lower piston rod end bearing (52) must be able to be moved
freely down, up, and then down, and bolt (39) replaced without any pressure, forcing, binding or bending or
piston rod in any direction fore, aft, left or right. One person must guide extension tube (2) to prevent damage
when conducting this step.
c. If cylinder meets requirements of step b. above, it is considered in alignment. If cylinder is aligned, proceed to
step d. If cylinder is misaligned, accomplish steps e. through m.
d. Install bolt (39), washer (43), nut (42), and cotter pin (41). Loosely install upper tube (2) to swashplate by
installing washer and bolt.
e. Remove lockwire (47) from jam nut (46), bearing nut (45), and keyed washer (53).
f. Loosen jam nut and bearing nut so cylinder is loose.
g. Move rod end bearing (52) up approximately 0.5 in (12.7 mm) above support (40). Rotate lower end of cylinder
in a 3.0 in (76.2 mm) circle.
h. Position rod end bearing (52) directly over lugs of support (40) and move piston down and install bolt (39).
i. Tighten bearing nut (45) by hand (approximately 70 in-lbs (7.91 Nm).
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E-AB412-PT6T-2
j. Remove bolt (39) and move rod end bearing up and out of support (40) then move down. Rod end bearing (52)
must be free of any side loading. Repeat steps e. through j. until free of side loading.
k. Install bolt (39). Torque bearing nut (45) to 200 in-lbs (22.60 Nm).
l. If cylinder meets requirements of step b., install washer (43), nut (42) and torque 95 to 100 in-pounds (10.73 to
12.43 Nm). Install cotter pin (41). Complete installation of upper extension tube (2) by installing two washers,
cotter pin and nut.
m. Torque bearing nut (45) 900 to 1100 in-lbs (101.68 to 124.28 Nm). Torque jam nut (46) 900 to 1100 in-lbs
(101.68 to 124.28 Nm). Secure nuts (45 and 46) to keyed washer (53) with lockwire (C-405).
n. Connect control tube (8) to valve arm (4), by installing bolt, washers, and nut. Leaving tube disconnected from
bellcrank (7).
NOTE
Repeat steps 10. and 11. on right cyclic hydraulic cylinder (12). With main rotor
pitch links connected, all cyclic and collective adjustments or checks shall be
accomplished using hydraulic boost.
12. Turn on hydraulic power cart and apply hydraulic power to helicopter.
CAUTION
WHEN PERFORMING OPERATIONAL CHECK OF CYCLIC CONTROLS

WITH HYDRAULIC SYSTEM PRESSURIZED, ENSURE COLLECTIVE STICK
IS POSITIONED NEAR MID TRAVEL.
13. Adjust control tubes (2 and 3, figure 2) as follows:
a. Adjust control tubes (2 and 3) to length of 20.86 in (529.84 mm).
b. Torque jam nuts 80 to 100 in-lbs (9.04 to 11.30 Nm) on control tube (2 and 3).
c. Connect each control tube (8 and 9 figure 1) to each bellcrank (7 and 10) temporarily with bolt.
14. Ensure pilot cyclic stick (33) is perpendicular to deck within 0.5° (as determined in step 8.) and held in this position.
15. Disconnect four pitch link assemblies from pitch horns (Chapter 62).
16. Set swashplate angle with respect to mast using swashplate rigging tool (T24-1) as follows (figure 4):
a. Ensure helicopter is level (Chapter 8).
b. Position swashplate rigging tool (T24-1) on rotating portion of swashplate with swashplate positioned fore and
aft.
c. Set swashplate angle with respect to mast utilizing an inclinometer (T82), or equivalent, located on upper surface
of rigging tool as follows:
(1) Fore and aft: Set swashplate 0° 33' to 1.0° 3' down forward.
(2) Lateral: Set swashplate 1.0° 0' to 1.0° 30' down left.
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1. Swashplate
2. Extension tube
3. Extension tube
4. Valve arm
5. Left cyclic hydraulic cylinder
6. Support (ref)
7. Bellcrank
8. Control tube
9. Control tube
10. Bellcrank
11. Support (ref)
12. Right cyclic hydraulic cylinder
13. Valve arm
14. Fore and aft cyclic series actuator
15. Copilot cyclic stick
16. Jackshaft
17. Fore and aft cyclic force gradient
18. Fore and aft cyclic rotary actuator
19. Spring
20. Clevis
21. Clevis
22. Control tube
23. Boot
24. Control tube
25. Lateral cyclic rotary actuator
26. Lateral cyclic force gradient
27. Clevis
28. Clevis
29. Lateral cyclic transducers
30. Control tube
31. Bellcrank
32. Friction adjustment knob
33. Pilot cyclic stick
34. Fore and aft cyclic transducers
35. Lateral cyclic series actuator
G6AB0144B
Figure 1. Cyclic rigging (sheet 1 of 3)
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36. Boot
37. Support
38. Support
39. Bolt
40. Support (ref)
41. Cotter pin
42. Nut
43. Washer
44. Support bracket
45. Nut
46. Nut
47. Lockwire
48. Lower actuator body
49. Lower piston
50. Locking device
51. Jam nut
52. Rod end bearing
53. Keyed washer
G6AB0145B
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NOTE:
With cyclic centering kit installed.
G6AB0146B
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1. Right cyclic hydraulic cylinder 8. Actuator support

2. Control tube 9. Stop
3. Control tube 10. Stop bolt
4. Left cyclic hydraulic cylinder 11. Bellcrank
5. Stop bolt 12. Stop bolt
6. Bellcrank 13. Actuator support
7. Stop bolt 14. Stop
G6AB0147B
Figure 2. Cyclic rigging - hydraulic cylinders
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2. Bellcrank 7. Bellcrank
4. Actuator support 9. Actuator support
5. Stop 10. Stop
G6AB0148B
Figure 3. Cyclic rigging - bellcrank stops
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POSITION OF T24-1
RIGGING TOOL
FOR LATERAL CYCLIC
SWASHPLATE SETTING
POSITION
SWASHPLATE
FORE AND AFT
SEE DETAIL A
PITCH LINK
POSITION OF T24-1
RIGGING TOOL
FOR FORE AND AFT CYCLIC
SWASHPLATE SETTING
SWASHPLATE
(VIEW LOOKING DOWN)
LOCKWIRE (MS20994C32)
T 1500 TO 1800 IN-LBS

(169.48 TO 203.37 Nm)
NOTE:
1 Apply adhesive (C-308) on nut, lockwire, and threads on clevis.
DETAIL A
TYPICAL
1. Swashplate horn
2. Bolt
5. Washer (AN960C516L)
6. Nut
7. Cotter pin
8. Hydraulic cylinder extension tube
9. Nut
10. Clevis
G6AB0149C
Figure 4. Cyclic rigging - swashplate
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NOTE
Provide a minimum of 1,5 exposed threads to left hand extension tube (2, figure 1)
upper clevis. If required at completion of step 18., it is permissible to shorten tubes
(8 and 9) equally, a maximum of five complete turns of adjustable rod end bearing.
Shortening tube assemblies (8 and 9) adjustable rod end bearing 1,5 turns is equal to
approximately one thread of extension tube (2 and 3) upper clevis.
17. Hold swashplate in position, adjust length of right hydraulic cylinder extension tube (8, figure 4) to fit swashplate.
Adjust length of left hydraulic cylinder extension tube to fit swashplate.
18. Torque nuts on both extension tubes 1500 to 1800 in-lbs (169.47 to 203.37 Nm) and secure with lockwire (C-405).
Apply adhesive (C-308) to nut, lockwire, and threads of clevis and both extension tubes.
19. Connect clevis (10) to swashplate horn (1) by installing washer (3), bolt (2), washers (4 and 5), nut (6) and cotter pin
(7).
20. Remove swashplate rigging tool (T24-1) and inclinometer (T82).
21. Connect four pitch links to pitch horns (Chapter 62).
22. Set stop bolts on bellcranks (6 and 11, figure 2) as follows:
a. Position pilot cyclic stick (33, figure 1) perpendicular to deck within 0.5° and tighten cyclic friction adjustment
knob (32).
NOTE
Aluminum strip work aids may be used in lieu of making marks on hydraulic
cylinders as described in steps b. through d. Fabricate two strips of aluminum from
aluminum sheet. Scribe index marks on aluminum strips to correspond to marks
described in steps b. through d. Attach strips to cylinder (1 and 4, figure 2) with tape
or rubber cushion clamps.
b. Make an index mark on each cyclic hydraulic cylinder and a corresponding mark on any suitable point on
airframe structure with a soft lead pencil as shown on figure 2. Label index mark “N” (neutral, and record
dimensions for each actuator.
c. Measure 1.61 in (40.89 mm) above index mark “N” (neutral) on the hydraulic cylinder and mark with soft lead
pencil on cylinder. Label index mark “F” (forward).
d. Measure 1.61 in (40.89 mm) below index mark “N” neutral on the hydraulic cylinder and mark another mark
with soft lead pencil on cylinder. Label index mark “A” (aft).
e. Loosen friction adjustment knob (32, figure 1) on pilot cyclic (33) and position stick against extreme left lateral
stop, then move stick toward forward left corner position until index mark “F” on left hydraulic cylinder
(4, figure 2) coincides with recorded dimensions for that actuator. Hold this position and adjust stop bolt (7) in
bellcrank (6) to make contact with actuator support (8).
f. Position pilot cyclic against extreme left lateral stop, then move stick toward aft left corner position until index
mark “A” on right hydraulic cylinder (1) coincides with recorded dimension for that actuator. Hold this position
and adjust stop bolt (10) in stop (14) to make contact with bellcrank (11).
g. Position pilot cyclic against extreme right lateral stop then move stick toward forward right corner position until
index mark “F” on right hydraulic cylinder (1) coincides with recorded dimensions for that actuator. Hold this
position and adjust stop bolt (3, figure 3) in bellcrank (2) to make contact with actuator support (4).
h. Position pilot cyclic against extreme right lateral stop. Move stick toward aft right corner position until index
mark “A” on left hydraulic cylinder (4, figure 2) coincides with recorded dimension for that actuator. Hold this
position and adjust stop bolt (6, figure 3) in stop (10) to make contact with bellcrank (7).
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23. Turn off hydraulic power cart.
24. Adjust copilot control tubes (22 and 24, figure 1) as follows:
a. Place pilot cyclic (33) and copilot cyclic (15) in extreme left position against stops and hold. Adjust control tube
(24) to fit bellcrank (31). Torque jam nut on clevis on control tube (24). Install control tube (24) on bellcrank
(31) by installing bolt, washer, nut and cotter pin.
b. Place pilot and copilot cyclics in extreme forward position against stops and hold. Adjust control tube (22) to fit
jackshaft (16). Torque jam nut on clevis on control tube (22). Install control tube (22) on jackshaft (16) by
installing bolt, washer, nut and cotter pin.
CAUTION

26. Move cyclic controls through full travel and check for binding and/or obstruction of control movement.
27. Turn off hydraulic power cart.
28. Perform fore and aft cyclic stick centering (figure 5, detail A), as follows:
a. Position output arm on fore and aft cyclic rotary actuator (18, figure 1).
b. Place pilot cyclic (33) against extreme forward stop.
c. Place output arm of the rotary actuator (18) against aft stop.
29. Adjust clevis (20) attached to force gradient (17) in fore and aft cyclic control system to fit jackshaft (16). Extend clevis
3.5 to 4,0 turns and torque jam nut. Install force gradient (17) onto rotary actuator (18) with nut, and washer. To install
clevis (20) to jackshaft (16) use bolt, washer, and lockwire (C-405).
NOTE
Check for approximately 0.9 in (22.86 mm) cushion at stick grip when against
forward cyclic stick stop.
30. Perform lateral cyclic stick centering (figure 5, detail B) as follows:
a. Position output arm on lateral cyclic rotary actuator (figure 6).
b. Check clearance between lateral force gradient (26) and structure at extreme positions of rotary actuator (25)
arm. If required, re-index arm relative to shaft by one serration for clearance.
c. Place pilot cyclic against right lateral stop.
d. Place output arm of lateral rotary actuator (25) to extreme left position against stop.
e. If necessary to extend clevis (28) to adjust clevis on force gradient (26), remove control tube (24) from bellcrank
(31) by removing cotter pin, nut, three washers, and bolt.
f. Adjust clevis (28) attached to force gradient (26) to fit bellcrank (31) and temporarily install.
g. Place one end of a 6.0 in (15.24 cm) (or similar measuring tool) scale against end cap of force gradient (26) and
measure to approximate center of clevis (28). Mark center with soft pencil and record dimension.
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G6AB0150A
Figure 5. Cyclic rigging - actuators
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h. Place and hold pilot cyclic against left lateral stop. Measure and record total travel distance of clevis (28). Extend
clevis one half recorded distance. Torque jam nut and install on bellcrank (31) with nut, three washers, bolt and
cotter pin.
i. Install control tube (24) to bellcrank (31) with nut, three washers (one under bolt hand and two under nut), bolt
and cotter pin.
31. Perform fore and aft cyclic control motion transducer (34) adjustment as follows:
a. With fore and aft cyclic transducer attached to structure (figure 6):
b. Position pilot cyclic against extreme forward stop, then against extreme aft stop. Check if transducers would
bottom out if connected to jackshaft (figure 6).
c. If bottoming occurs, loosen jam nut, adjust rod end bearings on transducer until bottoming is eliminated, torque
jam nut, then connect transducers to jackshaft. Overtravel of transducers should be approximately equal.
32. Perform lateral cyclic motion transducer (29, figure 1) adjustment as follows:
a. With transducer attached to structure (figure 6).
b. Position pilot cyclic against extreme right lateral stop, then against extreme left lateral stop. Check if transducers
bottom out if connected to bellcrank (figure 6).
c. If bottoming occurs, loosen jam nut, adjust rod end bearings on transducers until bottoming is eliminated, torque
jam nut, then connect to bellcrank. Overtravel of transducers should be approximately equal.
CAUTION

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G6AB0151A
Figure 6. Cyclic rigging - transducer (sheet 1 of 2)
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G6AB0152A
Figure 6. Cyclic rigging - transducer (sheet 2 of 2)
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34. Perform cyclic minimum friction adjustment (figure 7):
NOTE
Initial adjustment and check of fore and aft and lateral cyclic force shall be
accomplished by utilizing a hydraulic power cart connected to helicopter using steps
a. through g. Final check and adjustment shall be accomplished during ground run of
helicopter using steps b. through g.
a. Reduce cyclic friction to zero by loosening clamp. Rotate nut counterclockwise.
b. With force trim OFF, slowly increase stick friction while simultaneously pulling on cyclic stick with spring scale
attached at midpoint of pilot cyclic grip until a fore and aft cyclic breakout force of 0.50 to 1.0 lbs (2.22 to
4.44 N) is obtained.
c. Forces to be measured perpendicular to axis of cyclic stick with stick near center.
d. Check lateral cyclic breakout force of 0.50 to 1.00 lbs (2.22 to 4.44 N).
e. If lateral cyclic stick force exceeds above requirement, adjust fore and aft cyclic friction breakout within above
limits and recheck lateral cyclic breakout force (step b. through d. above).
f. Tighten clamp around sleeve with clamp resting on top surface of nut (figure 7). Tighten screws to obtain equal
gap between clamp halves.
NOTE
Steps g., h., and i. are not applicable to S/N 25901 and subsequent.
g. With force trim ON, check breakout force of fore and aft cyclic of 2.25 to 2.75 lbs (10.01 to 12.23 N) and lateral
force of 0.50 to 2.00 lbs (2.22 to 8.90 N).
h. If fore and aft or lateral breakout forces exceed above requirements, repeat steps a. through f. above.
i. If fore and aft or lateral breakout forces still exceed above requirements, readjust either fore and aft cyclic force
gradient or lateral cyclic force gradient spring preloads within respective limits to obtain required breakout force.
Repeat steps a. through g. above with hydraulic power applied.
NOTE
For cyclic force gradient spring preload adjustments and cyclic control stick mass
balance adjustment refer to module 67-13-17 paragraph "2. Rotary actuator (fore and
aft cyclic) - installation" and module 67-11-02 paragraph "2. Force gradient (fore
and aft cyclic) - installation".
35. Remove hydraulic power.
36. Accomplish rigging of cyclic controls position sensors in (paragraph "4. Cyclic controls - cyclic position sensor").
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G6AB0153A
Figure 7. Cyclic friction adjustment
3. CYCLIC CONTROLS - ALTERNATE METHOD
NUMBER NOMENCLATURE
T55-1 CYCLIC CORNER STOP RIGGING TOOL
T55-2 CYCLIC CORNER STOP RIGGING TOOL
T55-3 CYCLIC MIXING BELLCRANCK RIGGING TOOL
T55-5 COLLECTIVE LEVER RIGGING TOOL
T56-2 CYCLIC STICK RIGGING TOOL
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MATERIALS REQUIRED
NUMBER NOMENCLATURE
C-405 LOCKWIRE
NOTE
The procedures contained herein describe the alternate method of rigging cyclic
control system using special rigging tools listed above.
1. Comply with the following general procedures when rigging cyclic controls (figure 1).
a. When a rigging procedure requires a specified position to accomplish following steps, manually hold controls
in position or secure controls in position with pilot friction adjustment.
b. Tolerance for rigging dimensions is plus or minus 0.03 in (0.76 mm).
c. All adjustable control tubes shall have no more than 1.0 in (25.4 mm) of exposed threads, or less than 1,5 threads,
after adjustment.
adjustment.
and torque jam nuts, if necessary.
2. Connect hydraulic power cart to helicopter. Do not apply hydraulic power at this time.
NOTE
During rigging of cyclic controls, take care to keep helicopter as level as possible.
3. Retract stop bolts as far as possible (figure 2 and figure 3).
4. Disconnect the following control tubes and force gradients.
a. Disconnect extension tube (2, figure 1) from swashplate (1) by removing cotter pin, nut, washers, and bolt.
b. Disconnect extension tube (3) from swashplate (1) by removing cotter pin, nut, washers, and bolt.
c. Disconnect control tube (8) from bellcrank (7) by removing nut, two washers, and bolt and from valve arm (4)
remove nut, two washers, and bolt. Tag control tube (8) and valve arm (4).
d. Disconnect control tube (9) from bellcrank (10) by removing nuts, two washers, and bolts and from valve arm
(13) by removing nuts, two washers, and bolts. Remove control tube (9) and tag.
e. Disconnect fore and aft transducers (34) from jackshaft (16).
f. Disconnect control tube (22) from jackshaft (16) and control tube (24) from bellcrank (31).
g. Disconnect lateral transducers (29) from bellcrank (31).
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NOTE
Helicopters codes [A] [B] have control tube (30) (204-001-016-13) installed.
Helicopters codes [C] [D] use control tube (412-001-307-101) which are provided as
spares replacement for all serial number helicopters.
h. Disconnect control tube (30) from pilot cyclic stick (33).
5. Verify length of centered fore and aft series actuator (14, figure 1) of 27.505 to 27.555 in (698.627 to 699.897 mm).
6. Verify length of centered lateral series actuator (35) of 56.295 to 56.345 in (1429.893 to 1431.163 mm).
7. Level helicopter (Chapter 8).
8. Install cyclic stick rigging tool (T56-2) (2, figure 8). Align tool with bolt (3) at Sta. 38.65.
9. Place pilot cyclic (1) in rigging tool (2) as shown in figure 8. Position clamp (4) around cyclic (1) and secure with bolt
(6) and wing nut (5).
10. Install cyclic mixing bellcrank rigging tool base (T55-3) (15) with bolts (8).
11. Tighten screw (17) in slide (16) until slight friction is felt between slide (16) and base (15).
12. Position bushing (10) in support (12) over outboard bolt heads (11) of bellcrank (9).
13. Secure support (12) to slide (16) with screw (13) and wing nut (14).
14. With support (12) positioned per step 12., move slide (16) aft to align bellcrank (9) and tighten screw (17) to secure
slide (16).
15. Check and adjust (if necessary) control tube (30, figure 1) located between pilots cyclic stick (33) and bellcrank (31).
Torque jam nut 80 to 100 in-lbs (9.04 to 11.30 Nm) and install control tube (30).
16. Remove cyclic mixing bellcrank rigging tool (T55-3).
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1. Pilot cyclic stick

2. Rigging tool (T56-2)
3. Bolt
4. Clamp
5. Wing nut
6. Bolt
G6AB0154B
Figure 8. Cyclic rigging (alternate method) (sheet 1 of 4)
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7. Bellcrank
8. Bolt
9. Bellcrank
10. Bushing
11. Bolt
12. Support
13. Screw
14. Wing nut
15. Rigging tool base (T55-3)
16. Slide
17. Screw
G6AB0155B
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18. Screw 24. Collective lever

19. Index pin 25. Extension tube
20. Screw 26. Plate assembly
21. Rigging tool half (T55-6) 27. Rigging tool (T55-5)
22. Rigging tool half (T55-6) 28. Screw
23. Pin
G6AB0156B
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29. Actuator
30. Screw
31. Clamp
32. Screw
33. Slide
34. Rigging tool base (T55-1 left) (T55-2 right)
35. Screw
G6AB0157B
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CAUTION

18. Adjust control tubes (8 and 9, figure 1) in accordance with figure 2 as follows:
a. Connect control tubes (2 and 3) to valve arms with bolts, washers, nuts, and cotter pins, leaving tubes
disconnected from bellcranks.
b. Adjust control tubes (2 and 3) to length of 20.86 in (529.84 mm).
c. Torque jam nuts 80 to 100 in-lbs (9.04 to 11.30 Nm) on control tube.
d. Connect each control tube (8 and 9) to each bellcrank (7 and 10) with bolts, washers, nuts, and cotter pins.
19. Disconnect four pitch link assemblies from pitch horns. (Chapter 62)
20. Adjust copilot control tubes (22 and 24, figure 1) as follows:
a. Remove cyclic stick rigging tool (T56-2).
b. Place pilot cyclic (33) and copilot cyclic (15) in extreme left position against stops and hold. Adjust control tube
(24) to fit bellcrank (31). Torque jam nut on clevis (27) on control tube (24). Install control tube (24) on bellcrank
(31).
c. Place pilot and copilot cyclics in extreme forward position against stops and hold. Adjust control tube (22) to fit
jackshaft (16). Torque jam nut on clevis (21) on control tube (22). Install control tube (22) on jackshaft (16).
21. Disconnect hydraulic cylinder extension tube (25, figure 8) from collective lever (24).
22. Reconnect cyclic stick rigging tool (T56-2) and secure collective lever rigging tool (27) (T55-5) to pin (23) on
collective lever (24) with screw (28), then pull up on lever to seat tool base on plate assembly (26).
23. Install swashplate rigging tool halves (21 and 22) (T55-6) around collective sleeve with index pin (19) engaged in
swashplate outer ring. Secure tool halves (21 and 22) with screws (18).
24. Lightly tighten screw (20) in aft tool half (21) to seat sleeve in forward rigging tool half (22), then rotate tool assembly
clockwise to bottom index pin (19) in cutout of swashplate outer ring.
25. With swashplate rigging tool (T55-6) positioned per step 24., push tool assembly down until all three swashplate
positioning lugs are in contact with outer swashplate bearing retainer. Hold tool and swashplate in this position and
secure with screw (20).
NOTE
If necessary, rotate swashplate outer ring until bearing retainer ring fasteners clear
tool swashplate positioning lugs.
26. Ensure collective lever rigging tool (T55-5) is positioned per step 22., and swashplate rigging tool (T55-6) is
positioned per steps 23. through 25., before proceeding.
27. Adjust length of extension tubes (2 and 3, figure 1) to fit swashplate.
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NOTE
Provide a minimum of 1,5 exposed threads to extension tubes (2 and 3, figure 1)
upper clevis. If required at completion of step 27., it is permissible to shorten control
tubes (8 and 9) equally a maximum of five complete turns of adjustable rod end
bearing. Ensure extension tubes (2 and 3) are disconnected from swashplate before
adjusting control tubes (8 and 9). Shortening tube assemblies (8 and 9) adjustable
rod end bearing 1,5 turns is equal to approximately one thread of extension tube (2
and 3) upper clevis.
28. Torque nuts on both extension tubes 1500 to 1800 in-lbs (169.47 to 203.37 Nm) and secure with lockwire (C-405).
Apply adhesive (C-308) on nut, lockwire, and threads of clevis and both extension tubes.
29. Connect extension tubes (2 and 3) to swashplate (1) by installing bolts, washers, nut and cotter pins. Remove
swashplate rigging tool (T55-6).
30. Remove collective lever rigging tool (T55-5) and reconnect hydraulic cylinder extension tube (25, figure 8) to
collective lever (24).
31. Install cyclic corner stop rigging tool base (T55-1) (34, figure 8) on left series actuator and secure in place with screw
(30). Attach rod clamp (31) to left series actuator support and secure with screw (35). Align slide (33) index mark “N”
with pointer on tool base (34) and secure with screw (32).
32. Install cyclic corner stop rigging tool base (T55-2) (34) on right series actuator and secure in place with screw (30).
Attach rod clamp (31) to right series actuator support and secure with screw (35). Align slide (33) index mark “N” with
pointer on tool base (34) and secure in position with screw (32).
33. Remove cyclic stick rigging tool (T56-2).
34. Place pilot cyclic against extreme left lateral stop. Move stick forward toward forward left corner position until pointer
on left hand tool base (34) aligns with slide (33) index mark “F” (figure 8).
35. Adjust corner stop bolt (7, figure 2) in bellcrank (6) to make contact with actuator support (8).
36. Move cyclic stick from forward left corner position aft toward aft left corner position until pointer on right tool base
(34, figure 8) aligns with slide (33) index mark “A”.
37. Adjust corner stop bolt (10, figure 2) to make contact with bellcrank (11).
38. Place pilot cyclic against extreme right lateral stop. Move stick forward toward forward right corner position until
pointer on right tool base (34, figure 8) aligns with slide (33) index mark “F”.
39. Adjust corner stop bolt (7, figure 2) in bellcrank (6) to make contact with actuator support (8).
40. Move cyclic from forward right corner position aft towards aft right corner position until pointer on left tool base
(34, figure 8) aligns with slide (33) index mark “A”.
41. Adjust corner stop bolt (10, figure 2) to make contact with bellcrank (11).
42. Turn hydraulic power cart off and disconnect from helicopter.
43. Remove cyclic corner stop rigging tools (T55-1 and T55-2).
44. Connect four pitch links to pitch horns (Chapter 62).
45. Perform fore and aft cyclic transducer (34, figure 1) adjustments as follows:
a. Attach fore and aft cyclic transducers to structure (figure 6).
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b. Position pilot cyclic against extreme forward stop, then against extreme aft stop. Check if transducers would
bottom out if connected to jackshaft.
c. If bottoming occurs, adjust rod end bearings on transducers until bottoming is eliminated and connect
transducers to jackshaft. Overtravel to transducers should be approximately equal.
46. Perform lateral cyclic transducer (29, figure 1) adjustment as follows:
a. Attach lateral cyclic transducer to structure (figure 6).
b. Position pilot cyclic against extreme right lateral stop, then against extreme left lateral stop. Check if transducers
would bottom out if connected to bellcrank.
c. If bottoming occurs, adjust rod end bearings on transducers until bottoming is eliminated and connect
transducers to bellcrank. Overtravel of transducers should be approximately equal.
CAUTION

48. Perform cyclic minimum friction adjustment as follows:
NOTE
Initial adjustment and check of fore and aft and lateral cyclic stick force shall be
accomplished by utilizing a hydraulic power cart connected to helicopter using steps
a. through g. Final check and adjustment shall be accomplished during ground run of
helicopter using steps b. through g.
a. Reduce cyclic stick friction to zero by loosening clamp (figure 7). Rotate nut counterclockwise.
b. With force trim OFF, slowly increase stick friction while simultaneously pulling on cyclic stick with spring scale
attached at midpoint of grip until a fore and aft cyclic breakout force of 0.5 to 1.0 lbs (2.224 to 4.448 N) is
obtained.
c. Forces to be measured perpendicular to axis of stick with stick near center.
d. Check lateral cyclic breakout force of 0.5 to 1.0 lbs (2.224 to 4.448 N).
e. If lateral stick force exceeds above requirement, readjust fore and aft friction breakout within above limits and
recheck lateral breakout force.
f. Tighten clamp around sleeve with clamp resting on top surface of nut (figure 7). Tighten screws to obtain equal
gap between clamp halves.
NOTE
Steps g., h., and i. are not applicable to SN 25901 and subsequent.
g. With force trim ON, check breakout force of fore and aft cyclic stick force of 2.25 to 2.75 lbs (10.01 to 12.23 N)
and lateral stick force of 1.5 to 2.0 lbs (6.67 to 8.90 N).
h. If fore and aft or lateral breakout forces exceed above requirements, repeat steps a. through f. above.
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i. If fore and aft or lateral breakout forces still exceed above requirements, readjust either fore and aft force
gradient or lateral force gradient spring preloads within their respective limits to obtain required breakout force.
Repeat steps a. through g. above with hydraulic power applied.
NOTE
For cyclic force gradient spring preload adjustments and cyclic control stick mass
balance adjustment, refer to module 67-13-17 paragraph "2. Rotary actuator (fore
and aft cyclic) - installation" and module 67-13-18paragraph "2. Force gradient (fore
and aft cyclic) - installation".
49. Remove hydraulic power.
50. Accomplish rigging of cyclic controls position sensors (paragraph "4. Cyclic controls - cyclic position sensor").
4. CYCLIC CONTROLS - CYCLIC POSITION SENSOR
NUMBER NOMENCLATURE
T82 INCLINOMETER
T110 POSITION SENSOR RIGGING TOOL
MATERIALS REQUIRED
NUMBER NOMENCLATURE
C-405 LOCKWIRE
1. Verify cyclic rigging (paragraph "1. Cyclic controls - description" or paragraph "2. Cyclic controls - primary method")
prior to adjustment of cyclic controls position sensor and fore-and-aft cyclic sensor.
2. Prepare helicopter for rigging as follows:
a. Place jacks under helicopter as in jacking procedure (Chapter 7) and raise jacks just high enough to prevent
helicopter from shifting when maintenance personnel are working around swashplate and controls.
b. Verify both actuator assemblies, longitudinal and lateral, are centered when electrical power is applied to
helicopter. Centering measurement will be taken from the center of bolt hole on the clevis on one end, to the
center of rod end bearing on the other end of the actuator. Centered length of the longitudinal series actuator
(14, figure 1) is 27.505 to 27.555 in (698.627 to 699.897 mm).
c. Set swashplate to a level position as follows:
(1) Apply hydraulic power to helicopter.
(2) Position swashplate rigging tool (2, figure 9) on outer cap portion of swashplate (1).
(3) Position swashplate approximately perpendicular with respect to mast by moving cyclic stick as required.
(4) Place an inclinometer (propeller-protractor) on upper surface of rigging tool (2).
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(5) Move cyclic stick slightly to obtain desired attitude of:
(a) Fore and aft cyclic - position swashplate to 0° ±15' down forward with respect to the mast.
(b) Lateral cyclic - position swashplate to 0° ±15' with respect to the mast.
3. Apply cyclic stick friction to hold position established in preceding step (2.c.(5).
4. Rig fore and aft cyclic sensor (figure 10) as follows:
a. Position clamp assembly (13) on idler (5) to 3.05 in (77.47 mm) dimension as shown. Secure clamp assembly
to idler with yoke (12). Adjust screws (1) to obtain equal gap between both sides of clamp assembly and yoke.
Secure screw with lockwire (C-405) (21).
NOTE
F/A slot of tool (18) is used when rigging both fore and aft and lateral position
sensors.
b. Position and hold tool (18) (F/A slot) on sensor target index attached to the clamp assembly (13).
c. Position switch (15) attached to sensor plate (10) in opposite slot of tool to align switch with target (14). Secure
sensor plate (10) to support assembly (9) with screw (8).
d. With tool (18) still positioned per step b., position and hold switch (15) against tool to set air gap 0.064 to
0.065 in (1.625 to 1.651 mm). Secure switch (15) to sensor plate (10). (See figure 11 for installation).
NOTE
Idler (5) may be disconnected and rotated 180° (around vertical axis) on support
assembly (6) to facilitate adjustment of switch (15).
e. Use tool (18) to recheck switch (15) alignment and air gap. Readjust as required. Secure retaining nuts with
lockwire (C-405) (21) on either side of sensor plate (10). Remove tool (18).
5. Rig lateral sensor (figure 11) as follows:
a. Position and hold tool (8) on target (9) attached to arm assembly (6) and bellcrank (7).
b. Position switch (5) attached to sensor plate (3) in opposite slot of tool to align switch (5) with target (9). Secure
plate (3) to support assembly (1) using screws (2 and 4).
c. With tool (8) still positioned per steps a. and b., position and hold switch (5) against tool to set gap 0.078 to
0.080 in (1.981 to 2.032 mm). Secure switch (5) to sensor plate (3) using retaining nuts (10 and 11).
NOTE
Support assembly (1) may be adjusted to facilitate adjustment of sensor.
d. Use tool (8) to recheck switch alignment and air gap. Adjust as required. Secure retaining nut used to adjust
switch (5) with lockwire (C-405). Remove tool (8) and remove swashplate rigging tool (2, figure 9).
6. Electrical function and sensor rigging checkout.
a. Remove electrical power and remove 8Z1P3 center connector from RPM limit warning detector. RPM detector
is located on shelf in nose compartment (Chapter 96).
b. Install a jumper wire between pin F and pin G of 8Z1P3 connector.
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E-AB412-PT6T-2
c. Apply electrical power and Batt bus 1 and 2 on, and with hydraulic pressure applied, move pilot cyclic laterally
both directions. Note CYC CTR caution lights illuminate after stick moves approximately 10% either side of
center.
d. Repeat step c. for fore and aft cyclic.
e. From a centered position (CYC CTR caution lights extinguished), move pilot cyclic forward until caution light
comes on. Hold stick in this position and check for longitudinal swashplate angle of 1° to 1°30' down forward
with respect to the mast.
f. From a centered position (CYC CTR caution lights extinguished), move pilot cyclic backward until caution light
comes on. Hold stick in this position and check for longitudinal swashplate angle of 1° to 1°30' down forward
with respect to the mast.
g. If swashplate angle does not fall within previous limits (steps e. and f.), adjust fore and aft position sensor, as
required. It is acceptable to adjust the air gap between the F/A sensor and target within the range of 0.060 to
0.090 in to achieve the required swashplate angles in steps e. and f.
h. From a centered position, move pilot cyclic to left until caution light comes on. Hold stick in this position and
check for lateral swashplate angle of 0° 30' to 1° down left with respect to the mast.
i. Repeat step h. for right stick movement.
j. If swashplate angle does not fall within the previous limits, adjust as required.
k. Remove jumper and connect 8Z1P3 to the RPM limit warning detector.
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E-AB412-PT6T-2
SEE VIEW A
POSITION OF T24-1
RIGGING TOOL
FOR FORE & AFT CYCLIC
SWASHPLATE SETTING
POSITION OF T24-1
RIGGING TOOL
FOR LATERAL CYCLIC
SWASHPLATE SETTING
POSITION SWASHPLATE
FORE AND AFT
VIEW A
(LOOKING DOWN)
NOTE:
Inclinometer rests on upper surface of T24-1.
1. Swashplate and support assy

2. Rigging tool
G6AB0158C
Figure 9. Position verification
67-11-02
Rev. 3 Page 31
E-AB412-PT6T-2
G6AB0159B
Figure 10. Fore and aft cyclic sensor adjustment (sheet 1 of 2)
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E-AB412-PT6T-2
NOTE:
1 Use lateral (LAT) slot.
1. Screw 12. Yoke

2. Bolt 13. Clamp assembly
3. Retainer 14. Target
4. Tube assembly 15. Switch
5. Idler 16. Cotter pin
6. Support assembly 17. Bolt
7. Screw 18. Tool (T110)
8. Screw 19. Cotter pin
9. Support assembly 20. Lockwire
10. Sensor plate 21. Lockwire
11. Actuator
G6AB0160B
Figure 10. Fore and aft cyclic sensor adjustment (sheet 2 of 2)
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E-AB412-PT6T-2
G6AB0161A
Figure 11. Lateral cyclic sensor adjustment (sheet 1 of 2)
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E-AB412-PT6T-2
1. Support assembly
2. Screw
3. Sensor plate
4. Screw
5. Switch
6. Arm assembly
7. Bellcrank assembly
8. Tool (T110)
9. Target
10. Retaining nut
11. Retaining nut
* Lockwire (MS20995C32) together after final adjustment.
G6AB0162B
Figure 11. Lateral cyclic sensor adjustment (sheet 2 of 2)
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67-11-02
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E-AB412-PT6T-2
67-1 -03 FLIGHT CONTROLS RIGGING - ANTI-TORQUE CONTROLS
67-11-03
FLIGHT CONTROLS RIGGING - ANTI-TORQUE CONTROLS
1. ANTI-TORQUE CONTROLS - DESCRIPTION
NUMBER NOMENCLATURE
T49 TAIL ROTOR RIGGING TOOL
T83 SPRING SCALE (RANGE TO MEASURE 5 TO 6

POUNDS (22.2 TO 26.7 N)
MATERIALS REQUIRED
NUMBER NOMENCLATURE
NOTE
For Model 412EP [D] anti-torque controls rigging, refer to module 67-11-03
FLIGHT CONTROLS RIGGING - ANTI-TORQUE CONTROLS.
NOTE
Rigging procedures contained herein pertain to helicopters with dual controls
installed in basic controls systems.
1. Comply with the following general procedures when rigging anti-torque controls:
b. Tolerance for rigging dimensions is ± 0.03 in (0.76 mm).
c. All adjustable control tubes must have a maximum of 1.0 in (2.54 mm) of exposed threads after adjustment. If
control tubes have inspection holes, threads shall be engaged sufficiently to cover holes.
adjustment.
and torque jam nuts if necessary.
2. Disconnect the following control tubes and force gradient.
a. Disconnect anti-torque force gradient (14, figure 1) and transducer (20) from pilots pedal adjuster (21).
67-11-03
Rev. 2 Page 1
E-AB412-PT6T-2
b. Disconnect control tube (16) from pilots pedal adjuster (17).
c. Disconnect control tube (7) from bellcrank (8).
d. Disconnect link (4) from lever (3).
3. Retract two stop bolts on bellcrank (10) as far as possible.
4. Verify length of centered series actuator (11), 62.865 to 62.915 in (1596.771 to 1598.041 mm).
5. Push both pilot and copilot left directional pedals against extreme forward stops. Adjust control tube (16) to fit, torque
jam nut and install.
NOTE
Adjustment of pitch change link length not required for fixed length pitch link
P/N 212-310-701-101.
6. Check two pitch links (2) for 6.180 ± 0.010 in (156.972 ± 0.254 mm) between bolt hole centers (Chapter 65).
7. Remove bolt (2, figure 2) retaining pitch link to crosshead (1).
8. Install tail rotor rigging tool (3) (T103206-101) to crosshead and against trunnion (5). Retain with bolt (2).
9. Push inboard on crosshead (1) to cause tool to make firm contact with trunnion (5).
10. Adjust link (4, figure 1) to obtain 0.58 in (14.73 mm) clearance with bellcrank (6) (detail A). Torque jam nut on link
(4), and install link (4) on bellcrank (6) and lever (3).
NOTE
If hydraulic power cart is not available, omit steps 11. through 13. and proceed to
note preceding step 14. If hydraulic power is available, accomplish steps 11. through
13. and omit steps 14. through 17.
11. Connect hydraulic cart to helicopter.
12. Apply hydraulic power from hydraulic cart to helicopter.
13. Position pilot left anti-torque pedal forward against stop and retain in position. Adjust tube (7) to fit bellcrank (8).
Torque jam nut on tube (7). Install tube (7) on bellcrank (8).
NOTE
Alternate method of rigging anti-torque controls without pressurizing the hydraulic
system: If hydraulic power cart is not available, adjust tube (7) as outlined in steps
14 through 17.
14. Hold pilot left pedal forward against stop.
15. Push down and hold anti-torque hydraulic cylinder (9) piston rod to bottom anti-torque hydraulic cylinder.
16. Position bellcrank (6) as shown in detail A and hold.
17. Adjust tube assembly (7) to fit bellcrank (8), then shorten by one half turn of clevis on tube (7). Torque jam nut on
clevis on bellcrank (8). Install control tube (7) on bellcrank (8).
18. Remove rigging tool (3, figure 2) (T49) and install pitch link (6) to crosshead (1).
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E-AB412-PT6T-2
19. Position pilot left pedal forward against stop. Adjust forward stop bolt in bellcrank, (10, figure 1, detail D) 0.005 to
0.015 in (0.127 to 0.381 mm).
20. Position pilot right pedal forward against stop. Adjust aft stop bolt in bellcrank arm (10) 0.005 to 0.015 in (0.127 to
0.381 mm).
21. Turn off hydraulic power and disconnect cart from helicopter.
22. Flap tail rotor assembly to one extreme and check for clearance between blade and tail rotor yoke using a 0.010 in
(0.254 mm) feeler gauge (figure 4). Perform clearance check on the same blade with tail rotor flapped to opposite
extreme. Accomplish clearance check on opposite blade in the same manner.
23. If clearance is greater than 0.010 in (0.254 mm), rigging has been performed correctly.
24. Rig anti-torque controls force gradient (14) and magnetic brake (15) as follows:
a. Ensure anti-torque magnetic brake arm (26) is on anti-torque magnetic brake (15) with index mark D aligned
(detail C).
b. Place pilot pedals in neutral position and hold.
c. Position arm (26) on anti-torque magnetic brake (15) at center of travel.
d. Adjust anti-torque force gradient (14) to fit pilot pedal adjuster (21). Torque jam nut on anti-torque force gradient
clevis.
e. Install anti-torque force gradient (14) on pilot pedal adjuster (21).
f. Move pilot pedals through full travel and check clearance between anti-torque force gradient (14) and structure.
If there is interference, correct as described in step g. below.
g. Remove arm (26) from anti-torque magnetic brake (15). Move one serration and reinstall. Repeat clearance
check described in step f.
25. Perform directional control motion transducer adjustment as follows:
a. Attach transducer (3, figure 3) in directional control system to support only (4).
b. Place pilot pedal against one stop, then other stop. Check if transducer (3) bottoms out in either retracted or
extended position if connected to bellcrank (1).
c. If bottoming occurs, adjust rod end bearing (2) on transducer (3) until bottoming is eliminated. Connect
transducer to bellcrank (1). Overtravel of transducer should be approximately equal.
26. Adjust anti-torque minimum friction as follows:
a. Attach spring scale (T83) to one pilot pedal.
b. With boost on, measure force required to move pedal through neutral position.
c. If required, adjust screw (25, figure 1) on clamp (24) to obtain friction of 4.5 ± 0.25 lbs (20.16 ± 1.112 N).
27. Move anti-torque controls through full travel and check for binding and/or obstruction of control movement.
28. Ensure all control bolts are installed and cotter pins and lockwire installed where applicable.
67-11-03
Rev. 2 Page 3
E-AB412-PT6T-2
1. Crosshead
2. Pitch links
3. Lever
4. Link
5. Control tube
6. Bellcrank
7. Control tube
8. Bellcrank
9. Anti-torque hydraulic cylinder
10. Bellcrank
11. Series actuator
12. Control tube
13. Walking beam
14. Anti-torque force gradient
15. Anti-torque magnetic brake
16. Control tube
17. Copilot pedal adjuster
18. Copilot left pedal
20. Transducer
21. Pilot pedal adjuster
22. Pilot left pedal
23. Pilot right pedal
24. Clamp
25. Screw
26. Anti-torque magnetic brake arm
G6AB0177B
Figure 1. Anti-torque rigging (sheet 1 of 2)
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E-AB412-PT6T-2
G6AB0178A
Figure 1. Anti-torque rigging (sheet 2 of 2)
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E-AB412-PT6T-2
1. Crosshead
2. Bolt
3. Tail rotor rigging tool (T103206-101)
4. Tail rotor (ref)
5. Tail rotor hub trunnion
6. Pitch link (ref)
G6AB0179B
Figure 2. Rigging tool (T103206-101)
67-11-03
Page 6 Rev. 2
E-AB412-PT6T-2
1. Bellcrank
2. Rod end bearing
3. Transducer
4. Support
G6AB0180B
Figure 3. Control motion transducer rigging
67-11-03
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E-AB412-PT6T-2
G6AB1036A
Figure 4. Tail rotor blade to yoke clearance
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E-AB412-PT6T-2
67-1 -04 FLIGHT CONTROLS RIGGING - AERODINAMICALLY ACTUATED ELEVATOR
67-11-04
FLIGHT CONTROLS RIGGING - AERODINAMICALLY ACTUATED
ELEVATOR
1. AERODYNAMICALLY ACTUATED ELEVATOR - DESCRIPTION
NUMBER NOMENCLATURE
T56-1 RIGGING TOOL
T82 *INCLINOMETER
T84 FEELER GAGE OR 0,050 IN. (12,7 MM) (OR EQUIVALENT) SHIM
T85 SHOT BAGS (OR EQUIVALENT) 20 TO 30 LBS. (9.1 TO 13,6 KG)
T91 *CLINOMETER OR,
T112 *PROPELLER PROTRACTOR
MATERIALS REQUIRED
NUMBER NOMENCLATURE
C-405 LOCKWIRE
NOTE
Tools listed above coded with asterisk (*) are referred to as protractor in the
following text.
Rigging may be accomplished with helicopter leveled or not leveled. Caution must
be taken not to move helicopter regardless of leveling.
1. Remove tailboom panel below elevators (2 and 4, figure 1) to gain access to control tube (5).
2. Remove lockwire from clevis jam nut (10) locking washer (9). Loosen clevis jam nut (10).
3. Remove forward clevis (7) from tube support (6).
4. Install rigging tool (14) on shaft (15) as follows:
a. Separate rigging tool (14) into two halves by removing two tool screws (11) and tool washers (12).
b. Position two halves of rigging tool (14) on shaft (15) with shouldered ends against end cap (13). Secure halves
together with two tool screws (11) and tool washers (12).
67-11-04
Page 1
E-AB412-PT6T-2
G6AB0184A
Figure 1. Elevator rigging (sheet 1 of 2)
67-11-04
Page 2
E-AB412-PT6T-2
G6AB0185A
Figure 1. Elevator rigging (sheet 2 of 2)
67-11-04
Page 3
E-AB412-PT6T-2
5. Hold shaft (15) at wrenching flat. Tighten clevis jam nut (10) against rigging tool (14) until shaft (15) is extended to
maximum length (control tube (5) internal stop is bottomed).
6. Determine correct elevator nose down position for rigging as follows:
CAUTION
ENSURE INSTRUMENT USED TO MEASURE DECK ANGLE, WHEN

MOVED FROM LEFT SEAT RAIL TO LEFT ELEVATOR, IS PLACED IN SAME
FORE-AND-AFT DIRECTION AS WHEN DECK ANGLE WAS MEASURED.
a. Position protractor (3) fore and aft on copilot seat outboard seat rail.
NOTE
Removal of copilot seat not required.
b. Read and record protractor (3) indication. This reading indicates helicopter nose up or down position.
c. Add/subtract above indication to/from 6° 4' (6,067°) and 6° 15' (6.25°). The result is the correct elevator nose
down position for rigging.
EXAMPLE 1: Step b. above indicates that helicopter is in a level position.
6 °04’(6,067 °) + 0 °0’(0,0 °) = 6 °04’(6,067 °)

6 °15’(6,25 °) + 0 °0’(0,0 °) = 6 °15’(6,25 °)
Therefore correct elevator nose down position is 6 °04’ (6,067 °) to 6 °15’ (6,25 °) for rigging.
EXAMPLE 2: Step b. above indicates that helicopter is in a 1 °50’(1,833 °) nose up position.
6 °04’(6,067 °) – 1 °50’(1,833 °) = 4 °14’(4,234 °)

6 °15’(6,25 °) – 1 °50’(1,833 °) = 4 °25’(4,417 °)
EXAMPLE 3: Step b. above indicates that helicopter is in a 1 °50’ (1,833 °) nose down position.
6 °04’(6,067 °) + 1 °50’(1,833 °) = 7 °54’(7,9 °)

6 °15’(6,25 °) + 1 °50’(1,833 °) = 8 °05’(8,083 °)
7. Position left elevator (4) in correct nose down position as determined in step 6.b. above as follows:
CAUTION
PROTRACTOR (3) SHALL BE POSITIONED ON LEFT ELEVATOR AS

SHOWN ON FIGURE 1 TO OBTAIN CORRECT RIGGING.
a. Position protractor (3) on left elevator (4).
b. Position shot bags (1) near leading edge of right elevator (2) to temporarily hold left elevator (4) in correct nose
down position.
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E-AB412-PT6T-2
NOTE
If correct position cannot be obtained, remove lockwire, loosen and adjust aft stop
bolt (17) reinstall lockwire.
c. Adjust fwd and aft stop bolts (17 and 18) to firmly hold left elevator (4) in correct nose down position.
d. Verify protractor (3) is in correct position and left elevator (4) is in correct nose down position.
8. Adjust length of control tube (5) to align mounting holes of forward clevis (7) and tube support (6) as follows:
a. Hold shaft (15) at wrenching flat. Rotate forward clevis (7) until clevis reaches tube support (6).
b. Using shaft (15) wrenching flat, rotate shaft (15) and forward clevis (7) until mounting holes in clevis (7) and
tube support (6) are aligned.
9. Install forward clevis (7) on tube support (6) (module 67-12-16 paragraph "2. Control lever and stop assembly -
installation").
10. Inspect for minimum thread engagement of shaft (15) into forward clevis (7) using inspection hole in forward clevis
(7).
11. Verify protractor (3) is in correct position and left elevator (4) is in correct nose down position (step 7. above).
12. Adjust aft stop bolt (17) as follows:
a. Loosen aft stop bolt (17).
b. Position 0,050 in. (1.270 mm) feeler gage or shim stock on aft surface of elevator horn (8) in line with aft stop
bolt (17).
c. Tighten aft stop bolt (17) until it contacts feeler gage or shim stock.
d. Secure aft stop bolt (17) with aft jam nut (16). Secure jam nut to stop support with lockwire (C-405).
13. Verify protractor (3) is in correct position and left elevator (4) is in correct nose down position (step 7. above).
14. Remove rigging tool (14) as follows:
a. Hold shaft (15) at wrenching flat. Loosen clevis jam nut (10).
b. Separate rigging tool (14) into two halves by removing two tool screws (11) and tool washers (12).
15. Align keyway in shaft (15) with nearest keyway in forward clevis (7) by rotating shaft (15) no more than 45°. Use
wrenching flat to rotate shaft.
16. Position locking washer (9) tab in forward clevis (7) keyway. Tighten clevis jam nut (10) against locking washer (9).
Secure clevis jam nut (10) to washer (9) with lockwire (C-405).
17. Adjust forward stop bolt (18) as follows:
a. Cut and remove lockwire (C-405) loosen forward stop bolt (18).
b. Position a 0,050 in. (1.270 mm) feeler gage or shim stock on forward surface of elevator horn (8) in line with
forward stop bolt (18).
c. Tighten forward stop bolt (18) until it contacts feeler gage or shim stock.
d. Secure forward stop bolt (18) with forward jam nut (19). Secure forward jam nut (19) to stop support with
lockwire (C-405).
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Page 5
E-AB412-PT6T-2
18. Remove shot bags (1) and protractor (3).
19. Apply corrosion preventive compound (C-101) to threads of shaft (15) and clevis (7).
20. Install tailboom panel below right and left elevators (2 and 4).
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Page 6
E-AB412-PT6T-2
67-12-01
COLLECTIVE CONTROLS
1. COLLECTIVE CONTROLS - DESCRIPTION
Collective controls (figure 1) consists of linkage components from pilot collective stick (13) up to, but not including,
collective lever (1).
NOTE
Automatic flight control system (AFCS) is functional in collective control system
only when a Flight Director Kit is installed in helicopter.
Cylinder (5) reduces effort required for control and reduces feedback forces from main rotor.
Actuation of collective stick (13) causes hydraulic power assisted collective pitch change of main rotor blades.
67-12-01
Page 1
E-AB412-PT6T-2
G6AB0087A
Figure 1. Collective controls
67-12-01
Page 2
E-AB412-PT6T-2
67-12-02 COLLECTIVE CONTROLS - HYDRAULIC SERVO CYLINDER BOOT
67-12-02
COLLECTIVE CONTROLS - HYDRAULIC SERVO CYLINDER BOOT
1. HYDRAULIC SERVO CYLINDER BOOT - REMOVAL
1. Open forward pylon fairing (Chapter 52).
2. Open aft pylon access doors (Chapter 52).
3. Remove cotter pin (10, figure 1), nut (11), washers (8, 9, 14 and 16) and bolt (7).
4. Remove nut (2), thin aluminum washers (3 and 5) and screw (6) and clamp (4).
5. Loosen hydraulic servo cylinder boot (1) from retaining groove in support bracket at mount bearing (12) and remove
boot.
2. HYDRAULIC SERVO CYLINDER BOOT - INSTALLATION
1. Slide hydraulic servo cylinder boot (1, figure 1) over hydraulic cylinder extension tube (13). Secure bottom of boot (1)
into lip in mount bearing (12).
2. Position top of boot (1, detail B) on hydraulic cylinder extension tube (13) 18,45 in (468,63 mm) down from centerline
of bolt hole in clevis at top of tube (13).
3. Install clamp (4), screw (6), thin aluminum washers (3 and 5) and nut (2).
4. Position tube (13) onto collective lever (15) and install bolt (7), washers (8, 9, 14, and 16), nut (11) and cotter pin (10).
6. Verify collective control rigging is within limits (module 67-11-01 paragraph "1. Collective controls - description").
7. Stow hold-open brace assembly and close aft pylon access door(s).
8. Install forward pylon fairing (Chapter 52).
3. HYDRAULIC SERVO CYLINDER BOOT - INSPECTION
Inspect hydraulic servo cylinder boot (1) for tears and deterioration paying particular attention to the boot area contacting
clamp (4) and groove in support bracket at mount bearing (12).
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E-AB412-PT6T-2
1. Hydraulic servo cylinder boot 9. Washer (AN960C516L)

2. Nut 10. Cotter pin
3. Thin aluminum washer 11. Nut
4. Clamp 12. Mount bearing
5. Thin aluminum washer 13. Hydraulic cylinder extension tube
6. Screw 14. Washer (AN960C516)
7. Bolt 15. Collective lever
8. Washer (AN960C516) 16. Washer (AN960C516)
G6AB0088B
Figure 1. Hydraulic servo cylinder boot
67-12-02
Page 2 Rev. 1
E-AB412-PT6T-2
67-12-03
COLLECTIVE CONTROLS - HYDRAULIC CYLINDER EXTENSION TUBE
1. HYDRAULIC CYLINDER EXTENSION TUBE - REMOVAL
2. Open aft pylon access door(s) (Chapter 52).
3. Remove screw (13, figure 1) and loosen clamp (11). Slide lower end of boot (14) off groove in mount bearing (12) and
slide hydraulic servo cylinder boot (14) up to expose hydraulic cylinder extension universal (17).
4. Remove cotter pin (20), nut (19), washers (16 and 18) and bolt (15).
5. Remove cotter pin (7), nut (8), washers (3, 5, 4 and 6) and bolt (2). Remove hydraulic cylinder extension tube (21)
from helicopter.
2. HYDRAULIC CYLINDER EXTENSION TUBE - INSTALLATION
1. Place hydraulic cylinder extension tube (21, figure 1) into position on collective lever (1) and install bolt (2), washer
(6), washers (4, 5 and 3) as required, nut (8), and cotter pin (7).
2. Place tube (21) onto hydraulic cylinder extension universal (17) and install bolt (15), washer (16), washer (18), nut
(19), and cotter pin (20).
3. Position hydraulic servo cylinder boot (1, figure 2) on hydraulic cylinder extension tube (13) to obtain dimension
shown. Install clamp (11, figure 1) with screw (13), washer (12), washer (10), and nut (9).
4. Move collective controls through full travel and check for interference and binding. Verify hydraulic servo cylinder
boot (14) is correctly positioned in the groove of mount bearing (12) and does not bind when controls are moved
through full travel.
5. Verify collective rigging is within limits, (module 67-11-01 paragraph "1. Collective controls - description").
6. Close aft pylon access door(s) (Chapter 52).
7. Close forward pylon fairing (Chapter 52).
3. HYDRAULIC CYLINDER EXTENSION TUBE - INSPECTION
Inspect tube (21, figure 1) for serviceability in accordance with E-AB412-PT6T-3.
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E-AB412-PT6T-2
1. Collective lever
2. Bolt
7. Cotter pin
8. Nut
9. Nut
11. Clamp
13. Screw
14. Hydraulic servo cylinder boot
15. Bolt
17. Hydraulic cylinder extension universal
19. Nut
20. Cotter pin
G6AB0089B
Figure 1. Hydraulic cylinder extension tube
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E-AB412-PT6T-2

G6AB0088B
67-12-03
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E-AB412-PT6T-2
67-12-04
COLLECTIVE CONTROLS - HYDRAULIC CYLINDER EXTENSION
UNIVERSAL
1. HYDRAULIC CYLINDER EXTENSION UNIVERSAL - REMOVAL
2. Open aft pylon fairing access door(s) (Chapter 52).
3. Remove screw (4, figure 1). Loosen bottom of hydraulic servo cylinder boot (5) from retaining groove in support
bracket (21). Slide hydraulic servo cylinder boot upward to expose hydraulic cylinder extension universal (8).
4. Remove cotter pin (15), nut (14), washers (10 and 13) and bolt (9). Remove hydraulic cylinder extension universal (8)
from piston rod clevis (11) of upper piston (12).
from lower clevis of hydraulic cylinder extension tube (1).
2. HYDRAULIC CYLINDER EXTENSION UNIVERSAL - INSTALLATION
1. Place hydraulic cylinder extension universal (8, figure 1) in position in piston rod clevis (11) and install bolt (9),
washer (10), washer (13), nut (14), and cotter pin (15).
2. Place clevis on end of hydraulic cylinder extension tube (1) on universal (8) and install bolt (7), washer (6), washer
(16), nut (17), and cotter pin (18).
3. Slide hydraulic servo cylinder boot (5) down and secure lower end into retaining groove at support bracket (21).
4. Position top of hydraulic servo cylinder boot (1, figure 2) 18,45 in (468,63 mm) on hydraulic cylinder extension tube
(13) down from centerline of bolt hole in clevis at top of tube (13).
5. Secure boot with clamp (2, figure 1), screw (4), washer (3), washer (19), and nut (20).
6. Close aft pylon fairing access door(s) (Chapter 52).
3. HYDRAULIC CYLINDER EXTENSION UNIVERSAL - INSPECTION
1. Inspect hydraulic cylinder extension universal (8, figure 1) for mechanical and corrosion damage (E-AB412-PT6T-3).
2. Inspect bearings for secure installation in hydraulic cylinder extension universal and for wear. Replace as required
(Appendix I).
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E-AB412-PT6T-2

2. Clamp
4. Screw
7. Bolt
9. Bolt
11. Piston rod clevis
12. Upper piston
14. Nut
15. Cotter pin
17. Nut
18. Cotter pin
20. Nut
21. Support bracket
G6AB0090B
Figure 1. Hydraulic cylinder extension universal
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E-AB412-PT6T-2

G6AB0088B
67-12-04
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E-AB412-PT6T-2
67-12-04
Page 4 Rev. 1
E-AB412-PT6T-2
67-12-05
COLLECTIVE CONTROLS - PISTON ROD CLEVIS
1. PISTON ROD CLEVIS - REMOVAL
2. Open aft pylon fairing access door(s) (Chapter 52).
3. Remove nut (17, figure 1), washers (1 and 16) and screw (2) loosen clamp (3) and slide boot (4) up to expose piston
rod (10) and hydraulic cylinder extension tube (15).
5. Remove lockwire, loosen nut (8) and remove piston rod clevis (7).
6. Remove nut (8) and lock (9) from piston rod clevis (7).
2. PISTON ROD CLEVIS - INSTALLATION
MATERIALS REQUIRED
NUMBER NOMENCLATURE
C-405 LOCKWIRE
1. Coat threads of piston rod clevis (7, figure 1) with corrosion preventive compound (C-101). Place lock (9) into nut (8,
detail C). Install nut (8) and lock (9) on clevis (7) with hole in lock (9) up as illustrated.
2. Thread clevis (7) into piston rod (10) and adjust to obtain 1,90 in (48,26 mm) from centerline of bolt hole to top of
piston rod (detail B).
3. Torque nut (8) 660 to 780 lbf·in (74,57 to 88,13 Nm). Secure with lockwire (C-405).
4. Cover nut (8), lock (9), lockwire and threads on clevis (7) with adhesive (C-308).
CAUTION
AVOID GETTING SEALANT ON PISTON ROD SURFACE OR SCRAPER AND

ROD SEAL DAMAGE MAY OCCUR.
5. Place hydraulic cylinder extension universal (14) into clevis (7) and install bolt (5), washer (6), washer (11), nut (12),
and cotter pin (13).
6. Slide hydraulic servo cylinder boot down over universal and position top of boot 18,45 in (468,63 mm) from centerline
67-12-05
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E-AB412-PT6T-2
of bolt hole in top of hydraulic cylinder extension tube (13, figure 2, detail B). Secure clamp (3, figure 1) with screw
(2), thin aluminum washer (1), washer (16), and nut (17).
7. Move collective controls through full travel and check for interference and binding.
8. Verify collective and/or cyclic control rigging is within limits (module 67-11-01 paragraph "1. Collective controls -
description" through module 67-11-02 paragraph "4. Cyclic controls - cyclic position sensor").
9. Close aft pylon fairing access door(s) (Chapter 52).
3. PISTON ROD CLEVIS - INSPECTION
1. Inspect piston rod clevis (7, figure 1) for nicks, scratches, and damaged threads.
2. Inspect piston rod clevis (7) for elongated bolt holes.
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E-AB412-PT6T-2

2. Screw
3. Clamp
5. Bolt
8. Nut
9. Lock
10. Upper piston rod
12. Nut
13. Cotter pin
15 Hydraulic cylinder extension tube
17. Nut
G6AB0091B
Figure 1. Piston rod clevis
67-12-05
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E-AB412-PT6T-2

G6AB0088B
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E-AB412-PT6T-2
67-12-06
COLLECTIVE CONTROLS - SERVO VALVE BALANCE SPRING
1. SERVO VALVE BALANCE SPRING - DESCRIPTION
The servo valve balance spring is mounted on collective flight control cylinder to apply an upward force to control lever.
2. SERVO VALVE BALANCE SPRING - REMOVAL
NOTE
Gain access to collective hydraulic flight control cylinder (1, figure 1) through large
access in bottom of helicopter (Chapter 52).
1. Disconnect top of spring (4) from spring clip (2).
2. Disconnect bottom of spring (4) from spring clip (3). Remove spring.
3. SERVO VALVE BALANCE SPRING - INSTALLATION
1. Connect bottom of spring (4, figure 1) to clip (3).
2. Connect top of spring (4) to clip (2).
4. SERVO VALVE BALANCE SPRING - INSPECTION
1. Inspect spring (4, figure 1) for deformation and loss of tension. Free length should be approximately 3.5 in (88.9 mm).
2. Use a spring scale to verify a force of 42.4 lbs (188.6 N) will stretch spring (4) 1.0 in (25.4 mm).
67-12-06
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E-AB412-PT6T-2
1. Collective hydraulic flight control cylinder

2. Spring clip
3. Spring clip
4. Spring
G6AB0092B
Figure 1. Servo valve balance spring
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E-AB412-PT6T-2
67-12-07
COLLECTIVE CONTROLS - COLLECTIVE FLIGHT CONTROL CYLINDER
1. COLLECTIVE FLIGHT CONTROL CYLINDER - REMOVAL
1. Remove access panel on forward side of pylon support inside cabin (Chapter 52).
2. Remove aft pylon fairing assembly (Chapter 52).
3. Refer to Chapter 29 before performing maintenance on hydraulic systems.
4. Disconnect hoses (38, 46, 52, and 57, figure 1) (detail D). Remove bolts (30 and 37) and elbows (32 and 35). Cap or
plug open ports to prevent contamination.
5. Disconnect spring (56) from spring clip (54). Remove cotter pin (43), nut (42), washers (40 and 41) and bolt (55) and
disconnect tube (53). Retain bolt (55), clip (54) and spring (56).
6. Remove cotter pin (51), nut (50), washers (49) and bolt (47).
7. Remove nuts (25 and 29) and aluminum washers (26 and 28) (detail C).
8. Remove cotter pin (15), nut (14), washers (10,11,12 and 13), and bolt (9) (detail A).
9. Carefully remove collective flight control cylinder (6) and tube (16).
10. Reposition boot (24) to allow removal of cotter pin (23), nut (22), washers (19 and 21), and bolt (18) (detail B). Retain
bolt (18), with universal (17) and tube (16).
11. Loosen jam nut (70) and remove clevis (68) from upper piston (20).
2. COLLECTIVE FLIGHT CONTROL CYLINDER - INSTALLATION
MATERIALS REQUIRED
NUMBER NOMENCLATURE
C-308 SEALANT
C-405 LOCKWIRE
NOTE:
1 Refer to Chapter 12 for information on usage and mixing of hydraulic

fluid (C-002) and hydraulic fluid (C-072).
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E-AB412-PT6T-2
1. Cut and remove lockwire and loosen nut (65 and 66, figure 1) so support bracket (27) may be rotated easily (detail F).
2. Install clevis (68) with jam nut (70) and lock (69) in upper piston (20) to dimension of 1.90 in (48.26 mm) between
end of upper piston (20) and center of holes in clevis (68).
3. Torque jam nut (70) 660 to 780 in-lbs (74.57 to 88.13 Nm) and secure with lockwire (C-405). Cover jam nut, lock (69)
and threads of clevis (68) with sealant (C-308) (detail G).
4. Place universal (17), attached to tube (16), into clevis on upper piston (20) and install bolt (18), washers (19 and 21),
nut (22), and cotter pin (23) (detail B).
5. Raise bottom of boot (24) to expose universal (17) and clevises. Brush corrosion preventive compound (C-104) on
universal (17) and clevises as required. Brush corrosion preventive compound (C-104) on mount bearing and in
housing cavity. Position lower end of boot (24) in groove of support bracket (27).
6. Guide collective flight control cylinder (6) carefully into helicopter. Place support bracket (27) over studs in support
(5) (detail C). Install aluminum washers (26) and torque nuts (25) 75 to 95 in-lbs (8.47 to 10.73 Nm). Install aluminum
washer (28) and torque nut (29) 120 to 160 in-lbs (13.56 to 18.08 Nm).
7. Pull lower piston (61) full down and push actuator (60) full up (detail E). If hole in rod end bearing (64) does not align
with hole in support (48), adjust rod end bearing.
CAUTION

8. Remove lockwire and loosen nut (63) and turn rod end bearing (64) to align with bolt hole.
9. Torque nut (63) 200 to 250 in-lbs (22.60 to 28.25 Nm) and secure to locking device (62) with lockwire (C-405).
10. Inspect locking device (62) to endure tab is in groove of rod end bearing (64) and that it was not damaged when nut
(63) was tightened. Replace locking device if tab is twisted or damaged.
11. Align cylinder (6) into support (48) as follows:
a. Move lower piston rod up and clear of support (48). Lower piston rod must be able to be moved freely down,
up, and then down and bolt (47) replaced without any pressure, forcing, binding or bending of piston rod in fore,
aft, left or right direction. One person must guide extension tube (16) to prevent damage when conducting this
step and subsequent steps.
b. If cylinder meets requirements of step a. above, it is considered in alignment. If cylinder is aligned accomplish
step h. through step i. If cylinder is misaligned, accomplish step c. through step i.
c. Loosen nut (65) and bearing nut (66) so cylinder is loose.
d. Move rod end bearing (64) up approximately 0.5 in (12.7 mm) above support (48). Rotate lower end of cylinder
e. Position rod end bearing (64) directly over lugs of support (48) and move piston down and temporarily install
bolt (47).
f. Tighten bearing nut (66) by hand (approximately 70 in-lbs (7.91 Nm)).
g. Remove bolt (47) and move rod end bearing (64) up and out of support (48), then move down. Rod end bearing
must be free of any side loading. Repeat steps c. through g. until free of side loading.
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E-AB412-PT6T-2
h. Install bolt (47). Torque bearing nut (66) 900 to 1100 in-lbs (101.69 to 124.28 Nm). Torque jam nut (65) 900 to
1100 in-lbs (101.69 to 124.28 Nm). Secure nuts (65 and 66) to keyed washer (67) with lockwire (C-405).
i. If cylinder still meets requirements of step a. above, install washer (49) and nut (50). Torque nut (50) 95 to 110
in-lbs (10.73 to 12.43 Nm) and install cotter pin (51).
NOTE
If cylinder (6) still cannot be installed without preload, it is permissible to add one
AN960C416L washer (maximum) on two aft studs of support (5) between support
bracket (27) and support (5). Or, it is permissible to add one AN960C416L washer
(maximum) and one AN960C516L washer (maximum) on each of two forward studs
between support bracket (27) and support (5).
Use washers (12 and 13) as required to obtain proper engagement of cotter pin (15)
and nut (14).
12. Position extension tube (16) on collective lever (4). Install bolt (9), washer (10, 11, 12, and 13), and nut (14). Install
cotter pin (15) (detail A).
13. After installation and torquing of cylinder assembly and before installing boot (24) fill mount bearing housing cavity
as required with corrosion preventive compound (C-104) or corrosion preventive compound (C-127). Secure boot (24)
over universal (17) and mount bearing housing as shown in figure 2.
14. Secure tube (53, figure 1) to lever (39) with bolt (55), spring clip (54), washers (40 and 41), nut (42), and cotter pin
(43). Connect spring (56) to spring clip (54) (detail D).
15. Lubricate new packings (31, 33, 34, and 36) with hydraulic fluid (C-002) or hydraulic fluid (C-072). Install packings
(31, 33, 34 and 36), elbows (32 and 35), and bolts (30 and 37).
16. Lubricate new packings (44 and 59) with hydraulic fluid (C-002) or hydraulic fluid (C-072). Install packings (44 and
59) and bypass check valves (45 and 58) if removed. Connect hoses (38, 46, 52, and 57). Observing hydraulic systems
No. 1 and No. 2 labels.
17. Bleed hydraulic system (Chapter 29).
18. Energize hydraulic system and operate collective actuator through ten complete cycles. Visually inspect system for
leaks.
19. Verify collective rigging is within limits, (module 67-11-01 paragraph "1. Collective controls - description").
20. Install pylon access panel removed (Chapter 52).
21. Install aft pylon fairing assembly (Chapter 52).
3. COLLECTIVE FLIGHT CONTROL CYLINDER - INSPECTION
1. Inspect cylinder (6, figure 1) for damage and signs of leakage.
2. Inspect exposed portion of pistons for wear and corrosion.
3. Inspect bearings for looseness (Appendix I).
67-12-07
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E-AB412-PT6T-2
1. Pump
2. Reservoir
3. Swashplate horn
4. Collective lever
5. Support
G6AB0093B
Figure 1. Collective flight control cylinder (sheet 1 of 3)
67-12-07
Page 4 Rev. 3
E-AB412-PT6T-2
9. Bolt
12. Washer (AN960C516) 28. Aluminum washer
13. Washer (AN960C516L) 29. Nut
14. Nut 30. Bolt
15. Cotter pin 31. Preformed packing
16. Extension tube 32. Elbow
17. Universal 33. Preformed packing
18. Bolt 34. Preformed packing
19. Washer (AN960C516) 35. Elbow
20. Upper piston 36. Preformed packing
21. Washer (AN960C516) 37. Bolt
22. Nut 38. Hose
23. Cotter pin 39. Lever
24. Boot 40. Washer
25. Nut 41. Washer
26. Aluminum washer 42. Nut
27. Support bracket 43. Cotter pin
45. Bypass check valve
46. Hose
47. Bolt
48. Support
49. Aluminum washer
50. Nut
51. Cotter pin
52. Hose
53. Tube
54. Spring clip
55. Bolt
56. Spring
57. Hose
58. Bypass check valve
75 TO 95 IN-LBS 95 TO 110 IN-LBS 120 TO 160 IN-LBS

(8.47 TO 10.73 Nm) (10.73 TO 12.43 Nm) (13.56 TO 18.08 Nm)
G6AB0094B
67-12-07
Rev. 3 Page 5
E-AB412-PT6T-2
60. Actuator
61. Lower piston SEALANT (C-308)
62. Locking device
63. Nut 200 TO 250 IN-LBS
64. Rod end bearing
65. Nut (22.60 TO 28.25 Nm)
66. Bearing nut
67. Keyed washer 660 TO 780 IN-LBS
68. Clevis (74.57 TO 88.13 Nm)
69. Lock
70. Jam nut
900 TO 1100 IN-LBS
(101.69 TO 124.28 Nm)
NOTE:
1 Apply sealant (C-308) around jam nut (70), lock (69), and exposed threads of clevis (68).
G6AB0095B
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Page 6 Rev. 3
E-AB412-PT6T-2

2. Nut
4. Clamp
6. Screw
7. Bolt
10. Cotter pin
11. Nut
12. Mount bearing
15. Collective lever
G6AB0088B
67-12-07
Rev. 3 Page 7
E-AB412-PT6T-2
67-12-07
Page 8 Rev. 3
E-AB412-PT6T-2
67-12-08
COLLECTIVE CONTROLS - LEFT CYCLIC AND COLLECTIVE BOOST
SUPPORT
1. LEFT CYCLIC AND COLLECTIVE BOOST SUPPORT - REMOVAL
1. Remove transmission from helicopter (Chapter 63).
2. Remove collective hydraulic flight control cylinder (1, figure 1) (module 67-12-07 paragraph "1. Collective flight
control cylinder - removal").
3. Remove left cyclic hydraulic flight control cylinder (17) (module 67-13-07 paragraph "1. Left cyclic flight control
cylinder - removal").
4. Remove four nuts (11), one wiring bracket (18), four washers (19), four washers (10), four bolts (20). Remove peel
shims (9).
5. Remove two nuts (5), two washers (3), two washers (4), and two bolts (2) releasing cyclic and collective boost support
(7) from aft pylon support (6).
6. Remove two nuts (12), two washers (13), two washers (14), and two bolts (16) releasing cyclic and collective boost
support (7) from fwd pylon support (15). Remove cyclic and collective boost support (7).
2. LEFT CYCLIC AND COLLECTIVE BOOST SUPPORT - INSTALLATION
1. Place support (7, figure 1) into position in helicopter.
2. Install bolts (2), washers (3), washers (4), and nuts (5).
4. Measure gap between support (7) and lift beam (8). Peel shims (9) to obtain a maximum gap of 0,004 in. (0,101 mm).
Install bolts (20), wiring bracket (18), washers (19), washers (10), and nuts (11).
5. Install left cyclic flight control cylinder (17) (module 67-13-07 paragraph "2. Left cyclic flight control cylinder -
installation").
6. Install collective flight control cylinder (1) (module 67-12-07 paragraph "2. Collective flight control cylinder -
installation").
7. Install transmission (Chapter 63).
3. LEFT CYCLIC AND COLLECTIVE BOOST SUPPORT - INSPECTION
1. Inspect support (7, figure 1) (E-AB412-PT6T-3).
2. Inspect bushings for secure installation in support.
67-12-08
Page 1
E-AB412-PT6T-2
G6AB0096A
Figure 1. Left cyclic and collective boost support
67-12-08
Page 2
E-AB412-PT6T-2
67-12-09
COLLECTIVE CONTROLS - ADJUSTABLE ROD END TUBE
1. ADJUSTABLE ROD END TUBE - REMOVAL
1. Remove adjustable rod end tube (11, figure 1) from collective pitch control bellcrank (9) by removing cotter pin (6),
nut (7), washer (8) and bolt (10).
2. Disconnect spring (15) from spring clip (13). Remove cotter pin (4), nut (3), washers (2 and 1) and bolt (14) and
disconnect tube (11). Retain bolt (14), clip (13) and spring (15).
2. ADJUSTABLE ROD END TUBE - INSTALLATION
1. Place spring clip (13, figure 1) and adjustable rod end tube (11) into position on lever (12) and secure with bolt (14),
washer (1 and 2), nut (3), and cotter pin (4).
2. Place adjustable rod end tube (11) into position in bellcrank (9) and secure with bolt (10), washer (8), nut (7), and cotter
pin (6).
3. Exposed thread at upper rod end bearing shall not exceed 1,0 in. (25,4 mm).
5. Verify collective control rigging within limits (module 67-11-01 paragraph "1. Collective controls - description").
3. ADJUSTABLE ROD END TUBE - INSPECTION
1. Inspect adjustable rod end tube (11, figure 1) (E-AB412-PT6T-3).
2. Inspect rod end bearings in adjustable rod end tube (11) for secure installation and wear. Refer to bearing wear limits
illustration in Appendix I.
67-12-09
Page 1
E-AB412-PT6T-2
G6AB0097A
Figure 1. Adjustable rod end tube
67-12-09
Page 2
E-AB412-PT6T-2
67-12-10
COLLECTIVE CONTROLS - PITCH CONTROL BELLCRANK
1. PITCH CONTROL BELLCRANK - REMOVAL
NOTE
Access to bellcrank is provided through large access in bottom of helicopter.
1. Remove adjustable rod end tube (7, figure 1) from collective pitch control bellcrank (14) by removing cotter pin (9),
nut (11), aluminum washer (8) and bolt (6).
2. Remove droop compensator control tube (10) and adjustable control tube (19) from bellcrank (14) by removing cotter
pin (17), nut (16), aluminum washers (18 and 20) and bolt (21).
3. Remove bellcrank (14) from support (5) by removing cotter pin (2), nut (3), aluminum washers (4 and 13) and bolt
(12). Remove bellcrank (14) and washers (22 and 15).
2. PITCH CONTROL BELLCRANK - INSTALLATION
1. Place bellcrank (14, figure 1) in position in support (5). Use washer (15 and 22) to a maximum of four to obtain proper
fit of bellcrank (14) in support (5). Install bolt (12), washer (13 and 4), nut (3) and cotter pin (2).
2. Place tube (19) and tube (10) into bellcrank (14). Install bolt (21), washers (20 and 18), nut (16), and cotter pin (17).
3. Place tube (7) into bellcrank (14). Install bolt (6), washer (8), nut (11), and cotter pin (9).
4. Move pilot collective stick (1) through full travel and check for binding and/or obstruction of control movement.
5. Verify collective rigging within limits (module 67-11-01 paragraph "1. Collective controls - description").
3. PITCH CONTROL BELLCRANK - INSPECTION
1. Inspect bellcrank (14, figure 1) for mechanical and corrosion damage (E-AB412-PT6T-3).
67-12-10
Page 1
E-AB412-PT6T-2
G6AB0098A
Figure 1. Collective control bellcrank
67-12-10
Page 2
E-AB412-PT6T-2
67-12-11
COLLECTIVE CONTROLS - COLLECTIVE FORCE GRADIENT
1. COLLECTIVE FORCE GRADIENT - DESCRIPTION
NOTE
Applicable to helicopters with 4-axis Flight Director kit installed.
2. COLLECTIVE FORCE GRADIENT - REMOVAL
1. Remove access panel from cabin floor forward of pylon.
3. Remove force gradient (8) from collective bellcrank (4) by removing cotter pin (7), nut (6), washers (5 and 3), and bolt
(2).
4. Remove force gradient (8) from control lever (12) by removing cotter pin (10), nut (9), washers (11 and 14), and bolt
(13).
3. COLLECTIVE FORCE GRADIENT - INSTALLATION
MATERIALS REQUIRED
NUMBER NOMENCLATURE
C-405 LOCKWIRE
CAUTION
ENSURE THAT FORCE GRADIENT LENGTH IS ADJUSTED PRIOR TO

INSTALLATION ON ROTARY ACTUATOR.
NOTE
The collective force gradient (8, figure 1) is similar in appearance to the force
gradients (8) used in the cyclic controls but has a different part number. Ensure that
correct part number force gradient (8) is installed for the collective controls system.
1. If not previously accomplished, adjust spring preload on force gradient (8) to 40 to 41 lbs. (177,9 to 182,4 N) as
follows:
a. Loosen jam nut (23) and remove clevis (15) from shaft (22).
b. Cut nylon braids (33) holding switch and cable assembly (30) to force gradient (8).
67-12-11
Page 1
E-AB412-PT6T-2
c. Remove nut (28), washer (27), screw (26), packing (29), and ball (25) from cap (24), and switch and cable
assembly (30).
d. Cut lockwire and loosen jam nut (31), remove cap (24) from cylinder (17).
e. Remove spring assembly (32) from cylinder (17).
f. Loosen jam nut (21) while holding shaft (22) at wrench flat. Adjust spring preload to 40 to 41 lbs. (177,9 to 182,4
N) by turning spacer (20), (using wrench flat) clockwise against spring assembly (32). Tighten jam nut (21)
against spacer (20).
g. Position spring assembly (32) in cylinder (17) and install cap (24) until all end play is eliminated. Torque jam
nut (31) to 100 in.-lbs. (11,298 Nm) and lockwire (C-405) to prevent turning in either direction. After assembly
verify spring preload of 40 to 41 lbs. (177,9 to 182,4 N).
h. Install ball (25), packing (29), and switch and cable assembly (30) on cap (24).
i. Install screws (26), washers (27), nuts (28) in cap (24) and switch and cable assembly (30). Do not tighten screws
at this time.
j. Install clevis (15) on shaft (22). Adjust length of force gradient (8) as shown in figure 1, sheet 2. Tighten jam nut
(23) to clevis (15).
k. Push and hold switch and cable assembly (30), and ball (25) against cap (24). Hold this position to initially adjust
switch and cable assembly (30).
l. Adjust switch to actuate within ± 0,050 in. (1,27 mm) linear shaft travel of spring assembly (32) and secure
screws (26).
m. Install nylon braid (33), holding switch and cable assembly (30) to force gradient (8).
2. Place force gradient (8) into position on bellcrank (3). Install bolt (2), steel washers (3 and 5), nut (6), and cotter pin (7).
3. Place force gradient (8) into position on control lever (12). Install bolt (13), steel washers (14 and 11), nut (10), and
cotter pin (9).
5. Install access panel in cabin floor forward of pylon.
4. COLLECTIVE FORCE GRADIENT - INSPECTION
1. Inspect force gradient (8, figure 1) for corrosion and mechanical damage (E-AB412-PT6T-3). Superficial mechanical
damage is acceptable without repair. Mechanical damage in excess of superficial and/or corrosion damage is not
acceptable.
2. Inspect bearing for secure installation in housing and for wear (Appendix I).
5. COLLECTIVE FORCE GRADIENT - REPAIR
1. Repair of force gradient (8) consists of replacement of unserviceable components and adjustment of spring preload in
accordance with paragraph "3. Collective force gradient - installation", step 1.
67-12-11
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E-AB412-PT6T-2
Control
G6AB0834A
Figure 1. Collective force gradient (applicable to helicopters with 4-axis AFCS/flight director kit installed) (sheet 1
of 2)
67-12-11
Page 3
E-AB412-PT6T-2
G6AB0835A
Figure 1. Collective force gradient (applicable to helicopters with 4-axis AFCS/flight director kit installed) (sheet 2
of 2)
67-12-11
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E-AB412-PT6T-2
67-12-12
COLLECTIVE CONTROLS - COLLECTIVE BELLCRANK
1. COLLECTIVE BELLCRANK - DESCRIPTION
NOTE
Applicable to helicopters with 4-axis AFCS/Flight Director kit installed.
2. COLLECTIVE BELLCRANK - REMOVAL
2. Remove collective link (3, figure 1) from collective bellcrank (15) by removing cotter pin (17), nut (18), washers (2
and 19), and bolt (1).
3. Remove force gradient (16) from bellcrank (15) by removing cotter pin (12), nuts (13), washers (11 and 14), and bolt
(10).
4. Remove bellcrank (15) from support (4) by removing cotter pin (9), nut (8), washers (6 and 7), and bolt (5).
3. COLLECTIVE BELLCRANK - INSTALLATION
1. Place bellcrank (15, figure 1) into position on support (4). Install bolt (5), aluminum washers (6 and 7), nut (8), and
cotter pin (9).
2. Position force gradient (16) on bellcrank (15) and install bolt (10), aluminum washers (11 and 14), nut (13), and cotter
pin (12).
3. Position collective link (3) on bellcrank (15) and install bolt (1), steel washers (2 and 19), nut (18), and cotter pin (17).
4. COLLECTIVE BELLCRANK - INSPECTION
1. Inspect bellcrank (15, figure 1) for mechanical and corrosion damage in accordance with E-AB412-PT6T-3 manual.
2. Inspect bearings in bellcrank (15) for secure installation in bellcrank and for wear (Appendix I).
67-12-12
Page 1
E-AB412-PT6T-2
G6AB0836A
Figure 1. Collective bellcrank (applicable to helicopters with 4-axis AFCS/flight director kit installed)
67-12-12
Page 2
E-AB412-PT6T-2
67-12-13
COLLECTIVE CONTROLS - COLLECTIVE LINK
1. COLLECTIVE LINK - DESCRIPTION
NOTE
Applicable to helicopters with 4-axis AFCS/Flight Director kit installed.
2. COLLECTIVE LINK - REMOVAL
2. Remove collective link (2, figure 1) from collective bellcrank (7) by removing cotter pin (8), nut (9), washers (10 and
11), and bolt (1).
3. Remove collective link (2) from rotary actuator arm stud (3) by removing cotter pin (4), nut (5), and washer (6).
3. COLLECTIVE LINK - INSTALLATION
1. Place link (2, figure 1) into position on bellcrank (7). Install bolt (1), steel washers (10 and 11), nut (9), and cotter pin
(8).
2. Position link (2) on rotary actuator arm stud (3). Install steel washer (6), nut (5), and cotter pin (4).
4. COLLECTIVE LINK - INSPECTION
1. Inspect link (2, figure 1) for mechanical and corrosion damage in accordance with E-AB412-PT6T-3 manual.
2. Inspect bearing in link (2) for security and for wear (Appendix I).
67-12-13
Page 1
E-AB412-PT6T-2
G6AB0837A
Figure 1. Collective link (applicable to helicopters with 4-axis AFCS/flight director kit installed)
67-12-13
Page 2
E-AB412-PT6T-2
67-12-14
COLLECTIVE CONTROLS - COLLECTIVE ROTARY ACTUATOR
1. COLLECTIVE ROTARY ACTUATOR - DESCRIPTION
NOTE
Applicable to helicopter with 4-axis AFCS/Flight Director kit installed.
2. COLLECTIVE ROTARY ACTUATOR - REMOVAL
2. Disconnect electrical connector (6, figure 1) from rotary actuator (7).
3. Remove collective link (10) from rotary actuator arm stud (4) by removing cotter pin (1), nut (2), and steel washer (3).
4. Remove rotary actuator (7) from structure (5) by removing bolts (9) and washers (8).
3. COLLECTIVE ROTARY ACTUATOR - INSTALLATION
1. Place rotary actuator (7, figure 1) into position on structure (5). Install four aluminum washers (8), and four bolts (9).
2. Position link (10) on rotary actuator arm stud (4) and install steel washer (3), nut (2), and cotter pin (1).
3. Connect electrical connector (6) to rotary actuator (7).
4. COLLECTIVE ROTARY ACTUATOR - INSPECTION
1. Inspect rotary actuator (7, figure 1) for mechanical and corrosion damage and wear (Appendix I).
2. Inspect rotary actuator arm stud (4) for damaged threads. No damage that can be detected visually is acceptable.
3. Inspect electrical receptacle for bent pins and damaged threads. Superficial damage is acceptable without repair.
5. COLLECTIVE ROTARY ACTUATOR - REPAIR
Refer to vendor manual for rotary actuator repair instructions.
67-12-14
Page 1
E-AB412-PT6T-2
G6AB0838A
Figure 1. Collective rotary actuator (applicable to helicopters with 4-axis AFCS/flight director kit installed)
67-12-14
Page 2
E-AB412-PT6T-2
67-12-15
COLLECTIVE CONTROLS - ADJUSTABLE COLLECTIVE CONTROL TUBE
1. ADJUSTABLE COLLECTIVE CONTROL TUBE - REMOVAL
1. Remove access panel in aft cabin floor just forward of pylon (Chapter 52).
2. Remove adjustable collective control tube (6) from control lever (18) by removing cotter pin (14), nut (15), washers
(16 and 3) and bolt (2).
3. Remove adjustable collective control tube (6) and control tube, droop compensator (10) from bellcrank (9) by
removing cotter pin (12), nut (13), washers (11 and 8) and bolt (7).
4. Loosen clamp (4) and slide forward off of boot (5).
5. Slide adjustable collective control tube (6) forward out of helicopter. Place control tube, droop compensator (10) on
airframe structure.
2. ADJUSTABLE COLLECTIVE CONTROL TUBE - INSTALLATION
1. Slide adjustable collective control tube (6, figure 1), with rod end bearing aft, into boot (5).
2. Position adjustable collective control tube (6) on control lever (18). Install bolt (2), washer (3), washer (16), nut (15)
3. Position adjustable collective control tube (6) and control tube, droop compensator (10) on bellcrank (9). Install bolt
(7), washer (8), washer (11), nut (13) and cotter pin (12).
4. Position forward end of boot (5) on tube (6) 7,9 in. (200,7 mm) forward of bulkhead with collective control stick (1)
full down and tighten clamp (4).
5. Move pilot collective stick (1) through full travel and check for interference and binding.
6. Verify collective rigging within limits (module 67-11-01 paragraph "1. Collective controls - description").
7. Install access panel in the aft cabin floor just forward of pylon (Chapter 52).
3. ADJUSTABLE COLLECTIVE CONTROL TUBE - INSPECTION
1. Inspect adjustable collective control tube (6, figure 1) (E-AB412-PT6T-3).
2. Inspect rod end bearing for secure installation in tube and for wear (Appendix I).
67-12-15
Page 1
E-AB412-PT6T-2
18 17
17
18
G6AB0099A
Figure 1. Adjustable collective control tube
67-12-15
Page 2
E-AB412-PT6T-2
67-12-16
COLLECTIVE CONTROLS - CONTROL LEVER AND STOP ASSEMBLY
1. CONTROL LEVER AND STOP ASSEMBLY - REMOVAL
1. Remove access panel from cabin floor forward of pylon (Chapter 52).
3. Remove bolt (8).
4. Remove bolt (19). Remove lever (17).
2. CONTROL LEVER AND STOP ASSEMBLY - INSTALLATION
1. Place lever (17, figure 1) into position in structure with long end down. Install bolt (19), washer (18), washer (16), nut
(15), and cotter pin (14).
2. Position tube (10) on lever (17) and install bolt (8), washer (9), washer (11), nut (12), and cotter pin (13).
3. Position tube (2) on lever (17) install bolt (3), washer (4), washer (5), nut (6) and cotter pin (7).
4. Move collective controls travel full trow and check for binding and/or obstruction of controls.
5. Confirm that collective control riging is within limits.
6. Install access panel in cabin floor forward of pylon (Chapter 52).
3. CONTROL LEVER AND STOP ASSEMBLY - INSPECTION
1. Inspect lever (17, figure 1) for mechanical and corrosion damage. Refer to E-AB412-PT6T-3 Overhaul Manual.
2. Inspect bearings in lever (17) for secure installation in lever and for wear. Refer to Bearing Wear Limit illustration in
Appendix I.
67-12-16
Page 1
E-AB412-PT6T-2
G6AB0832A
Figure 1. Collective control lever installation
67-12-16
Page 2
E-AB412-PT6T-2
67-12-17
COLLECTIVE CONTROLS - PILOT COLLECTIVE BOOT
1. PILOT COLLECTIVE BOOT - DESCRIPTION
The pilot collective stick boot (1, figure 1) is mounted around base of pilot collective stick to prevent foreign objects and
dirt from fouling controls. The boot is made of synthetic fabric with a metal base to secure boot to floor. Snaps provide a
tight fit to stick. A similar boot is installed on copilot stick.
2. PILOT COLLECTIVE BOOT - REMOVAL
1. Unsnap buttons (4, figure 1).
3. Remove pilot collective stick boot (1).
3. PILOT COLLECTIVE BOOT - INSTALLATION
1. Slide pilot collective stick boot (1, figure 1) over pilot collective stick (3).
2. Install screws (2) to secure boot (1) to floor.
3. Fasten buttons (4).
4. PILOT COLLECTIVE BOOT - INSPECTION
1. Inspect pilot collective stick boot (1, figure 1) for tears and deterioration.
2. Inspect for defective buttons (4).
67-12-17
Page 1
E-AB412-PT6T-2
G6AB0100A
Figure 1. Pilot collective stick boot
67-12-17
Page 2
E-AB412-PT6T-2
67-12-18
COLLECTIVE CONTROLS - COLLECTIVE JACKSHAFT
1. COLLECTIVE JACKSHAFT - DESCRIPTION
The collective jackshaft (figure 1) installation consists of the jackshafts, pilot collective stick, throttle interconnect tubes,
bellcranks, and supports. A downlock is mounted on floor below stick. An elbow and support are provided to allow a copilot
collective stick to be installed.
2. COLLECTIVE JACKSHAFT - REMOVAL
1. Remove pilot collective stick boot (module 67-12-17 paragraph "2. Pilot collective boot - removal").
2. Remove access panels from cabin floor under aft end of pedestal, from under left crew seat, and from cabin floor on
left side of left crew seat (Chapter 52).
3. Remove access panel from lower left side of helicopter just below aft corner of left crew door (Chapter 52).
4. Disconnect collective stick electrical connector.
5. Remove tube (52, figure 1) from stick assembly (1) by removing cotter pin (9), nut (8), washers (7) and bolt (6).
6. Remove bolts (18), tapered bushings (17 and 12), washers (11) and nuts (10). Index bushings for installation in original
location.
7. Remove nuts (14 and 19) and washers (13 and 20) screws (2 and 5) from stick assembly (1) and remove nut (16) and
washers (3 and 15) and bolt (4).
NOTE
Ensure bearing in support (21) is not damaged in following step.
8. Tap stick assembly (1) with soft mallet to slide stick out of tube assembly. Remove stick assembly.
9. Remove cotter pin (34), nut (33), washers (30 and 32) and bolt (29). Disengage flight control tube (31).
10. Remove bolts (23), tapered bushings (24 and 26), washers (27), and nuts (28). Index bushings for installation in
original location.
11. Slide tube (25) to the right to disengage tube from lever (22). Remove tube.
12. Disengage lever (22) and remove.
13. Remove tubes (52) by removing cotter pin (56), nut (57), washers (58 and 60) and bolts (61).
14. Remove tube (50) from bellcrank (51) by removing nut (49), washers (48 and 40) and bolt (41).
15. Remove tubes (59) by removing cotter pin (53), nut (54), washers (55 and 62) and bolts (63).
16. Remove tube (47) from bellcrank (44) by removing nut (46), washers (45 and 42) and bolt (43).
67-12-18
Rev. 2 Page 1
E-AB412-PT6T-2
17. Remove cotter pin (76), nut (77), washer (75) and bolt (78) from tube (59).
18. Remove bolts (67), tapered bushings (68 and 72), washers (73) and nuts (74). Index bushings for installation in original
location.
19. Remove nut (70), washers (66 and 69) and bolts (65).
20. Disengage elbow and support (64) from tube (71) and remove from helicopter.
21. Remove tubes (71).
22. Remove nuts (35), washers (36 and 38) and bolts (37). Remove support (21).
67-12-18
Page 2 Rev. 2
E-AB412-PT6T-2
G6AB0101B
Figure 1. Collective jackshaft (sheet 1 of 2)
67-12-18
Rev. 2 Page 3
E-AB412-PT6T-2
1. Stick assembly 28. Nut 55. Aluminum washer

2. Screw 29. Bolt 56. Cotter pin
3. Washer (NAS1197-416) 30. Aluminum washer 57. Nut
4. Bolt 31. Flight control tube 58. Aluminum washer
5. Screw 32. Aluminum washer 59. Tube
6. Bolt 33. Nut 60. Aluminum washer
7. Thin aluminum washer 34. Cotter pin 61. Bolt
8. Nut 35. Nut 62. Aluminum washer
9. Cotter pin 36. Aluminum washer 63. Bolt
10. Nut 37. Bolt 64. Elbow and support
11. Washer 38. Washer (NAS1197-416) 65. Bolt
12. Tapered bushing 39. Support 66. Aluminum washer
13. Aluminum washer 40. Washer 67. Bolt
14. Nut 41. Bolt 68. Tapered bushing
15. Aluminum washer 42. Washer 69. Aluminum washer
16. Nut 43. Bolt 70. Nut
17. Tapered bushing 44. Bellcrank 71. Tube
18. Bolt 45. Washer 72. Tapered bushing
19. Nut 46. Nut 73. Washer
20. Aluminum washer 47. Tube 74. Nut
21. Support 48. Washer 75. Thin aluminum washer
22. Lever 49. Nut 76. Cotter pin
23. Bolt 50. Tube 77. Nut
24. Tapered bushing 51. Bellcrank 78. Bolt
25. Tube 52. Tube 79. Shim
26. Tapered bushing 53. Cotter pin
27. Washer 54. Nut
G6AB0102B
Figure 1. Collective jackshaft (sheet 2 of 2)
67-12-18
Page 4 Rev. 2
E-AB412-PT6T-2
3. COLLECTIVE JACKSHAFT - INSTALLATION
MATERIALS REQUIRED
NUMBER NOMENCLATURE
C-204 PRIMER
C-430 TAPE
NUMBER NOMENCLATURE
T76 REAMER
NOTE
If stick (1, figure 1), tube (25), lever (22), tube (71), or elbow (64) is being replaced,
the new component must be drilled and reamed to pick up holes existing in original
components. If holes have been drilled and reamed, proceed to step 8.
1. Assemble jackshaft to dimensions and angles shown on figure 2. Clamp jackshaft assembly in a suitable holding
fixture.
2. Center punch and drill new holes using an F drill (0.257 in). If existing holes are not visible, use a number 20 drill
(0.161 in) initially to permit hole to be centered with existing holes.
3. Insert reamer (T76) into hole so pilot projects through part being reamed. Ream one side for installation of tapered
bushings so bushing will extend 0.007 to 0.060 in (0.178 to 1.524 mm) (View A-A).
4. Insert reamer (T76) into opposite hole. Insert a tapered bushing into reamed hole to act as a pilot for reamer. Ream to
depth for installation of tapered bushings as described in step 3.
5. Repeat steps 2. through 4. for all remaining holes.
6. Remove jackshaft assembly from holding fixture and disassemble. Remove all burrs and metal particles.
7. Apply primer (C-204) to all bare metal areas.
8. Apply tape (C-430) between faying surfaces and place support (21, figure 1) into position in helicopter and install bolts
(37), washers (38), washers (36), and nuts (35).
9. Place tube (71), lever (22), and tube (25), into position in helicopter and fit together.
10. Place tubes (52 and 59) into helicopter.
NOTE
Adjust shim to minimize lateral deflection of shafts during installation.
11. Apply tape (C-430) between faying surfaces of structure and shims (79), then place elbow and support assembly (64)
in helicopter. Engage tube (71) on elbow and support assembly. Install bolts (65), washer (66 and 69), and nuts (70).
Ensure a 212-001-168-1 shim (79) is installed between structure and elbow and support assembly (64).
67-12-18
Rev. 2 Page 5
E-AB412-PT6T-2
12. Apply tape (C-430) between faying surfaces of structure and stick assembly (1), then place stick assembly in
helicopter. Engage tube (25) onto stick assembly (1). Install screw (2), washer (20), nut (19), screw (5), washer (13),
nut (14), bolts (4), washers (3), washers (15), and nuts (16).
13. Align holes in tube (71) with holes in elbow and support (64). Install bolts (67), bushings (68), bushings (72), washers
(73), and nuts (74). Torque nuts 50 to 70 in-lbs (5.65 to 7.91 Nm).
14. Align holes in tubes (71 and 25) with holes in lever (22) and support (21) and install bolts (23), bushing (24 and 26),
washers (27) and nuts (28). Torque nuts 50 to 70 in-lbs (5.65 to 7.91 Nm).
15. Align holes in tube (25) with holes in stick assembly (1) and install bolts (18), bushings (17), bushings (12), washers
(11), and nuts (10). Torque nuts 50 to 70 in-lbs (5.65 to 7.91 Nm).
NOTE
After torquing, the tapered bushings must protrude within the 0.030 to 0.060 in
(0.761 to 1.525 mm) limits shown in figure 2.
16. Place tubes (52, figure 1) into position and install bolts (6), washers (7), nuts (8), and cotter pins (9).
17. Place tubes (59) into position and install bolts (78), washers (75), nuts (77), and cotter pins (76). Secure inboard end
of tubes (59), with bolts (63), washers (62), washer (55), nuts (54), and cotter pin (53).
18. Secure tubes (52) to tubes (59) with bolts (61), washers (60), washers (58), nuts (57), and cotter pins (56).
19. Place tube (47) into bellcrank (44). Install bolt (43), washer (42), washer (45) and nut (46).
20. Place tube (50) into bellcrank (51). Install bolt (41), washer (40), washer (48), and nut (49).
21. Place tube (31) on lever (22). Install bolt (29), washer (30), washer (32), nut (33), and cotter pin (34).
22. Connect electrical wires from stick assembly (1).
23. Rig collective flight controls (module 67-11-01 paragraph "1. Collective controls - description").
24. Rig power controls (throttle) (Chapter 76).
25. Install pilot collective stick boot (module 67-12-17 paragraph "3. Pilot collective boot - installation").
26. Install the following access panels (Chapter 52):
a. Cabin floor aft of pedestal.
b. Cabin floor under left crew seat.
c. Cabin floor left side of left crew seat.
67-12-18
Page 6 Rev. 2
E-AB412-PT6T-2
1. Bolt 8. Collective jackshaft

2. Beam 9. Power control tube
3. Support 10. Power control tube
4. Collective jackshaft 11. Pilot collective control assembly
5. Shim 12. Pilot stick
6. Elbow and support copilot collective 13. Tapered bushing
7. Lever
G6AB0103B
Figure 2. Collective jackshaft assembly
67-12-18
Rev. 2 Page 7
E-AB412-PT6T-2
4. COLLECTIVE JACKSHAFT - INSPECTION
1. Inspect stick assembly (1, figure 1) as follows:
a. Inspect stick assembly for mechanical and corrosion damage. Superficial mechanical and corrosion damage is
acceptable if polished out and repaired area refinished to original condition.
b. Inspect wiring for secure installation and damaged insulation.
c. Inspect switches for secure installation.
d. Inspect throttle controls for smooth operation. If necessary, adjust throttle control gears (module 67-11-01
paragraph "1. Collective controls - description").
2. Inspect support (21) as follows:
a. Inspect support for mechanical and corrosion damage (E-AB412-PT6T-3).
b. Inspect bearing for security and wear (Appendix I).
3. Inspect tubes (25, 52, 59 and 71) for mechanical and corrosion damage (E-AB412-PT6T-3).
4. Inspect elbow and support (64) as follows:
a. Inspect elbow and support for mechanical and corrosion damage (E-AB412-PT6T-3).
b. Inspect power control bellcranks in base of elbow and support (64) for freedom of movement.
c. Inspect bearings for security and wear (Appendix I).
67-12-18
Page 8 Rev. 2
E-AB412-PT6T-2
67-12-19
COLLECTIVE CONTROLS - FRICTION CLAMP
1. FRICTION CLAMP - REMOVAL
1. Remove copilot seat and access panel below seat (Chapter 52).
2. Remove bolt (4, figure 1), washers (3 and 10), and nut (11) attaching clamp halves (5 and 8) to elbow support assembly
(12).
3. Remove bolt (1), washers (2), and nut (9).
4. Remove bolt (6) and washer (7) and remove two halves of clamp assembly from elbow support assembly.
2. FRICTION CLAMP - INSTALLATION
1. Place clamp halves around elbow support assembly (12, figure 1).
2. Install washer (7) and bolt (6).
3. Install bolt (1), washers (2) and nut (9). Tighten nut (9) only enough to hold clamp halves in contact with elbow.
3. FRICTION CLAMP - INSPECTION
1. Inspect clamp assembly for cracks or deformation. No cracks are allowed. Any deformation which prevents proper
operation is cause for rejection.
2. Inspect friction lining for excessive wear. Wear which prevents proper operation necessitates replacement of friction
liner.
4. FRICTION CLAMP - REPAIR
MATERIALS REQUIRED
NUMBER NOMENCLATURE
C-363 ADHESIVE
C-407 ABRASIVE PAD
C-465 LINER
67-12-19
Page 1
E-AB412-PT6T-2
1. Remove all old liner material and adhesive from clamp halves (5 and 8, figure 1) using 180 grit abrasive cloth or paper
(C-423).
2. Rinse clamp halves in clean water and dry using clean cloths or a heat gun.
3. Cut liner (C-465) material to approximately 1,0 x 3,0 in. (25,4 x 76,2 mm) size to match inside areas of clamp halves.
4. Lightly abrade dacron surface (pink side) of liner material with 180 grit abrasive cloth or paper (C-423).
NOTE
The dark (teflon) side of liner material is friction side.
5. Mix adhesive (C-363) according to manufacturers instructions.
NOTE
Pot life of adhesive not to exceed 30 minutes at 75°F (24°C).
6. Apply adhesive to inner surface of both clamp halves and to dacron (pink) surface of liner material. Install liner in
clamp halves.
7. Install clamp halves around cylindrical work aid 2,03 to 2,09 in. (51,56 to 53,09 mm) diameter and install bolt (6) and
washer (7).
8. Install bolt (1), washers (2) and nut (9) through tongues of clamp halves (5 and 8) and tighten nut (9) to one in.-lbs.
(0,113 Nm) greater than nut tare torque.
9. Remove adhesive squeeze-out. Allow adhesive to cure 24 hours at 75°F (24°C) or heat assembly to 175°F to 190°F
(80°C to 88°C) for one hour.
10. After complete curing, remove clamp assembly from work aid and scuff friction surface of liner with 180 grit abrasive
cloth or paper (C-423) followed by an abrasive pad (C-407) until a uniform finish is attained.
11. Wash clamp assembly with mild soap and water followed by rinse of MEK (309) to remove all grit and foreign
material.
67-12-19
Page 2
E-AB412-PT6T-2
G6AB0104A
Figure 1. Collective friction clamp assembly
67-12-19
Page 3
E-AB412-PT6T-2
67-12-19
Page 4
E-AB412-PT6T-2
67-13-01
CYCLIC CONTROLS
1. CYCLIC CONTROLS - DESCRIPTION
The cyclic controls (figure 1) consists of controls and components from pilot cyclic stick (22) up to and including extension
tubes (1 and 34).
The AFCS cyclic control system incorporates two series actuators, one connected in roll system and one connected in pitch
system. A control tube and idler arm are attached to series actuator in pitch system.
Four transducers, two in roll system and two in pitch system, are used to convert mechanical movement to electrical signals
for injecting pilot control commands to AFCS.
Two transducers are attached to right end of cyclic jackshaft providing a fore and aft cyclic signal. Two transducers are
attached to a forward cyclic bellcrank providing a lateral cyclic signal.
A force gradient assembly connected to an electromechanical rotary actuator is also installed in each cyclic system. Cyclic
roll system force gradient attaches to a bellcrank forward of jackshaft. The cyclic pitch system force gradient attaches
directly to left end of cyclic jackshaft.
A support assembly and idler are used to connect pitch series actuator and a pitch control tube, which is attached to mixing
lever assembly.
Two proximity switches and two cyclic centering (CYC CTR) caution lights are installed by kit 412-704-115-101 for aid in
centering swashplate. The lights are located in pilot and copilot instrument panel. The two proximity switches are located
underneath floor near mixing lever assembly.
Cyclic control AFCS system components forward of mixing lever assembly (28) are identified as "lateral cyclic" or "fore
and aft cyclic" as applicable, i.e., "lateral cyclic force gradient".
Cyclic control system components aft of mixing lever assembly (28) are identified as "left cyclic" or "right cyclic" as
applicable, i.e., "left cyclic flight control cylinder".
The fore and aft control linkage and lateral control linkage are separate from cyclic stick to mixing lever (28). From mixing
levers to swashplate effects of control linkages are combined and cannot be considered separately as to effect.
Actuation of pilot cyclic stick (22) causes hydraulic power assisted cyclic pitch change of main rotor blades.
The forward series actuators in each cyclic system are connected to Helipilot (HP-1) system. Aft series actuators in each
cyclic system are connected to Helipilot (HP-2) system.
Refer to Chapter 96, for AFCS system wiring diagrams.
67-13-01
Page 1
E-AB412-PT6T-2
G6AB0109A
Figure 1. Cyclic controls
67-13-01
Page 2
E-AB412-PT6T-2
67-13-02
CYCLIC CONTROLS - HYDRAULIC CYLINDER EXTENSION TUBE
1. HYDRAULIC CYLINDER EXTENSION TUBE - REMOVAL
NOTE
The removal procedure for hydraulic cylinder extension tube (20, figure 1) in left
cyclic system is given. The removal procedure for corresponding hydraulic cylinder
extension tube (23) in right cyclic system is the same.
1. Remove forward pylon fairing (Chapter 52).
2. Disconnect hydraulic cylinder extension tube (20) from swashplate (1) by removing cotter pin (6), nut (5), washers (4,
3, 2 and 21) and bolt (22).
3. Remove nut (7), thin aluminum washers (8 and 10) and screw (11). Loosen bottom of boot (12) from lip on mount (16)
and remove boot and clamp (9) from helicopter.
4. Remove cotter pin (19), nut (18), washers (13 and 17) and bolt (14). Separate hydraulic cylinder extension tube (20)
from hydraulic cylinder extension universal (15).
2. HYDRAULIC CYLINDER EXTENSION TUBE - INSTALLATION
NOTE
The installation procedure for hydraulic cylinder extension tube (20, figure 1) in left
cyclic system is given. The installation procedure for hydraulic cylinder extension
tube (23) in right cyclic system is the same.
1. Place hydraulic cylinder extension tube (20) in position with lower end on hydraulic cylinder extension universal (15).
Install bolt (14), washer (13), washer (17), nut (18), and cotter pin (19).
2. Place boot (12) and clamp (9) over top of tube (20) and slide down to secure bottom of boot into lip on mount (16).
3. Place top of tube (20) on swashplate (1) and install bolt (22), washers (21, 2, 3, and 4), nut (5), and cotter pin (6).
4. Position top of boot (12) 22,2 in. (563,9 mm) below center line of bolt (22, detail B). Install clamp (9), screw (11),
washers (10 and 8), and nut (7).
6. Verify cyclic rigging within limits (module 67-11-02 paragraph "2. Cyclic controls - primary method" and paragraph
"3. Cyclic controls - alternate method").
3. HYDRAULIC CYLINDER EXTENSION TUBE - INSPECTION
NOTE
The inspection procedure for hydraulic cylinder extension tube (20 and 23, figure 1)
in left cyclic system is contained in E-AB412-PT6T-3.
67-13-02
Page 1
E-AB412-PT6T-2
G6AB0110A
67-13-02
Page 2
E-AB412-PT6T-2
67-13-03
CYCLIC CONTROLS - HYDRAULIC SERVO CYLINDER BOOT
1. HYDRAULIC SERVO CYLINDER BOOT - DESCRIPTION
NOTE
The maintenance procedures for boot (12, figure 1) on left cyclic flight control
cylinder is given. The procedures for boot on right cyclic flight control cylinder are
the same.
2. HYDRAULIC SERVO CYLINDER BOOT - REMOVAL
2. Disconnect hydraulic cylinder extension tube (20) from swashplate horn (1) by removing cotter pin (6), nut (5),
washers (4, 3, 2 and 21) and bolt (22).
3. Remove nut (7), thin aluminum washers (8 and 10) and screw (11).
4. Loosen bottom of boot (12) from mount bearing (16) and slip boot off tube (20).
3. HYDRAULIC SERVO CYLINDER BOOT - INSTALLATION
1. Slide boot (12, figure 1) over tube (20) and secure lower end of boot into lip on mount (16).
2. Position tube (20) on swashplate (1). Install bolt (22), washer (21), washers (2, 3, and 4), nut (5), and cotter pin (6).
3. Position top of boot (12) 22,2 in. (563,9 mm) below center line of bolt (22) (detail B). Install clamp (9), screw (11),
washer (10), washer (8), and nut (7).
4. HYDRAULIC SERVO CYLINDER BOOT - INSPECTION
Inspect boot (12, figure 1) for tears and signs of deterioration. Torn or deteriorated boots are not acceptable and shall be
replaced.
67-13-03
Page 1
E-AB412-PT6T-2
G6AB0110A
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E-AB412-PT6T-2
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CYCLIC CONTROLS - HYDRAULIC CYLINDER EXTENSION UNIVERSAL
1. HYDRAULIC CYLINDER EXTENSION UNIVERSAL - DESCRIPTION
NOTE
The maintenance procedures for hydraulic cylinder extension universal (8, figure 1)
on right hydraulic cylinder extension tube (5) is given. Procedures for universal on
left cylinder are the same.
2. HYDRAULIC CYLINDER EXTENSION UNIVERSAL - REMOVAL
2. Remove nut (19, figure 1), thin aluminum washers (2 and 18) and screw (3). Slide boot (4) and clamp (1) upward to
expose bolts (7 and 9).
from piston rod clevis (11).
3. HYDRAULIC CYLINDER EXTENSION UNIVERSAL - INSTALLATION
1. Place universal (8, figure 1) in clevis of extension tube (5).
2. Install bolt (7), washers (6 and 15), nut (16), and cotter pin (17).
3. Place bottom of universal into piston rod clevis (11) and install bolt (9), washers (10 and 12), nut (13), and cotter pin
(14).
4. Slide boot (4) and clamp (1) down 22,2 in. (563,9 mm) from center line of top bolt (20). Install screw (3), washers (2
and 18), and nut (19).
4. HYDRAULIC CYLINDER EXTENSION UNIVERSAL - INSPECTION
Inspect hydraulic cylinder extension universal (8, figure 1) for mechanical and corrosion damage (E-AB412-PT6T-3).
5. HYDRAULIC CYLINDER EXTENSION UNIVERSAL - BEARING REPLACEMENT
Refer to E-AB412-PT6T-3 for bearing replacement procedure.
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E-AB412-PT6T-2
G6AB0111A
Figure 1. Hydraulic cylinder extension universal
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E-AB412-PT6T-2
67-13-05
CYCLIC CONTROLS - LEFT CYCLIC PISTON ROD CLEVIS
1. LEFT CYCLIC PISTON ROD CLEVIS - REMOVAL
2. Remove nut (18, figure 1), thin aluminum washers (2 and 17) and screw (3).
3. Loosen bottom of boot (5) from lip on mount (13) and slide boot upward to expose universal assembly (6).
5. Loosen nut (10). Remove piston rod clevis (9) from piston rod (12). Remove nut (10) and lock (11) from clevis (9).
2. LEFT CYCLIC PISTON ROD CLEVIS - INSTALLATION
MATERIALS REQUIRED
NUMBER NOMENCLATURE
C-405 LOCKWIRE
1. Coat threads of clevis (9, figure 1) with corrosion preventive compound (C-101).
2. Place lock (11) into nut (10). Install nut (10) and lock (11) on clevis (9).
3. Install clevis (9) into piston rod (12). Adjust clevis (9) to obtain 1,75 in. (44,45 mm) from clevis bolt hole center line
to top of piston rod (detail B).
4. Torque nut (10) 660 to 780 in.-lbs. (74,57 to 88,13 Nm). Secure nut with lockwire (C-405).
CAUTION
AVOID GETTING ADHESIVE (SEALANT) ON PISTON ROD SURFACE OR

SCRAPER AND ROD SEAL DAMAGE MAY OCCUR.
5. Coat nut (10), lock (11), lockwire and threads on clevis (9) with adhesive (C-308).
6. Place universal (6) in clevis (9). Install bolt (7), washer (8), washer (14), nut (15), and cotter pin (16).
7. Slide boot (5) down over piston rod (12) and engage bottom of boot into lip on mount (13).
8. Position top of boot (5) 22,2 in. (563,9 mm) from center line of bolt (19) (detail A).
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E-AB412-PT6T-2
9. Secure boot to hydraulic cylinder extension tube (1) with clamp (4) using screw (3), washer (2), washer (17) and nut
(18).
10. Verify cyclic rigging is within limits (module 67-11-02 paragraph "2. Cyclic controls - primary method" and paragraph
11. Move cyclic controls through full travel and check for interference and binding.
3. LEFT CYCLIC PISTON ROD CLEVIS - INSPECTION
1. Inspect clevis (9, figure 1) for mechanical and corrosion damage. Superficial mechanical and corrosion damage is
acceptable if repaired (paragraph "4. Left cyclic piston rod clevis - repair").
2. Inspect bolt holes for elongation.
3. Inspect threads for damage. No visible thread damage is acceptable.
4. LEFT CYCLIC PISTON ROD CLEVIS - REPAIR
Repair piston rod clevis (9, figure 1) (E-AB412-PT6T-3).
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E-AB412-PT6T-2
G6AB0112A
Figure 1. Left cyclic piston rod clevis
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E-AB412-PT6T-2
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E-AB412-PT6T-2
67-13-06
CYCLIC CONTROLS - RIGHT CYCLIC PISTON ROD CLEVIS
1. RIGHT CYCLIC PISTON ROD CLEVIS - REMOVAL
2. Loosen bottom of boot (5, figure 1) from lip in mount (13).
3. Remove nut (18), thin aluminum washers (2 and 17) and screw (3). Slide clamp (4) and boot (5) upward on hydraulic
cylinder extension tube (1) to expose universal (6).
5. Loosen nut (10). Remove piston rod clevis (9) from piston rod (12). Remove nut (10) and lock (11) from clevis (9).
2. RIGHT CYCLIC PISTON ROD CLEVIS - INSTALLATION
MATERIALS REQUIRED
NUMBER NOMENCLATURE
C-405 LOCKWIRE
1. Coat threads of clevis (9, figure 1) with corrosion preventive compound (C-101). Place lock (11) into nut (10). Install
nut (10) and lock (11) on clevis (9).
2. Adjust clevis (9) to obtain 1,90 in. (48,26 mm) between bolt hole center line and top of piston rod (12) (detail B).
3. Torque nut (10) 660 to 780 in.-lbs. (74,57 to 88,13 Nm) and secure with lockwire (C-405).
4. Coat nut (10), lock (11), lockwire, and threads on clevis (9) with adhesive (C-308).
CAUTION
DO NOT ALLOW SEALANT TO CONTACT PISTON ROD SURFACE OR

SCRAPER AND ROD SEAL OR DAMAGE MAY OCCUR.
5. Place universal (6) to piston rod clevis (9). Install bolt (7), washer (8), washer (14), nut (15), and cotter pin (16).
6. Slide boot (5) downward and secure bottom of boot into lip in mount (13).
7. Position top of boot (5) 22,2 in. (563,9 mm) below center line bolt (19) (detail A).
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E-AB412-PT6T-2
8. Secure boot (5) to hydraulic cylinder extension tube (1) with clamp (4), screw (3), washer (2), washer (17), and nut
(18).
9. Verify cyclic control rigging within limits (module 67-11-02 paragraph "2. Cyclic controls - primary method" and
paragraph "3. Cyclic controls - alternate method").
3. RIGHT CYCLIC PISTON ROD CLEVIS - INSPECTION
1. Inspect piston rod clevis (9, figure 1) for mechanical and corrosion damage (E-AB412-PT6T-3).
3. Inspect threads for damage. No visible damage to threads is acceptable.
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E-AB412-PT6T-2
G6AB0113A
Figure 1. Right cyclic piston rod clevis
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E-AB412-PT6T-2
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E-AB412-PT6T-2
67-13-07
CYCLIC CONTROLS - LEFT CYCLIC FLIGHT CONTROL CYLINDER
1. LEFT CYCLIC FLIGHT CONTROL CYLINDER - REMOVAL
1. Remove access panels that are around the pylon support structure in aft cabin. Remove forward pylon fairing (Chapter
52).
2. Position bottom of boot (18, figure 1) to gain access. Remove cotter pin (25), nut (24), washers (23), and bolt (20)
(detail B).
3. Remove cotter pin (13), nut (12), washers (9, 10, 11, and 16), and bolt (17), (detail A). Remove extension tube (14)
with attached universal (19).
4. Disconnect hoses (37, 40, 43, and 54) (detail D). Remove bolts (34 and 55) and elbows (32 and 57) and discard
packings (31, 33, 56, and 58). Plug or cap open ports to prevent contamination.
5. Remove cotter pin (53), nut (52), two washers (51), bolt (38), and washer (39).
6. Remove nuts (26 and 30) and washers (27 and 29) (detail C).
7. Remove cotter pin (48), nut (47), washer (46), and bolt (44).
NOTE
If transmission is installed, cylinder assembly must be removed by rotating support
bracket (28), so it will pass downward through support. If transmission has been
removed, cylinder assembly can be removed upward.
8. Carefully remove left cyclic flight control cylinder (7) from helicopter.
2. LEFT CYCLIC FLIGHT CONTROL CYLINDER - INSTALLATION
MATERIALS REQUIRED
NUMBER NOMENCLATURE
C-308 SEALANT
C-405 LOCKWIRE
NOTE:

67-13-07
Rev. 3 Page 1
E-AB412-PT6T-2
NOTE
When transmission is installed, insert lower end of cylinder assembly through
passenger/cargo compartment (refer to Chapter 52) until top surface clears access
hole in forward island then raise cylinder assembly through cylinder support until
support bracket (28, figure 1) is past attachment studs.
1. Cut and remove lockwire, and loosen nuts (65 and 66, figure 1) so support bracket (28) may be rotated easily (detail F).
end of upper piston (21) and center of holes in clevis (22).
3. Torque jam nut (68) 660 to 780 in-lbs (74.57 to 88.13 Nm) and secure with lockwire (C-405). Cover jam nut (68), lock
(67) and threads of clevis (22) with sealant (C-308) (detail G).
4. Place universal (19), attached to tube (14), into clevis on upper piston (21) and install bolt (20), washers (23), nut (24),
and cotter pin (25) (detail B).
universal and clevises as required. Brush corrosion preventive compound (C-104) on mount bearing and in housing
cavity. Position lower end of boot in groove of support bracket (28).
6. Guide left cyclic flight control cylinder (7) carefully into helicopter. Place support bracket (28) over studs in support
(5) (detail C). Install aluminum washers (27) and torque nuts (26) 75 to 95 in-lbs (8.47 to 10.73 Nm). Install aluminum
CAUTION

a. Remove lockwire and loosen nut (62), and turn rod end bearing (63) to align with bolt hole.
b. Torque nut (62) to 200 to 250 in-lbs (22.60 to 28.25 Nm) and secure to locking device (61) with lockwire
(C-405).
c. Inspect locking device (61) to ensure tab is in groove of rod end bearing (63) and that it was not damaged when
nut (62) was tightened. Replace locking device if tab is twisted or damaged.
8. Align left cyclic flight control cylinder (7) into support (45) as follows:
up, and then down, and bolt replaced without any pressure, forcing, binding, or bending of piston rod in fore, aft,
left, or right direction. One person must guide extension tube (14) to prevent damage when conducting this step
and subsequent steps.
b. If cylinder meets requirements of step a., it is considered in alignment. If cylinder is aligned, accomplish step h.
through step i. If cylinder is misaligned, accomplish step c. through step i.
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E-AB412-PT6T-2
bolt (44).
(63) must be free of any side loading. Repeat steps c. through g. until free of side loading.
NOTE
bracket (28) and support. Or, it is permissible to add one AN960C416L washer
between support bracket and support.
h. Install bolt (44). Torque bearing nut (65) 900 to 1100 in-lbs (101.68 to 124.28 Nm). Torque nut (64) 900 to 1100
in-lbs (101.68 to 124.28 Nm). Secure nuts (65 and 64) to keyed washer (66) with lockwire (C-405).
i. If cylinder still meets requirements of step a., install washer (46) and nut (47) and torque 95 to 110 in-lbs (10.73
to 12.42 Nm). Install cotter pin (48).
NOTE
and nut (12).
9. Position extension tube (14) on swashplate horn (3). Install bolt (17), washers (16, 9, 10, and 11), and nut (12). Install
10. Position tube assembly (49, detail D) into lever (50) and secure with bolt (38), washer (39), washers (51), nut (52), and
cotter pin (53).
11. Lubricate new packings (31, 33, 56, and 58) with hydraulic fluid (C-002) or hydraulic fluid (C-072). Install packing
(31 and 58), elbows (32 and 57), and packings (33 and 56) with bolts (34 and 55).
12. If bypass check valves have been removed, lubricate new packings (35 and 41) with hydraulic fluid (C-002) or
hydraulic fluid (C-072). Install packings (35 and 41) and bypass check valves (36 and 42).
13. Connect hoses (37, 40, 43 and 54) observing labels on hydraulic systems 1 and 2.
14. Bleed and leak check hydraulic system (Chapter 29).
15. Energize hydraulic system and operate cyclic controls through ten complete operations. Leak check.
16. Verify cyclic control rigging is within limits (module 67-11-02 paragraph "2. Cyclic controls - primary method" and
17. Install access panel on pylon support. Install forward pylon fairing (Chapter 52).
3. LEFT CYCLIC FLIGHT CONTROL CYLINDER - INSPECTION
2. Inspect exposed areas of piston for scratches and wear.
3. Inspect bearings for looseness. Refer to bearing wear limit illustrated in Appendix I for acceptable limits.
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E-AB412-PT6T-2
1. Pump
2. Reservoir
3. Swashplate horn
4. Collective lever
5. Support
7. Left cyclic flight control cylinder
8. Right cyclic flight control cylinder
G6AB0114B
Figure 1. Left cyclic flight cylinder (sheet 1 of 3)
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Page 4 Rev. 3
E-AB412-PT6T-2
12. Nut
13. Cotter pin
14. Extension tube
15. Clevis
17. Bolt
18. Boot
19. Universal
20. Bolt
21. Upper piston
24. Nut
25. Cotter pin
75 TO 95 IN-LBS 95 TO 110 IN-LBS 120 TO 160 IN-LBS 660 TO 780 IN-LBS

(8.47 TO 10.73 Nm) (10.73 TO 12.43 Nm) (13.56 TO 18.08 Nm) (74.57 TO 88.13 Nm)
G6AB0115B
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Rev. 3 Page 5
E-AB412-PT6T-2
26. Nut 37. Hose 48. Cotter pin 59. Actuator

27. Aluminum washer 38. Bolt 49. Tube assembly 60. Lower piston
28. Support bracket 39. Washer 50. Lever 61. Locking device
29. Aluminum washer 40. Hose 51. Washer 62. Nut
30. Nut 41. Preformed packing 52. Nut 63. Rod end bearing
31. Preformed packing 42. Bypass check valve 53. Cotter pin 64. Nut
32. Elbow 43. Hose 54. Hose 65. Bearing nut
33. Performed packing 44. Bolt 55. Bolt 66. Keyed washer
34. Bolt 45. Support 56. Preformed packing 67. Lock
35. Preformed packing 46. Aluminum washer 57. Elbow 68. Jam nut
36. Bypass check valve 47. Nut 58. Preformed packing
SEALANT (C-308) 200 TO 250 IN-LBS 900 TO 1100 IN-LBS

(22.60 TO 28.25 Nm) (101.69 TO 124.28 Nm)
NOTE:
G6AB0116B
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E-AB412-PT6T-2
67-13-08
CYCLIC CONTROLS - RIGHT CYCLIC FLIGHT CONTROL CYLINDER
1. RIGHT CYCLIC FLIGHT CONTROL CYLINDER - REMOVAL
1. Remove access panels that are around the pylon support structure in aft cabin. Remove forward pylon fairing
(Chapter 52).
2. Disconnect hoses (35, 40, 46 and 52, figure 1) (detail D). Remove bolts (34 and 56) and elbows (32 and 58). Plug or
cap open ports.
3. Remove cotter pin (55), nut (49), washers (37, 50, and 51), and bolt (38). Remove tube assembly (39) from lever (36).
4. Remove cotter pin (45), nut (44), washer (43) and bolt (41) (detail D).
5. Remove nuts (25 and 30) and washers (26 and 29) (detail C).
6. Remove cotter pin (9, detail A), nut (10), washers (11, 12, 13, and 14) and bolt (15).
7. Carefully remove right cyclic control cylinder (7) and extension tube (3) from helicopter.
8. Reposition boot (16) to provide access to universal (18) (detail B). Remove cotter pin (23), nut (24), washers (20) and
bolt (19).
9. Remove extension tube (3) with attached universal (18) from right cyclic control cylinder (7).
2. RIGHT CYCLIC FLIGHT CONTROL CYLINDER - INSTALLATION
MATERIALS REQUIRED
NUMBER NOMENCLATURE
C-308 SEALANT
C-405 LOCKWIRE
NOTE:

67-13-08
Rev. 3 Page 1
E-AB412-PT6T-2
NOTE
When transmission is installed, insert lower end of cylinder assembly through
passenger/cargo compartment until top surface clears access hole in forward island.
Then, raise cylinder assembly through cylinder support until support bracket
(27, figure 1) is past attachment studs.
1. Cut and remove lockwire, and loosen nuts (65 and 66, figure 1) so support bracket (27) may be rotated easily (detail F).
end of piston (21) and center of holes in clevis (22).
3. Torque jam nut (69) 660 to 780 in-lbs (74.57 to 88.13 Nm) and secure with lockwire (C-405). Cover jam nut (69), lock
(68) and threads of clevis (22) with sealant (C-308) (detail G).
4. Place universal (18), attached to tube (3), into clevis on upper piston (21) and install bolt (19), washers (20), nut (24),
and cotter pin (23) (detail B).
universal and clevises as required. Brush corrosion preventive compound (C-104) on mount bearing and in housing
cavity. Position lower end of boot in groove of support bracket (27).
6. Guide right cyclic flight control cylinder (7) carefully into helicopter. Place support bracket (27) over studs in support
(28) (detail C). Install aluminum washer (29) and torque nuts (30) 75 to 95 in-lbs (8.47 to 10.73 Nm). Install aluminum
CAUTION

a. Remove lockwire and loosen nut (63), and turn rod end bearing (64) to align with bolt hole.
b. Torque nut (63) to 200 to 250 in-lbs (22.60 to 28.25 Nm) and secure to locking device (62) with lockwire
(C-405).
c. Inspect locking device (62) to ensure tab is in groove of rod end bearing (64) and that it was not damaged when
nut (63) was tightened. Replace locking device if tab is twisted or damaged.
8. Align right cyclic flight control cylinder (7) into support (28) as follows:
up, and then down, and bolt replaced without any pressure, forcing, binding, or bending of piston rod in fore, aft,
left, or right direction. One person must guide extension tube (3) to prevent damage when conducting this step
and subsequent steps.
b. If cylinder meets requirements of step a., it is considered in alignment. If cylinder is aligned, accomplish step h.
through step i. If cylinder is misaligned, accomplish step c. through step i.
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E-AB412-PT6T-2
bolt (41).
must be free of any side loading. Repeat steps c. through g. until free of side loading.
NOTE
bracket (27) and support (28). Or, it is permissible to add one AN960C416L washer
between support bracket and support.
h. Install bolt (41). Torque bearing nut (66) 900 to 1100 in-lbs (101.69 to 124.28 Nm). Torque nut (65) 900 to 1100
in-lbs (101.69 to 124.28 Nm). Secure nuts (66 and 65) to keyed washer (67) with lockwire (C-405).
i. If cylinder still meets requirements of step a., install washer (43) and nut (44) and torque 95 to 110 in-lbs
(10.73 to 12.43 Nm). Install cotter pin (45).
NOTE
and nut (10).
9. Install extension tube (3) on swashplate horn (2). Install bolt (15), washers (14, 13, 12, and 11), and nut (10). Install
10. Position tube assembly (39) into lever (36) and install bolt (38), washer (37), washers (50 and 51), nut (49), and cotter
pin (55) (detail D).
11. Lubricate new packings (31, 33, 57, and 59) with hydraulic fluid (C-002) or hydraulic fluid (C-072).
12. Install bolt (34), packing (33), elbow (32), and packing (31).
13. Install bolt (56), packing (57), elbow (58), and packing (59).
14. Lubricate new packings (48 and 54) with hydraulic fluid (C-002) or hydraulic fluid (C-072). Install packings and
bypass check valves (47 and 53), if removed (detail D). Connect hoses (35. 40, 46 and 52).
15. Bleed and inspect hydraulic system (Chapter 29).
16. Energize hydraulic system and operate cyclic controls through ten complete operations. Check for leaks.
18. Install access panel on pylon support. Install forward pylon fairing (Chapter 52).
3. RIGHT CYCLIC FLIGHT CONTROL CYLINDER - INSPECTION
Inspect cylinder in same manner outlined for left cylinder (module 67-13-07 paragraph "3. Left cyclic flight control cylinder
- inspection").
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E-AB412-PT6T-2
1. Reservoir
2. Swashplate horn
3. Extension tube
4. Pump
6. Left cyclic flight control cylinder
7. Right cyclic flight control cylinder
G6AB0117B
Figure 1. Right cyclic flight control cylinder (sheet 1 of 4)
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Page 4 Rev. 3
E-AB412-PT6T-2
8. Clevis
9. Cotter pin
10. Nut
15. Bolt
16. Boot
17. Clevis
18. Universal
19. Bolt
21. Upper piston
22. Clevis
23. Cotter pin
24. Nut
25. Nut
26. Aluminum washer
27. Support bracket
28. Support
29. Aluminum washer
30. Nut
75 TO 95 IN-LBS
(8.47 TO 10.73 Nm)
120 TO 160 IN-LBS

(13.56 TO 18.08 Nm)
660 TO 780 IN-LBS

(74.57 TO 88.13 Nm)
G6AB0118B
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Rev. 3 Page 5
E-AB412-PT6T-2
31. Preformed packing 44. Nut 57. Preformed packing

32. Elbow 45. Cotter pin 58. Elbow
33. Preformed packing 46. Hose 59. Preformed packing
34. Bolt 47. Bypass check valve 60. Actuator
35. Hose 48. Preformed packing 61. Lower piston
36. Lever 49. Nut 62. Locking device
37. Washer 50. Washer 63. Nut
38. Bolt 51. Washer 64. Rod end bearing
39. Tube assembly 52. Hose 65. Nut
40. Hose 53. Bypass check valve 66. Bearing nut
41. Bolt 54. Preformed packing 67. Keyed washer
42. Support 55. Cotter pin
43. Aluminum washer 56. Bolt
95 TO 110 IN-LBS 200 TO 250 IN-LBS 900 TO 1100 IN-LBS

(10.73 TO 12.43 Nm) (22.60 TO 28.25 Nm) (101.69 TO 124.28 Nm)
G6AB0119B
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E-AB412-PT6T-2
68. Lock
69. Jam nut
SEALANT (C-308)
NOTE:
G6AB0120B
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E-AB412-PT6T-2
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Page 8 Rev. 3
E-AB412-PT6T-2
67-13-09
CYCLIC CONTROLS - RIGHT CYCLIC BOOST CYLINDER SUPPORT
1. RIGHT CYCLIC BOOST CYLINDER SUPPORT - DESCRIPTION
NOTE
Support (4, figure 1) is for the left cyclic control and collective boost cylinders.
Maintenance for support (4) is covered in collective controls (module 67-12-08).
2. RIGHT CYCLIC BOOST CYLINDER SUPPORT - REMOVAL
1. Remove access panel on right side and forward side of pylon structure inside cabin (Chapter 52).
2. Remove right cyclic hydraulic flight control cylinder (module 67-13-08 paragraph "1. Right cyclic flight control
cylinder - removal").
3. Remove hydraulic system no. 1 hydraulic pump (Chapter 29).
4. Remove main rotor tachometer generator (Chapter 63).
5. Remove nut (10, figure 2), two washers (3 and 9) and bolt (2).
6. Remove nut (8), two washers (5 and 7) and bolt (4).
7. Remove nut (15), two washers (12 and 14), bolt (11). Remove cyclic control boost cylinder support (1) from lift beam
(6).
3. RIGHT CYCLIC BOOST CYLINDER SUPPORT - INSTALLATION
1. Place cyclic control boost cylinder support (1, figure 2) into position in pylon structure (13) and lift beam (6).
4. Install bolts (4), washers (5), washers (7), and nut (8).
5. Install main rotor tachometer generator (Chapter 63).
6. Install no. 1 hydraulic system pump (Chapter 29).
7. Install right cyclic flight control cylinder (module 67-13-08 paragraph "2. Right cyclic flight control cylinder -
installation").
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E-AB412-PT6T-2
10. Install access panel on right side of pylon structure inside cabin (Chapter 52).
11. Install access panel on forward side of pylon structure inside cabin (Chapter 52).
4. RIGHT CYCLIC BOOST CYLINDER SUPPORT - INSPECTION
Inspect cyclic control boost cylinder support (1, figure 2) in accordance with E-AB412-PT6T-3.
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Page 2
E-AB412-PT6T-2
G6AB0109A
Figure 1. Cyclic controls
67-13-09
Page 3
E-AB412-PT6T-2
G6AB0121A
Figure 2. Right cyclic control boost cylinder support
67-13-09
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E-AB412-PT6T-2
67-13-10
CYCLIC CONTROLS - CYCLIC CONTROL TUBES
1. CYCLIC CONTROL TUBES - REMOVAL
NOTE
The removal and installation procedures for control tube (8, figure 1) are typical for
left and right sides.
1. Remove access panel from center of aft cabin floor (Chapter 52).
2. Remove cotter pin (1) and nut (2). Remove bolt (6), and washers (3) from lever (5).
3. Remove cotter pin (13) and nut (12). Remove bolt (10) and washers (11).
4. Remove control tube (8).
7. Remove bellcrank (20).
9. Loosen clamp (26) and slide forward off of boot (27).
10. Slide control tube (28) forward out of helicopter.
2. CYCLIC CONTROL TUBES - INSTALLATION
1. Slide control tube (28, figure 1) aft through boot (27). Position control tube (28) and install clamp (26) on boot (27)
and tighten.
2. Install control tube (28) on mixing lever assembly (33) with bolt (32), two washers (31), nut (30), and cotter pin (29).
3. Install bellcrank (20) in clevis (25) of control tube (28) with bolt (24), two washers (23), nut (22), and cotter pin (21).
4. Install bellcrank (20) with bolt (17), two washers (16), nut (19), and cotter pin (18).
5. Install clevis (9) of control tube (8) on bellcrank (20) with bolt (10), two washers (11), nut (12), and cotter pin (13).
6. Install rod end bearing (7) of control tube (8) on lever (5) with bolt (6), washers (3), nut (2), and cotter pin (1).
7. With cyclic stick in neutral position, locate aft end of boot (27) on control tube (28) 6.95 in (176.53 mm) aft of
bulkhead attachment for the boot. Tighten the clamp (26).
paragraph "3. Cyclic controls - alternate method") and that cyclic controls move freely through their entire travel with
no binding or restriction.
67-13-10
Rev. 2 Page 1
E-AB412-PT6T-2
9. Install access panel in the center aft cabin floor (Chapter 52).
3. CYCLIC CONTROL TUBES - INSPECTION
NOTE
The inspection procedure for control tubes (8 and 28, figure 1), clevises (9 and 25),
and bellcrank (20) in left and right cyclic system are covered in E-AB412-PT6T-3.
Inserts and bearings in control tubes and bellcranks are covered in
E-AB412-PT6T-3.
2. Inspect threads for damage. No visible damage to threads is acceptable.
3. Inspect boot (27, figure 1) for tears and signs of deterioration. Torn or deteriorated boots are not acceptable and shall
be replaced.
4. CYCLIC CONTROL TUBES - REPAIR
NOTE
Repair bellcranks and control tubes in accordance with E-AB412-PT6T-3. Refer to
E-AB412-PT6T-3 for bearing replacement procedure.
67-13-10
Page 2 Rev. 2
E-AB412-PT6T-2
1. Cotter pin 18. Cotter pin

2. Nut 19. Nut
3. Washers 20. Bellcrank
4. Cyclic flight control cylinder 21. Cotter pin
5. Lever 22. Cotter pin
6. Bolt 23. Washers
7. Rod end bearing 24. Bolt
8. Control tube 25. Clevis
9. Clevis 26. Clamp
10. Bolt 27. Boot
11. Washers 28. Control tube
13. Cotter pin 30. Nut
14. Bearing 31. Washers
15. Bearing 32. Bolt
16. Washers 33. Mixing lever assembly
17. Bolt
G6AB0122B
Figure 1. Right cyclic control tubes and bellcranks
67-13-10
Rev. 2 Page 3
E-AB412-PT6T-2
67-13-10
Page 4 Rev. 2
E-AB412-PT6T-2
67-13-11
CYCLIC CONTROLS - MIXING LEVER ASSEMBLY
1. MIXING LEVER ASSEMBLY - REMOVAL
1. Removal access panel in center of aft cabin floor (Chapter 52).
2. Remove flight control tube (19, figure 1) from mixing lever assembly (26) by removing cotter pin (18), nut (17),
washer (16) and bolt (3).
3. Remove flight control tube (6) from mixing lever assembly (26) by removing cotter pin (9), nut (8), washers (7 and 5)
and bolt (4).
4. Remove flight control tube (12) from mixing lever (26) by removing cotter pin (15), nut (14), washers (13 and 11),
and bolt (10).
5. Disconnect series actuator (23) by removing cotter pin (22), nut (21), washers (20 and 24) and bolt (25) from lever
assembly (26).
6. Remove four bolts (2) and washers (1). Remove mixing lever assembly (26).
2. MIXING LEVER ASSEMBLY - INSTALLATION
1. Place mixing lever assembly (26, figure 1) in position in helicopter and install bolts (2) and washers (1).
2. Place flight control tube (6) on lever assembly (26) and install bolt (4), washer (5 and 7), nut (8), and cotter pin (9).
3. Place flight control tube (12) on lever assembly (26) and install bolt (10), washers (11 and 13), nut (14), and cotter pin
(15).
4. Place flight control tube (19) in lever assembly (26) and install bolt (3), washer (16), nut (17), and cotter pin (18).
5. Place series actuator (23) onto lever assembly (26) and install bolt (25), washers (24 and 20), nut (21), and cotter pin
(22).
6. Move cyclic controls through full travel and check for obstructions and binding.
8. Install access panel in center of aft cabin floor. (Chapter 52).
3. MIXING LEVER ASSEMBLY - INSPECTION

Inspect mixing lever (26, figure 1) for mechanical and corrosion damage in accordance with E-AB412-PT6T-3.
4. MIXING LEVER ASSEMBLY - REPAIR
Repair mixing lever assembly (26, figure 1) (E-AB412-PT6T-3).
67-13-11
Page 1
E-AB412-PT6T-2
G6AB0123A
Figure 1. Mixing lever
67-13-11
Page 2
E-AB412-PT6T-2
67-13-12
CYCLIC CONTROLS - FORE AND AFT PROXIMITY SWITCH
1. FOR AND AFT PROXIMITY SWITCH - REMOVAL
1. Remove access panel in center of aft cabin floor (Chapter 52).
2. Cut lockwire and remove nut (1, figure 1) from fore and aft proximity switch (2).
3. Separate wires at splice to switch.
4. Remove switch (2) from support assembly (3).
2. FOR AND AFT PROXIMITY SWITCH - INSTALLATION
MATERIALS REQUIRED
NUMBER NOMENCLATURE
C-405 LOCKWIRE
1. Place fore and aft proximity switch (2, figure 1) in support assembly (3) and loosely install nut (1). Do not tighten nut
at this time.
2. Connect wires at splice to switch.
3. Adjust switch as required (module 67-11-02 paragraph "4. Cyclic controls - cyclic position sensor"). Tighten nut (1)
and secure with lockwire (C-405).
4. Install access panel in center of cabin floor (Chapter 52).
3. FOR AND AFT PROXIMITY SWITCH - INSPECTION
1. Inspect fore and aft proximity switch (2, figure 1) for cracks and security.
2. Inspect wires for deterioration and looseness.
4. FOR AND AFT PROXIMITY SWITCH - REPAIR
1. Tighten loose connections on wires.
2. Proximity switches are unrecoverable and shall be replaced if unserviceable.
67-13-12
Page 1
E-AB412-PT6T-2
G6AB0124A
Figure 1. Fore and aft lateral proximity switches
67-13-12
Page 2
E-AB412-PT6T-2
67-13-13
CYCLIC CONTROLS - LATERAL PROXIMITY
1. LATERAL PROXIMITY - REMOVAL
2. Cut lockwire and remove nut (4, figure 1) from lateral proximity switch (5).
3. Separate wires at splice to switch.
4. Remove switch (5) from sensor plate (6).
2. LATERAL PROXIMITY - INSTALLATION
MATERIALS REQUIRED
NUMBER NOMENCLATURE
C-405 LOCKWIRE
1. Place lateral proximity switch (5, figure 1) in sensor plate (6), and install nut (4). Do not secure nut at this time.
2. Connect wires at splice to switch.
3. Adjust switch as required (module 67-11-02 paragraph "4. Cyclic controls - cyclic position sensor"). Tighten nut (4)
and secure with lockwire (C-405).
4. Install access panel in center of cabin floor (Chapter 52).
3. LATERAL PROXIMITY - INSPECTION
1. Inspect lateral proximity switch (5, figure 1) for cracks and security.
2. Inspect wires for deterioration and looseness.
4. LATERAL PROXIMITY - REPAIR
1. Tighten loose connections on wires.
2. Proximity switches are unrecoverable and shall be replaced if unserviceable.
67-13-13
Page 1
E-AB412-PT6T-2
G6AB0124A
Figure 1. Fore and aft and lateral proximity switches
67-13-13
Page 2
E-AB412-PT6T-2
67-13-14
CYCLIC CONTROLS - LATERAL SERIES ACTUATOR
1. LATERAL SERIES ACTUATOR - REMOVAL
CAUTION
DISASSEMBLY OF SERIES ACTUATOR (3, FIGURE 1) IS NOT PERMITTED.
1. Remove access panel in center of aft cabin floor. (Chapter 52).
2. Disconnect electrical connector.
3. Remove panel in cabin floor to provide access to lateral cyclic control bellcrank (7, figure 1) (Chapter 52).
4. Remove series actuator (3) from mixing lever assembly (15) by removing cotter pin (10), nut (11), washers (12 and
13) and bolt (14).
5. Remove series actuator (3) from lateral cyclic control bellcrank (7) by removing cotter pin (6), nut (5), washers (4 and
8) and bolt (9). Disconnect electrical connector. Slide series actuator (3) forward and remove from helicopter.
2. LATERAL SERIES ACTUATOR - INSTALLATION
CAUTION
1. Place series actuator (3, figure 1) into position in helicopter. Place clevis of actuator on bellcrank (7). Install bolt (9),
washer (8), washer (4), nut (5), and cotter pin (6).
2. Place aft clevis of series actuator onto mixing lever (15). Install bolt (14), washer (13), washer (12), nut (11), and cotter
pin (10).
3. Connect electrical connector.
4. Install cabin floor panels. (Chapter 52).
3. LATERAL SERIES ACTUATOR - INSPECTION
Inspect series actuator (3, figure 1) for damage, distortion, corrosion, and security of clevis (E-AB412-PT6T-3).
67-13-14
Rev. 2 Page 1
E-AB412-PT6T-2
4. LATERAL SERIES ACTUATOR - REPAIR
CAUTION
Series actuators are not field repairable and shall be replaced if unserviceable.
NOTE
Linear actuator portions of series actuators are unrecoverable and shall be replaced if
unserviceable. Clevis and couplings are repairable (E-AB412-PT6T-3).
67-13-14
Page 2 Rev. 2
E-AB412-PT6T-2
1. Flight control tube (ref)

2. Series actuator (fore and aft) (ref)
3. Series actuator (lateral)
4. Aluminum washer
5. Nut
6. Cotter pin
7. Lateral cyclic control bellcrank
8. Aluminum washer
9. Bolt
10. Cotter pin
11. Nut
12. Aluminum washer
13. Aluminum washer
NOTE: 14. Bolt
15. Mixing lever assembly
1 16. Proximity switch
1 After installation of cyclic centering assembly. 17. Sensor plate
1
G6AB0125B
Figure 1. Lateral series actuator and proximity switch
67-13-14
Rev. 2 Page 3
E-AB412-PT6T-2
67-13-14
Page 4 Rev. 2
E-AB412-PT6T-2
67-13-15
CYCLIC CONTROLS - LONGITUDINAL SERIES ACTUATOR
1. LONGITUDINAL SERIES ACTUATOR - REMOVAL
CAUTION
2. Remove panel from left side of console. (Chapter 52).
3. Remove cotter pin (5, figure 1), nut (4), washers (3 and 14), and bolt (15).
4. Remove cotter pin (7), nut (8), washers (9 and 12), and bolt (11).
5. Disconnect electrical connectors. Slide series actuator (13) aft and remove from helicopter.
2. LONGITUDINAL SERIES ACTUATOR - INSTALLATION
CAUTION
1. Place series actuator (13, figure 1) into position in helicopter. Place forward end onto arm of tube and lever assembly
(10) and install bolt (11), washer (12), washer (9), nut (8), and cotter pin (7).
2. Place aft end into idler (2), install bolt (15), washer (14), washer (3), nut (4), and cotter pin (5). Connect electrical
connectors.
4. Move controls through full travel and check for binding and obstructions.
5. Install access panel in center of cabin floor. (Chapter 52).
6. Install panel on left side of console. (Chapter 52).
3. LONGITUDINAL SERIES ACTUATOR - INSPECTION
1. Inspect series actuator in accordance with E-AB412-PT6T-3.
2. Inspect rod end bearings on series actuator for wear (Appendix I).
67-13-15
Rev. 2 Page 1
E-AB412-PT6T-2
4. LONGITUDINAL SERIES ACTUATOR - REPAIR
CAUTION
1. Series actuators are not field repairable and shall be replaced if unserviceable.
2. Repairs are limited to clevis and coupling (E-AB412-PT6T-3).
67-13-15
Page 2 Rev. 2
E-AB412-PT6T-2
1. Control tube
2. Idler
3. Aluminum washer
4. Nut
5. Cotter pin
6. Support
7. Cotter pin
8. Nut
9. Aluminum washer
10. Tube and lever assembly
11. Bolt
12. Aluminum washer
13. Series actuator
14. Aluminum washer
15. Bolt
G6AB0126B
Figure 1. Longitudinal series actuator
67-13-15
Rev. 2 Page 3
E-AB412-PT6T-2
67-13-15
Page 4 Rev. 2
E-AB412-PT6T-2
67-13-16
CYCLIC CONTROLS - ROTARY ACTUATOR (LATERAL CYCLIC)
1. ROTARY ACTUATOR (LATERAL CYCLIC) - REMOVAL
1. Remove access panel from bottom of helicopter just aft and inboard of left lower nose window (Chapter 52).
2. Remove cotter pin (4, figure 1) and nut (3).
3. Disconnect electrical connectors (9 and 10) from rotary actuator (7).
4. Remove four bolts (5) and four washers (6). Remove rotary actuator (7) and rotary actuator adapter plate (8).
2. ROTARY ACTUATOR (LATERAL CYCLIC) - INSTALLATION
MATERIALS REQUIRED
NUMBER NOMENCLATURE
C-405 LOCKWIRE
1. Inspect rotary actuator (7, figure 1) to ensure arm (11) is installed with index mark on arm positioned six teeth from
index mark on shaft (View A). Loosen stud locking screw (12) and reposition arm (11) if index marks are not properly
located.
2. Torque rotary actuator arm stud locking screw (12), 12 to 15 in.-lbs. (1,35 to 1,69 Nm). Secure with lockwire (C-405)
as required.
3. Position actuator (7) on rotary actuator adapter plate (8). Install bolts (5) and washers (6).
4. Adjust length of force gradient (2) (refer to (module 67-11-02 paragraph "2. Cyclic controls - primary method" for
rigging instructions. After force gradient (2) length is set, position force gradient and tube and lever assembly (1) on
arm (11). Install nut (3) and cotter pin (4).
5. Install electrical connectors (9 and 10).
6. Move cyclic controls through full travel and check for binding and/or obstructions.
7. Verify cyclic control rigging within limits (module 67-11-02 paragraph "2. Cyclic controls - primary method"and
8. Install access panel (Chapter 52).
3. ROTARY ACTUATOR (LATERAL CYCLIC) - INSPECTION
Inspect, rotary actuator for mechanical and corrosion damage (E-AB412-PT6T-3).
67-13-16
Page 1
E-AB412-PT6T-2
G6AB0127A
Figure 1. Lateral cyclic rotary actuator
67-13-16
Page 2
E-AB412-PT6T-2
67-13-17
CYCLIC CONTROLS - ROTARY ACTUATOR (FORE AND AFT CYCLIC)
1. ROTARY ACTUATOR (FORE AND AFT CYCLIC) - REMOVAL
1. Remove access panel from cabin floor under left crew seat. Remove access panel from bottom of left side of helicopter
just forward of forward landing gear cross tube (Chapter 52).
2. Disconnect hook (14, figure 1), spring (17) from bolt (12).
3. Remove cotter pin (3) and nut (4) and separate force gradient (2) from arm (6).
4. Disconnect electrical connectors (5, 10 and 11).
6. Remove rotary actuator (8) from structure (13).
2. ROTARY ACTUATOR (FORE AND AFT CYCLIC) - INSTALLATION
MATERIALS REQUIRED
NUMBER NOMENCLATURE
C-405 LOCKWIRE
1. Inspect rotary actuator (8, figure 1) to ensure arm (6) is installed with index mark on arm positioned 14 teeth from
index mark on shaft (View A). Loosen stud locking screw (7) and reposition arm (6) if index marks are not properly
located.
2. Torque rotary actuator arm stud locking screw (7), 12 to 15 in-lbs (1.35 to 1.69 Nm). Secure with lockwire (C-405) as
required.
3. Position rotary actuator (8) on structure (13).
4. Install special bolt (12) in lower outboard hole.
5. Install bolts (9) in remaining holes.
6. Adjust length of force gradient (2) (module 67-11-02 paragraph "2. Cyclic controls - primary method". After force
gradient (2) length is set, position force gradient and tube and lever assembly (1) on arm (6).
7. Install nut (4) and cotter pin (3).
8. Install spring (17), plate (15), and hook (14) on bolt (12). Refer to module 67-13-18 paragraph "2. Force gradient (fore
and aft cyclic) - installation" for procedure to position spring (17) in correct hole in plate.
67-13-17
Rev. 2 Page 1
E-AB412-PT6T-2
NOTE
For initial installation, install spring in fourth hole of plate (17). With hydraulic
boost on or during ground run, adjust spring tension to position pilot cyclic
(longitudinal only) perpendicular to deck within 2°.
9. Close loop on hook (14) on bolt (12). Secure spring (17) to plate (15) with lockwire (C-405).
10. Install electrical connectors (5, 10 and 11).
11. Move cyclic controls through full travel and check for binding and/or obstructions.
12. Verify cyclic rigging within limits (module 67-11-02 paragraph "2. Cyclic controls - primary method"and paragraph
13. Install access panel on cabin floor under left crew seat (Chapter 52).
14. Install access panel on bottom of helicopter (Chapter 52).
3. ROTARY ACTUATOR (FORE AND AFT CYCLIC) - INSPECTION
Inspect actuator (8, figure 1) for mechanical and corrosion damage (E-AB412-PT6T-3).
67-13-17
Page 2 Rev. 2
E-AB412-PT6T-2
1. Tube and lever assembly

2. Force gradient
3. Cotter pin
4. Nut
6. Arm
7. Stud locking screw
8. Rotary actuator
9. Bolt
12. Bolt (212-001-315-001)
13. Structure
14. Hook
15. Plate
16. Lockwire
17. Spring
18. Clevis
G6AB0128B
Figure 1. Fore and aft cyclic rotary actuator
67-13-17
Rev. 2 Page 3
E-AB412-PT6T-2
67-13-17
Page 4 Rev. 2
E-AB412-PT6T-2
67-13-18
CYCLIC CONTROLS - FORCE GRADIENT (FORE AND AFT CYCLIC)
1. FORCE GRADIENT (FORE AND AFT CYCLIC) - REMOVAL
1. Remove access panel from cabin from under left crew seat (Chapter 52).
2. Remove access panel from bottom of helicopter on left side forward of forward landing gear cross tube. (Chapter 52).
3. Remove hook (7, figure 1) from bolt (6).
5. Remove cotter pin (3) and nut (4) from rotary actuator (5).
6. Remove aluminum washer (11) and bolt (12).
7. Remove fore and aft cyclic controls force gradient (2) from tube and lever assembly (1).
2. FORCE GRADIENT (FORE AND AFT CYCLIC) - INSTALLATION
MATERIALS REQUIRED
NUMBER NOMENCLATURE
C-405 LOCKWIRE
NOTE
Force gradient (2, figure 1) in fore and aft cyclic controls is similar in appearance to
force gradient in lateral cyclic controls, but the force gradients have different part
numbers. Ensure correct part number force gradient is installed at lateral or fore and
aft positions. (Refer to E-AB412-PT6T-4 Illustrated Parts Catalogue)
1. If not previously accomplished, adjust spring preload of force gradient as follows:
a. Cut and remove lockwire, loosen jam nut (1) and remove cap (9, figure 2).
b. Remove spring assembly (4) from cylinder (5).
c. Adjust inboard nut (3) to provide 7,5 to 8,5 lbs. (33,4 to 37,8 N) preload against spring assembly (4). Tighten
outboard nut (2) against inboard nut (3).
d. Position spring assembly (4) in cylinder (5) and install cap (9) with jam nut (1) until all end play is eliminated.
Tighten jam nut (1) and secure with lockwire (C-405) to cylinder (5).
2. If not previously accomplished, adjust actuator (7) on force gradient as follows:
a. Loosen nuts (6 and 8) on shaft of spring assembly (4).
b. Ensure retainer (13) is secured by screws (15) and washers (14).
67-13-18
Page 1
E-AB412-PT6T-2
c. Align actuator (7) on shaft of spring assembly (4) with ball (10) and plunger of cable assembly (switch) (18).
d. Loosen screws (11), washers (12 and 16) and nut (17) cable assembly (switch) (18) to retainer (13).
e. Push and hold actuator (7) down (180°) against cap (9) at point opposite location of cable assembly (18). Hold
this position to initially adjust switch (18) then adjust switch to actuate within ± 0,050 in. (1,27 mm) linear travel
of spring assembly (4). Secure switch (18) to retainer (13) with screws (11), washers (12 and 16) and nut (17).
Secure actuator (7) with nut (8).
f. Install clevis (13, figure 1) on shaft of spring assembly (4, figure 2), secure with nut (6).
3. After assembly of force gradient, prior to installation, verify spring assembly (4) preload of 7,5 to 8,5 pounds (33,36
to 37,81 N).
4. Position spring (10, figure 1) on clevis (13) as illustrated.
5. Position force gradient (2) on tube and lever (1). Clevis (13) has a threaded helicoil insert in one side. Position clevis
with threaded insert inboard. Install bolt (12) and washer (11). Secure bolt head to hole in clevis (13) with lockwire
(C-405).
CAUTION
ENSURE FORCE GRADIENT LENGTH IS ADJUSTED PRIOR TO

INSTALLATION OF FORCE GRADIENT ON ROTARY ACTUATOR.
6. If not previously accomplished, adjust length of force gradient as outlined in rigging instructions (module 67-11-02
paragraph "2. Cyclic controls - primary method").
7. Position force gradient (2) on rotary actuator (5). Install nut (4) and cotter pin (3).
8. Install plate (8) on spring (10) with spring through fourth hole in plate (8). Do not lockwire spring to plate at this time.
9. Attach plate (8) with hook (7) to bolt (6). Do not close loop on hook (7) at this time.
11. Move fore and aft cyclic controls through full travel and check for binding and obstructions.
12. Apply external hydraulic power to helicopter (Chapter 29).
13. Loosen cyclic friction and observe cyclic stick position. If cyclic stick is not perpendicular (longitudinally) within two
degrees, move spring (10) to different hole in plate (8) to cause cyclic stick to be vertical (longitudinally).
14. When tension on spring (10) is correctly adjusted, secure spring (10) to plate (8) with lockwire (C-405) (9) close loop
on hook (7) to prevent accidental disengagement of hook.
15. Move cyclic controls through full travel and check for binding and obstructions.
17. Remove external power from helicopter.
18. Install access panel on bottom of helicopter on left side forward of forward landing gear cross tube. (Chapter 52).
19. Install access panel on cabin floor under left crew seat (Chapter 52).
67-13-18
Page 2
E-AB412-PT6T-2
3. FORCE GRADIENT (FORE AND AFT CYCLIC) - INSPECTION
1. Inspect force gradient (2, figure 1) for corrosion and mechanical damage. Superficial mechanical damage is acceptable
without repair. Mechanical damage in excess of superficial and/or corrosion is not acceptable and force gradient shall
be replaced.
2. Inspect clevis (13) for damaged threaded helicoil insert and for elongated hole in bushing opposite the threaded helicoil
insert.
3. Inspect hook (7), plate (8), and spring (10) for obvious mechanical damage and for loss of tension in spring. Spring
tension at 10,36 in. (263,1 mm) is 6,4 ± 0,5 lbs. (28,4 ± 2,2 N).
4. Inspect bearing for wear and for secure installation in cylinder (5, figure 2) (Appendix I).
5. Inspect two nuts (6 and 8) for secure installation. If adjustment of nuts (2 and 3, spring preload) is suspected of being
incorrect, adjust spring preloads (paragraph "2. Force gradient (fore and aft cyclic) - installation").
6. Inspect jam nut (1) and cylinder (5) for lockwire installation.
7. Inspect switch and electrical cable assembly (18) for frayed wires and broken pins in connector. Check continuity from
connector pins through switch.
4. FORCE GRADIENT (FORE AND AFT CYCLIC) - REPAIR
Repair of force gradient consists of replacement of unserviceable components and adjustment of spring preload
(paragraph "2. Force gradient (fore and aft cyclic) - installation").
67-13-18
Page 3
E-AB412-PT6T-2
G6AB0129A
Figure 1. Fore and aft cyclic force gradient
67-13-18
Page 4
E-AB412-PT6T-2
G6AB0130A
Figure 2. Fore and aft cyclic force gradient assembly
67-13-18
Page 5
E-AB412-PT6T-2
67-13-18
Page 6
E-AB412-PT6T-2
67-13-19
CYCLIC CONTROLS - FORCE GRADIENT (LATERAL CYCLIC)
1. FORCE GRADIENT (LATERAL CYCLIC) - REMOVAL
1. Remove panel from bottom of helicopter below lateral cyclic control force gradient (5, figure 1), (Chapter 52).
3. Remove cotter pin (7) and nut (6). Separate lateral cyclic control force gradient (5) and lateral cyclic controls rotary
actuator (8).
4. Remove cotter pin (9), nut (10), washers (3 and 11) and bolt (2). Remove lateral cyclic control force gradient (5).
2. FORCE GRADIENT (LATERAL CYCLIC) - INSTALLATION
MATERIALS REQUIRED
NUMBER NOMENCLATURE
C-405 LOCKWIRE
NOTE
Lateral cyclic control force gradient (5, figure 1) in lateral cyclic controls is similar
in appearance to force gradient in fore and aft cyclic controls, but the force gradients
have different part numbers. Ensure correct part number force gradient is installed in
lateral cyclic control system position. (refer to Illustrated Parts Catalogue)
The instructions in step 1. are for lateral cyclic controls force gradient (5, figure 1).
1. If not previously accomplished, adjust spring preload of lateral cyclic control force gradient as follows:
a. Cut and remove lockwire, loosen jam nut (1, figure 2) and remove cap (9).
b. Remove spring assembly (4) from cylinder (5).
d. Position spring assembly (4) in cylinder (5) and install cap (9) with jam nut (1) until all end play is eliminated.
Install jam nut (1) and secure with lockwire (C-405) to cylinder (5).
2. If not previously accomplished, adjust actuator (7) on force gradient as follows:
a. Loosen nuts (6 and 8) on shaft of spring assembly (4).
b. Ensure retainer (13) is secured by screws (15) and washer (14).
c. Align actuator (7) on shaft of spring assembly (4) with ball (10) and plunger of cable assembly (18) (switch).
67-13-19
Page 1
E-AB412-PT6T-2
d. Loosen screws (11), washers (12 and 16) and nut (17) mounting switch (18) to retainer (13).
e. Push and hold actuator (7) down (180°) against cap (9) at point opposite location of cable assembly (18). Hold
this position to initially adjust switch (18) then adjust switch to actuate within ± 0,050 in. (1,27 mm) linear travel
of spring assembly (4). Secure switch (18) to retainer (13) with screws (11), washers (12 and 16) and nut (17).
Secure actuator (7) with nut (8).
f. Install clevis (4, figure 1) on shaft of spring assembly (4, figure 2), secure with nut (6).
3. After assembly of force gradient, prior to installation, verify spring assembly (4) preload of 3,5 to 4,5 pounds (15,57
to 20,02 N).
4. Position lateral cyclic control force gradient (5, figure 1) on lateral cyclic control bellcrank (1). Install bolt (2), washer
(3), washer (11), nut (10) and cotter pin (9).
CAUTION
ENSURE FORCE GRADIENT LENGTH IS ADJUSTED PRIOR TO FINAL

INSTALLATION OF LATERAL CYCLIC CONTROL FORCE GRADIENT ON
ROTARY ACTUATOR.
5. If not previously accomplished, adjust length of lateral cyclic control force gradient as outlined in rigging instructions
(module 67-11-02 paragraph "2. Cyclic controls - primary method").
6. Position lateral cyclic control force gradient (5) on lateral cyclic control rotary actuator (8). Install nut (6) and cotter
pin (7).
8. Move lateral cyclic controls through full travel and check for binding and/or obstructions.
10. Install access panel on bottom of helicopter below force gradient (Chapter 52).
67-13-19
Page 2
E-AB412-PT6T-2
G6AB0131A
Figure 1. Lateral cyclic force gradient
67-13-19
Page 3
E-AB412-PT6T-2
G6AB0132A
Figure 2. Lateral cyclic force gradient assembly
3. FORCE GRADIENT (LATERAL CYCLIC) - INSPECTION
1. Inspect lateral cyclic control force gradient (5, figure 1) for corrosion and mechanical damage. Superficial mechanical
damage is acceptable without repair. Mechanical damage in access of superficial and/or corrosion is not acceptable.
2. Inspect clevis on link (4) for elongated holes.
3. Inspect bearing for wear and for secure installation in cylinder (5, figure 2) (Appendix I).
4. Inspect two nuts (6 and 8) for secure installation. If adjustment of nuts (2 and 3) (spring preload) is suspected of being
incorrect, adjust spring preload (paragraph "2. Force gradient (lateral cyclic) - installation").
5. Inspect jam nut (1) and cylinder (5) for correct lockwire installation.
6. Inspect switch and electrical cable assembly (18) for frayed wires and broken pins in connector. Check continuity from
connector pins through switch.
4. FORCE GRADIENT (LATERAL CYCLIC) - REPAIR
Repair of lateral cyclic control force gradient is restricted to replacement of faulty parts and adjustment of spring preload.
67-13-19
Page 4
E-AB412-PT6T-2
67-13-20
CYCLIC CONTROLS - TRANSDUCERS (FORE AND AFT CYCLIC)
1. TRANSDUCERS (FORE AND AFT CYCLIC) - REMOVAL
1. Remove access panel from cabin floor under pilot seat (Chapter 52).
3. Remove cotter pin (1), nut (2), spacers (3 and 5) and bolt (6) from support (4) and transducers (7 and 15).
4. Cut and remove lockwire (12), bolt (13), spacer (14) spacers (10 and 11). Remove transducer (15) and transducer (7)
from tube and lever assembly (8) and control tube (9).
2. TRANSDUCERS (FORE AND AFT CYCLIC) - INSTALLATION
MATERIALS REQUIRED
NUMBER NOMENCLATURE
C-405 LOCKWIRE
1. Position transducer (7, figure 1) and transducer (15) on support (4) and install bolt (6), spacers (5 and 3), nut (2), and
cotter pin (1).
2. Install bolt (13), spacer (14), transducer (15), spacer (11), transducer (7), spacer (10) on tube and lever assembly (8).
Secure with lockwire (C-405).
NOTE
If not previously accomplished perform transducer adjustment. Refer to module
67-11-02 paragraph "2. Cyclic controls - primary method".
3. Connect electrical connectors (16 and 17).
5. Install access panel on cabin floor under pilot seat (Chapter 52).
3. TRANSDUCERS (FORE AND AFT CYCLIC) - INSPECTION
1. Inspect transducer for damage.
2. Inspect electrical cable and connectors for damage.
67-13-20
Page 1
E-AB412-PT6T-2
4. TRANSDUCERS (FORE AND AFT CYCLIC) - REPAIR
The fore and aft cyclic transducers are unrecoverable and shall be replaced when defective.
67-13-20
Page 2
E-AB412-PT6T-2
G6AB0133A
Figure 1. Fore and aft cyclic transducers
67-13-20
Page 3
E-AB412-PT6T-2
67-13-20
Page 4
E-AB412-PT6T-2
67-13-21 CYCLIC CONTROLS - JACKSHAFT (FORE AND AFT) TUBE AND LEVER ASSEMBLY (RIGHT SIDE)
67-13-21
CYCLIC CONTROLS - JACKSHAFT (FORE AND AFT) TUBE AND LEVER
ASSEMBLY (RIGHT SIDE)
1. JACKSHAFT (FORE AND AFT) TUBE AND LEVER ASSEMBLY (RIGHT SIDE) -
REMOVAL
1. Remove access panel from cabin floor under pilot seat. Remove access panel from cabin floor at aft end of console.
Remove access panel from left side of console. Remove oval access panel from right side of helicopter below pilot
door (Chapter 52).
2. For removal of control motion transducers refer to module 67-13-20 "CYCLIC CONTROLS - TRANSDUCERS
(FORE AND AFT CYCLIC)".
3. Remove cotter pin (18, figure 1), nut (19), washers (20 and 2) and bolt (1) from tube and lever assembly (right) (3) and
flight control tube (21).
4. Remove cotter pin (7), nut (8), washers (9 and 11) and bolt (12) from series actuator (10) and arm assembly (14).
5. Remove two nuts (17), two washers (16) two bolts (6), bushings (5 and 15). Index bushings for reinstallation in original
location.
6. Tap on tube and lever assembly (3) with a plastic mallet to loosen inboard joint and to slide tube and lever assembly
(3) outboard.
7. Carefully work tube and lever assembly (3) outboard to disengage arm assembly (14) and housing (4). Remove tube
and lever assembly (3) from helicopter.
INSTALLATION
MATERIALS REQUIRED
NUMBER NOMENCLATURE
C-204 PRIMER
NUMBER NOMENCLATURE
T76 REAMER
NOTE
Inspect tube and lever (3, figure 1) to determine whether holes for bolts (6) have
been drilled. If holes have been drilled and reamed, proceed to step 14. If tube and
lever (3) has not been drilled and reamed, accomplish steps 1. through 13.
67-13-21
Page 1
E-AB412-PT6T-2
1. Measure and record gap between arm assembly (1, figure 2) and tube and lever assembly (3).
2. Remove arm assembly (1) from helicopter to use as an aid in drilling new tube and lever assembly (module 67-13-24
paragraph "1. Arm assembly - removal").
3. Fit arm assembly (1) into tube and lever assembly (4) and establish dimension obtained in step 1. Set angle between
arm assembly (1) and tube and lever assembly (3).
4. Holding lateral and angular dimensions, mark and center punch top holes in tube and lever assembly (4).
5. Drill through top surface of tube and lever assembly (4) using a No. 20 drill (0,161 in.) as a pilot. Insert drill through
top of tube and lever assembly (4) and drill bottom hole using a No. 20 drill (0,161 in.).
6. Turn tube and lever assembly (4) and arm assembly over, keeping everything aligned and redrill bottom hole with an
F drill (0,257 in.).
7. Inspect hole in top of tube and lever assembly (4). Verify hole is centered in existing hole in arm assembly (1). If hole
is not centered, use a small grinder or a router bit in a drill motor to center hole. Redrill top hole with an F drill (0,257
in.).
8. Insert reamer (T76) through hole so pilot projects through far side and ream hole to a smooth finish and until tapered
bushings extend 0,030 to 0,060 in. (0,762 to 1,524 mm) (figure 2).
9. Turn arm assembly (1) and tube and lever assembly (4) over. Place one tapered bushing in hole already reamed and
insert reamer (T76) so pilot projects into bushing. Ream hole to a smooth finish. Remove all burrs.
10. Repeat steps 4. through 11. to drill and ream holes for remaining bolt.
11. Temporarily install bolts (6, figure 1), tapered bushings (5 and 15), washers (16), and nuts (17). Ensure bushings
protrude 0,030 to 0,060 in. (0,762 to 1,524 mm) out of tube and lever assembly (3). Remove and retain bolts (6),
washers (16), nuts (17), and bushings (5 and 15).
12. Place arm assembly (14) in position and mount to tube and lever assembly (13), being sure washer bonded to arm
assembly (14) is on left side.
13. Apply primer (C-204) to end of arm assembly (14) and tube and lever assembly (3) being sure to coat all holes and
bare surfaces.
14. Install tube and lever assembly (3) in helicopter, guiding it through housing (4) and aligning holes in tube and lever
assembly (3) and arm assembly (14).
NOTE
After final installation of hardware, bushings (5 and 15) must protrude from
jackshaft tube within the 0,030 to 0,060 in. (0762 to 1,524 mm) limits shown in
figure 2 view A-A.
15. Install bolts (6), bushings (5 and 15), washers (16), and nuts (17).
16. Place tube (21, figure 1) onto tube and lever assembly (3) and install bolt (1), washers (2 and 20), nut (19), and cotter
pin (18).
17. Place series actuator (10) on arm assembly (14) and install bolt (12), washers (11 and 9), nut (8), and cotter pin (7).
19. For installation of control motion transducers refer to module 67-13-20 "CYCLIC CONTROLS - TRANSDUCERS
(FORE AND AFT CYCLIC)".
67-13-21
Page 2
E-AB412-PT6T-2
21. Install access panel on cabin floor under pilot seat. Install access panel on cabin floor aft of console. Install access panel
on left side of console. Install oval access panel on right side of helicopter below pilot door (Chapter 52).
INSPECTION
1. Inspect tube and lever assembly (3, figure 1) for mechanical and corrosion damage.
3. Inspect bearing for secure installation in tube and for wear (Appendix I).
67-13-21
Page 3
E-AB412-PT6T-2
G6AB0134A
Figure 1. Fore and aft cyclic jackshaft tube and lever assembly (right side)
67-13-21
Page 4
E-AB412-PT6T-2
G6AB0135A
Figure 2. Fore and aft cyclic jackshaft tube and lever assembly (right side) alignment
67-13-21
Page 5
E-AB412-PT6T-2
67-13-21
Page 6
E-AB412-PT6T-2
67-13-2 CYCLIC CONTROLS - JACKSHAFT (FORE AND AFT) TUBE AND LEVER ASSEMBLY (LEFT SIDE)
67-13-22
CYCLIC CONTROLS - JACKSHAFT (FORE AND AFT) TUBE AND LEVER
ASSEMBLY (LEFT SIDE)
1. JACKSHAFT (FORE AND AFT) TUBE AND LEVER ASSEMBLY (LEFT SIDE) -
REMOVAL
1. Remove access panel from cabin floor under copilots seat, access panel from under aft end of console and oval access
panel from lower left side of helicopter under left crew door (Chapter 52).
2. Remove lockwire, bolt (15, figure 1) and washers (14) from force gradient (13).
3. Remove cotter pin (8), nut (7), washers (4 and 6) and bolt (3) from series actuator (5) and arm (19).
4. Remove bolts (9), tapered bushings (10 and 16), washers (17), and nuts (18). Index bushings (10 and 16) for
reinstallation in same location.
5. If copilot cyclic controls are installed, disconnect control tube (not illustrated) from tube and lever assembly (11).
6. Tap tube and lever assembly (11) with a plastic mallet to loosen it from arm assembly (19). Carefully work tube and
lever assembly outboard and out of helicopter.
INSTALLATION
MATERIALS REQUIRED
NUMBER NOMENCLATURE
C-204 PRIMER
C-405 LOCKWIRE
NUMBER NOMENCLATURE
T76 REAMER
NOTE
Inspect tube and lever assembly (11, figure 1) to determine whether holes for two
bolts (9) have been drilled. If holes have been drilled and reamed, proceed to step 14.
If tube and lever assembly (11) has not been drilled and reamed, accomplish steps 1.
through 13.
1. Measure distance between inboard end of tube and lever assembly (8, figure 2) and arm assembly (1).
67-13-22
Page 1
E-AB412-PT6T-2
2. Remove arm assembly (1) from helicopter (module 67-13-24 paragraph "1. Arm assembly - removal").
3. Fit arm assembly (1) into end of new tube and lever assembly (8). Set distance between inboard end of tube and lever
assembly (8) and arm assembly (1) to correspond with dimension obtained in step 1.
4. Set arm assembly (1) at angle shown. Holding angular and lateral dimension, measure holes for bolts (9 and 10) to pick
up existing holes in arm assembly. Center punch top holes for bolts (9 and 10).
5. Drill a pilot hole through top surface of tube and lever assembly (8) with a No. 20 drill (0,161 in.) for bolts (9 and 10).
Drill holes in bottom of tube and lever assembly (8) using a No. 20 drill (0,161 in.).
6. Turn over tube and lever assembly (8) and arm assembly (1) and redrill the holes in bottom of tube and lever assembly
(8) using an F drill (0,257 in.).
7. Verify holes in top of tube and lever assembly (8) are centered with existing holes in arm assembly (1). If not centered,
use a small hand grinder or a router bit to center holes. Redrill holes with an F drill (0,257 in.).
8. Insert reamer (T76) so end of pilot projects through opposite side of tube and lever assembly (8).
9. Ream one side to a smooth finish. Remove all burrs. Install a tapered bushing and insert reamer (T76) so end of pilot
projects into tapered bushing.
10. Ream opposite side to a smooth finish. Remove all burrs.
11. Repeat steps 4. through 10. to drill and ream holes for remaining bolts.
12. Temporarily install bolt (9, figure 1), tapered bushings (10 and 16), washer (17) and nut (18). Check tapered bushings
(10 and 16) protrude 0,030 to 0,060 in. (0,762 to 1,524 mm). Remove bolts (9), washers (17), nuts (18), and bushings
(10 and 16).
13. Coat inboard end of tube and lever assembly (23) and arm assembly (19) with primer (C-204). Insert arm assembly
(19) into tube and lever assembly (23) with washer on left side of arm. Install bolts (2), bushings (1 and 22), washers
(21), and nuts (20).
14. Coat inside of inboard end of tube and lever assembly with primer (C-204). Carefully guide tube and lever assembly
(11) into helicopter through housing (12) and onto end of arm assembly (19).
NOTE
After final installation of hardware, bushings (10 and 16) must protrude from
jackshaft tube within the 0,030 to 0,060 in. (0,762 to 1,524 mm) limits shown in
figure 2 view A-A.
15. Install bolts (9, figure 1), bushings (10 and 16), washers (17), and nuts (18).
16. Install series actuator (5) on arm assembly (19) and secure with bolt (3), washers (4 and 6), nut (7), and cotter pin (8).
17. Place clevis of force gradient (13) on tube and lever assembly (11), install bolt (15) and washer (14). Secure bolt (15)
with lockwire (C-405).
18. Attach control tube (not illustrated) from copilot cyclic controls to tube and lever assembly (11) arm adjacent to force
gradient (13).
67-13-22
Page 2
E-AB412-PT6T-2
21. Install access panel from cabin floor under copilots seat, access panel from under aft end of console and oval access
panel from lower left side of helicopter under left crew door (Chapter 52).
INSPECTION
1. Inspect tube and lever assembly (11, figure 1) for mechanical and corrosion damage.
2. Inspect bearings for freedom of movement and excessive wear.
67-13-22
Page 3
E-AB412-PT6T-2
G6AB0136A
Figure 1. Fore and aft cyclic jackshaft tube and lever assembly (left side)
67-13-22
Page 4
E-AB412-PT6T-2
G6AB0137A
Figure 2. Fore and aft cyclic jackshaft tube and lever assembly (left side) alignment
67-13-22
Page 5
E-AB412-PT6T-2
67-13-22
Page 6
E-AB412-PT6T-2
67-13-23
CYCLIC CONTROLS - JACKSHAFT HOUSING
1. JACKSHAFT HOUSING - REMOVAL
1. Remove access panel from cabin floor under pilot seat. Remove access panel from cabin floor at aft end of console.
Remove access panel from left side of console. Remove oval access panel from right side of helicopter below pilot
door. Remove access panel from cabin floor under copilots seat, access panel from under aft end of console and oval
access panel from lower left side of helicopter under left crew door (Chapter 52).
2. Remove left tube and lever assembly (7, figure 1) (module 67-13-22 paragraph "1. Jackshaft (fore and aft) tube and
lever assembly (left side) - removal").
3. Remove nuts (6), washers (2 and 5) and bolts (1). Remove housing (4) from structure (3). Remove housing (4) from
tube and lever assembly (7).
2. JACKSHAFT HOUSING - INSTALLATION
1. Place housing (4, figure 1) on structure (3) and install bolts (1), washers (2 and 5), and nuts (6).
2. Install tube and lever assembly (7) (module 67-13-22 paragraph "2. Jackshaft (fore and aft) tube and lever assembly
(left side) - installation").
5. Install access panel from cabin floor under pilot seat. Install access panel from cabin floor at aft end of console. Install
access panel from left side of console. Install oval access panel from right side of helicopter below pilot door. Install
access panel from cabin floor under copilots seat, access panel from under aft end of console and oval access panel
from lower left side of helicopter under left crew door (Chapter 52).
3. JACKSHAFT HOUSING - INSPECTION
1. Inspect housing (4, figure 1) for mechanical and corrosion damage.
2. Inspect bearing for secure installation in housing and for wear (Appendix I).
67-13-23
Page 1
E-AB412-PT6T-2
G6AB0138A
Figure 1. Cyclic jackshaft housing
67-13-23
Page 2
E-AB412-PT6T-2
67-13-24
CYCLIC CONTROLS - ARM ASSEMBLY
1. ARM ASSEMBLY - REMOVAL
1. Remove access panel from cabin floor under pilot seat. Remove access panel from left side of pedestal (Chapter 52).
2. Remove cotter pin (21, figure 1), nut (22), washers (23 and 26) and bolt (25). Remove flight control tube (24) from
tube and lever assembly (1).
3. Remove cotter pin (9), nut (8), washers (5 and 7) and bolt (4). Remove series actuator (6) from arm assembly (16).
4. Remove bolts (10), tapered bushings (11 and 13), washers (14) and nuts (15). Index tapered bushings (11 and 13) for
5. Remove nuts (20), tapered bushings (2 and 18), washers (19) and bolts (3). Index tapered bushings (2 and 18) for
6. Tap tube and lever assembly (1) with a plastic mallet to slide out of arm assembly (16). Tap arm assembly (16) with a
plastic mallet to disengage it from tube and lever assembly (12). Remove arm assembly.
2. ARM ASSEMBLY - INSTALLATION
MATERIALS REQUIRED
NUMBER NOMENCLATURE
C-204 PRIMER
NUMBER NOMENCLATURE
T76 REAMER
NOTE
If arm assembly is being replaced, tube and lever assemblies must be used as a jig to
drill and ream holes for tapered bushings.
1. Remove tube and lever assembly (1, figure 1) (module 67-13-21 paragraph "1. Jackshaft (fore and aft) tube and lever
assembly (right side) - removal".
2. Remove tube and lever assembly (12) (module 67-13-22 paragraph "1. Jackshaft (fore and aft) tube and lever assembly
(left side) - removal").
3. Fit new arm assembly (1, figure 2) into tube and lever assemblies (5 and 8) with washer (2) on left side.
67-13-24
Page 1
E-AB412-PT6T-2
4. With levers (3 and 7) vertical and arm assembly (1) 6° aft, establish lateral dimensions as shown. Clamp all
components in place.
5. Center punch top bolt holes in center of existing holes in tube and lever assemblies (5 and 8).
6. Drill a pilot hole through top surface of tube and lever assembly (3) with a No. 20 drill (0,161 in.) for bolts (9 and 10).
Drill holes in bottom of tube and lever assembly (3) using a No. 20 drill (0,161 in.).
7. Turn over tube and lever assembly (3) and arm assembly (1) and redrill the holes in bottom of tube and lever assembly
(3) using an F drill (0,257 in.).
8. Verify holes in top of tube and lever assembly (3) are centered with existing holes in arm assembly (1). If not centered,
use a small hand grinder or a router bit to center holes. Redrill holes with an F drill (0,257 in.).
9. Insert reamer (T76) so end of pilot projects through opposite side of tube and lever assembly (5).
10. Ream four top bolt holes so tapered bushings extend 0,030 to 0,060 in. (0,762 to 1,524 mm) as illustrated.
11. Insert a tapered bushing into top holes and insert reamer (T76) so pilot projects into bushing. Ream the four bottom
holes to same dimension described in preceding step.
12. Fit tube and lever assembly (1) and tube and lever assembly (12) into arm assembly (16). Install bolts (10), bushings
(11), bushings (13), washers (14), and nuts (15).
13. Fit flight control tube (24) on tube and lever assembly (1). Install bolt (25), washers (23 and 26), nut (22), and cotter
pin (21).
14. Install bolts (3), bushings (2), bushings (18), washers (19), and nuts (20).
15. Install series actuator (6) on arm and washer assembly (16) using bolt (4), washers (5 and 7), nut (8), and cotter pin (9).
16. Move cyclic controls through full travel and check for obstructions and binding.
3. ARM ASSEMBLY - INSPECTION
1. Inspect arm assembly (16, figure 1) for mechanical and corrosion damage (E-AB412-PT6T-3).
2. Inspect washer (17) for secure installation on arm (16).
3. Inspect bearing in arm assembly (16) for secure installation in arm and for wear (Appendix I).
67-13-24
Page 2
E-AB412-PT6T-2
G6AB0139A
Figure 1. Cyclic controls arm
67-13-24
Page 3
E-AB412-PT6T-2
G6AB0140A
Figure 2. Cyclic controls arm and washer positioning
67-13-24
Page 4
E-AB412-PT6T-2
67-13-25
CYCLIC CONTROLS - LATERAL TRANSDUCERS
1. LATERAL TRANSDUCERS - REMOVAL
1. Remove access panel from bottom of helicopter immediately aft of lower nose window line and right of helicopter
centerline (Chapter 52).
3. Remove bolt (3, figure 1) by removing cotter pin (14), nut (15). Remove spacer (2) and spacer (16).
4. Remove bolt (6) by removing cotter pin (12), and nut (11). Remove spacers (5 and 10).
5. Remove transducer (4) with spacer (7) and transducer (13) with spacer (9).
2. LATERAL TRANSDUCERS - INSTALLATION
1. Position transducer (4, figure 1) and transducer (13) on support (1) and install bolt (3), spacer (2), spacer (16), nut (15),
2. Position spacer (7) and spacer (9) on bellcrank (8). Install transducer (4) and transducer (13) onto bellcrank (8) with
bolt (6), spacer (5), spacer (10), nut (11), and cotter pin (12).
NOTE
If not previously accomplished, perform transducer adjustment. Refer to module
67-11-02 paragraph "2. Cyclic controls - primary method".
3. Connect electrical connectors.
5. Install access panel on bottom of helicopter aft of lower nose window line and to right of helicopter centerline (Chapter
52).
3. LATERAL TRANSDUCERS - INSPECTION
67-13-25
Page 1
E-AB412-PT6T-2
4. LATERAL TRANSDUCERS - REPAIR
Lateral cyclic transducers are unrecoverable and shall be replaced when defective.
G6AB0141A
Figure 1. Lateral transducers
67-13-25
Page 2
E-AB412-PT6T-2
67-13-26
CYCLIC CONTROLS - CYCLIC STICK BOOT
1. CYCLIC STICK BOOT - REMOVAL
1. Unsnap buttons (1, figure 1).
3. Remove boot (2) from pilot cyclic control stick (3).
2. CYCLIC STICK BOOT - INSTALLATION
1. Slide boot (2, figure 1) down over cyclic stick (3).
2. Align holes in boot (2) and in floor and install screws (5) and washers (4).
3. Snap buttons (1) around stick (3).
3. CYCLIC STICK BOOT - INSPECTION
1. Inspect boot (2, figure 1) for tears, deterioration, and defective buttons.
2. Replace boot if unserviceable.
67-13-26
Page 1
E-AB412-PT6T-2
G6AB0142A
Figure 1. Cyclic stick boot
67-13-26
Page 2
E-AB412-PT6T-2
67-13-27
CYCLIC CONTROLS - PILOT CYCLIC CONTROL STICK ASSEMBLY
1. PILOT CYCLIC CONTROL STICK ASSEMBLY - REMOVAL
1. Remove access panel from bottom of helicopter under pilot cyclic stick (Chapter 52).
2. Remove boot (module 67-13-26 paragraph "1. Cyclic stick boot - removal").
3. Remove bolt (7, figure 1) by removing cotter pin (2) and nut (3). Remove washers (4 and 6). Remove flight control
tube (5) clevis from control stick (1).
4. Remove cotter pin (8), nut (9) and washer (10). Remove bolt (13) and washer (12). Remove flight control tube (11)
clevis from control stick (1).
6. Remove bolts (16) and washers (15). Remove pilot cyclic control stick (1).
2. PILOT CYCLIC CONTROL STICK ASSEMBLY - INSTALLATION
1. Place stick (1, figure 1) in position and install bolts (16) and washers (15).
2. Place tube (5) on arm on stick (1) and install bolt (7), washers (6 and 4), nut (3) and cotter pin (2).
3. Place tube (11) on arm of stick (1) and install bolt (13), washers (12 and 10), nut (9) and cotter pin (8).
4. Connect electrical connector (14) to airframe mounted receptacle.
6. Install boot (module 67-13-26 paragraph "2. Cyclic stick boot - installation").
7. Install access panel on bottom of helicopter under pilot control stick (Chapter 52).
3. PILOT CYCLIC CONTROL STICK ASSEMBLY - INSPECTION
1. Inspect stick assembly (1, figure 1) for mechanical and corrosion damage. Superficial mechanical and corrosion
damage is acceptable if repaired in accordance with E-AB412-PT6T-3.
2. Inspect bearings for secure installation in stick and for wear (Appendix I).
3. Inspect electrical connector (14) and wiring for security.
67-13-27
Page 1
E-AB412-PT6T-2
G6AB0143A
Figure 1. Pilot cyclic stick
67-13-27
Page 2
E-AB412-PT6T-2
67-21-01
ANTI-TORQUE CONTROLS
1. ANTI-TORQUE CONTROLS - DESCRIPTION
The anti-torque control system (figure 1) consists of control linkage and components from pilot pedals (23) aft to tail rotor
assembly. The AFCS provides a single electrical series actuator and a transducer. Series actuator is located forward of
cylinder and support (15). A transducer is connected to airframe structure and bellcrank located aft of pedals.
Movement of pedals causes a hydraulic power assisted pitch change of tail rotor blades to offset main rotor torque and to
control directional heading of helicopter.
67-21-01
Rev. 2 Page 1
E-AB412-PT6T-2
1. Tail rotor 17. Series actuator

2. Crosshead 18. Lever
3. Pitch link 19. Control tube
4. Control tube 20. Lever (walking beam)
5. Lever 21. Control tube
6. Link 22. Adjuster knob
7. Bellcrank 23. Pilot pedal
9. Bellcrank 25. Pedal adjuster
10. Control tube 26. Transducer
11. Walking beam 27. Force gradient
12. Control tube 28. Magnetic brake
13. Bellcrank 29. Friction clamp
14. Control tube 30. Friction screw
15. Cylinder and support 31. Boot
16. Bellcrank 32. Clamp
G6AB0163B
Figure 1. Anti-torque controls
67-21-01
Page 2 Rev. 2
E-AB412-PT6T-2
67-21-02
ANTI-TORQUE CONTROLS - PITCH CHANGE CONTROL BELLCRANK
1. PITCH CHANGE CONTROL BELLCRANK - REMOVAL
1. Remove cotter pin (11, figure 1), nut (10), and washers (12 and 15), and bolt (16). Remove flight control tube (14).
2. Remove cotter pin (5), nut (6), washers (2 and 4), and bolt (1). Remove link (7).
3. Remove cotter pin (8), nut (9), washer (13), and bolt (17). Remove anti-torque control bellcrank (3).
2. PITCH CHANGE CONTROL BELLCRANK - INSTALLATION
1. Place anti-torque control bellcrank (3, figure 1) into position on fin. Install bolt (17), washer (13), nut (9) and torque
to 60 to 110 in.-lbs. (6,78 to 12,4 Nm), and secure with cotter pin (8).
2. Place tube (14) onto bellcrank (3). Install bolt (16), washer (15), washer (12), nut (10), and cotter pin (11).
3. Place link (7) onto anti-torque control bellcrank (3). Install bolt (1), washer (2), washer (4), torque nut (6) and torque
to 60 to 110 in.-lbs. (6,78 to 12,42 Nm), and secure with cotter pin (5).
3. PITCH CHANGE CONTROL BELLCRANK - INSPECTION
1. Inspect anti-torque control bellcrank (3) for corrosion and mechanical damage (E-AB412-PT6T-3).
2. Inspect bearings in bellcrank (Appendix I).
4. PITCH CHANGE CONTROL BELLCRANK - REPAIR
1. Repair anti-torque control bellcrank (3, figure 1) in accordance with E-AB412-PT6T-3.
67-21-02
Page 1
E-AB412-PT6T-2
G6AB0164A
Figure 1. Pitch change control bellcrank
67-21-02
Page 2
E-AB412-PT6T-2
67-21-03
ANTI-TORQUE CONTROLS - TUBE GUIDES
1. TUBE GUIDES - REMOVAL
NOTE
Maintenance procedures for guide (5, figure 1) is given. Maintenance for remaining
guides is similar with the exception that appropriate flight control tube(s) (1, 11, or
16) must be removed.
1. Remove access door from lower side of tailboom (Chapter 52).
2. Remove flight control tube (11) (module 67-21-04 paragraph "2. Flight control tubes and bellcranks - removal").
3. Remove two screws (7) and two washers (6). Remove guide (5).
2. TUBE GUIDES - INSTALLATION
1. Position guide (5) on bulkhead (4). Install two screws (7) and two washers (6).
2. Install flight control tube (11) (module 67-21-04 paragraph "3. Flight control tubes and bellcranks - installation").
3. Verify anti-torque rigging within limits (module 67-11-03 "FLIGHT CONTROLS RIGGING - ANTI-TORQUE
CONTROLS").
4. Install access door on lower side of tailboom (Chapter 52).
3. TUBE GUIDES - INSPECTION
1. Inspect guide (figure 1) for wear, distortion and cracks. Damage that can be detected visually is cause to replace guide.
Guides are fabricated from nylatron material and are not repairable.
67-21-03
Page 1
E-AB412-PT6T-2
G6AB0165A
Figure 1. Control tube guides
67-21-03
Page 2
E-AB412-PT6T-2
67-21-04
ANTI-TORQUE CONTROLS - FLIGHT CONTROL TUBES AND
BELLCRANKS
1. FLIGHT CONTROL TUBES AND BELLCRANKS - DESCRIPTION
Anti-torque control tubes and bellcranks transmit pilot motion at the tail rotor pedals to pitch change mechanism at tail rotor
gearbox (figure 1).
2. FLIGHT CONTROL TUBES AND BELLCRANKS - REMOVAL
1. Remove appropriate access panel(s) and door(s) to gain access to desired control tube or bellcrank (Chapter 52).
2. Remove cotter pins, nuts, washers, and bolts and remove desired component.
3. FLIGHT CONTROL TUBES AND BELLCRANKS - INSTALLATION
1. Position control tube (or bellcrank) in fuselage or tailboom as appropriate.
2. Retain component in position with bolts, washers, and nuts. Secure with cotter pins.
3. Install components, panels, or doors removed for access (Chapter 52).
4. Move anti-torque controls through full travel and check for interference and binding.
5. Verify anti-torque control rigging within limits (module 67-11-03 "FLIGHT CONTROLS RIGGING -
ANTI-TORQUE CONTROLS").
4. FLIGHT CONTROL TUBES AND BELLCRANKS - INSPECTION
1. Inspect components for corrosion and mechanical damage (E-AB412-PT6T-3).
2. Inspect abrasion strip(s) for wear and for secure installation on flight control tube(s).
3. Inspect clevises for secure installation on tubes.
67-21-04
Page 1
E-AB412-PT6T-2
G6AB0163A
67-21-04
Page 2
E-AB412-PT6T-2
67-21-05
ANTI-TORQUE CONTROLS - WALKING BEAM SUPPORT ASSEMBLY
1. WALKING BEAM SUPPORT ASSEMBLY - REMOVAL
1. Remove walking beam (module 67-21-08 paragraph "1. Walking beam and friction clamp - removal").
2. Remove bolts (3, figure 1) and washers (2). Remove anti-torque controls support (1).
2. WALKING BEAM SUPPORT ASSEMBLY - INSTALLATION
MATERIALS REQUIRED
NUMBER NOMENCLATURE
C-430 TAPE
1. Apply pressure-sensitive tape (C-430) to mating surface of support (1, figure 1).
2. Place support (1) in position on structure (4). Install bolts (3) and washers (2).
3. Install walking beam (module 67-21-08 paragraph "2. Walking beam and friction clamp - installation").
4. Move anti-torque pedals through full range of travel and check for interference and binding.
CONTROLS").
3. WALKING BEAM SUPPORT ASSEMBLY - INSPECTION AND REPAIR
1. Inspect and repair support (1, figure 1) mechanical and corrosion damage (E-AB412-PT6T-3).
2. Inspect bolt holes for elongation (E-AB412-PT6T-3). Damage which can be detected visually is not acceptable and is
cause for replacement of support.
3. Inspect pressure-sensitive tape (C-430) for adhesion to mating surface of support (1).
67-21-05
Page 1
E-AB412-PT6T-2
G6AB0166A
Figure 1. Anti-torque control support
67-21-05
Page 2
E-AB412-PT6T-2
67-21-06
ANTI-TORQUE CONTROLS - CONTROL CYLINDER
1. CONTROL CYLINDER - REMOVAL
1. Open door on aft right side of fuselage.
NOTE
Refer to Chapter 29 for general maintenance practices when in hydraulic areas.
2. Disconnect hoses (7 and 9, figure 1). Plug or cap open ports to prevent contamination.
3. Remove bolt (4) by removing cotter pin (29), nut (30), and washers (3 and 31).
4. Remove cotter pin (18), nut (17), washer (16), and remove bolt (21) and washer (20), including spacer (15).
5. While supporting cylinder (6), remove nut (27), bolt (11) with washers (10 and 26). Remove nut (25), bolt (13) with
washers (12 and 24).
6. Disengage trunnion plates (22 and 28) from trunnion (8). Remove cylinder (6).
7. If cylinder (6) is being replaced, loosen nut (5) and remove clevis (2).
2. CONTROL CYLINDER - INSTALLATION
MATERIALS REQUIRED
NUMBER NOMENCLATURE
C-516 CLOTH
1. If cylinder (6, figure 1) is a replacement, install clevis (2) in top of piston to obtain 1,22 in. (30,99 mm) from bolt hole
center line to top of piston. Secure with nut (5).
2. Thoroughly clean and dry trunnion (8) and plates (22 and 28) with aliphatic naphtha (C-305) and lint-free cloth
(C-516).
3. Place plates (22 and 28) over trunnion (8) and position plates onto support (23). Install bolts (11 and 13), washers (10
and 12), washers (24 and 26), and nuts (25 and 27).
4. Position bellcrank (19) onto lever (14). Install spacer (15), bolt (21), washer (20), washer (16), nut (17), and cotter pin
(18).
5. Position tube (1) into clevis (2). Install bolt (4), washer (3), washer (31), nut (30), and cotter pin (29).
6. Remove plugs or caps and connect hoses (7 and 9).
67-21-06
Page 1
E-AB412-PT6T-2
7. Service hydraulic system reservoir.
8. Pressurize hydraulic system 1 and operate anti-torque controls through ten complete cycles (Chapter 29).
CONTROLS"). Bleed hydraulic system (Chapter 29).
10. Close door on right aft side of fuselage (Chapter 52).
3. CONTROL CYLINDER - INSPECTION
2. Inspect trunnion (8) and plates (22 and 28) for wear. Fit plates onto trunnion and feel for looseness and smoothness of
movement.
3. Inspect bearing in lever (14) for freedom of movement.
4. Perform the following inspections only when high frequency vibrations due to anti-torque controls are suspected and/
or anti-torque controls series actuator motors. Refer to troubleshooting chart in Chapter 29.
a. Grasp cylinder (6, figure 1) just below plates (22 and 28) and move cylinder laterally. Lateral movement of
cylinder should be 0,003 to 0,050 in. (0,076 to 1,27 mm). If binding is noted, refer to paragraph "4. Control
cylinder - repair". There should not be any evidence of binding.
b. Inspect bearing in lever (14) for freedom of movement. Maximum acceptable force to rotate bearing is eight oz.
(2,22 N).
(1) Remove cotter pin (18), nut (17), washer (16), and bolt (21) with washer (20). Separate bellcrank (19) from
lever (14).
(2) Install bolt (21) in bearing in lever (14).
(3) Attach a spring scale to bolt (21) (figure 2). Measure force required to rotate bearing. If force required to
rotate bearing is in excess of value shown on illustration, refer to paragraph "4. Control cylinder - repair".
4. CONTROL CYLINDER - REPAIR
MATERIALS REQUIRED
NUMBER NOMENCLATURE
C-407 ABRASIVE PAD
1. If binding was noted during accomplishment of step 4. of paragraph "3. Control cylinder - inspection", clean trunnion
plates (22 and 28, figure 1) with abrasive pad (C-407).
2. If force to rotate bearing during accomplishment of step 4. above exceeds value shown on illustration, attach an air
drill motor to bolt as shown on figure 2. Spin bearing with drill to loosen bearing until it will rotate within limits.
67-21-06
Page 2
E-AB412-PT6T-2
G6AB0167A
Figure 1. Anti-torque hydraulic cylinder
67-21-06
Page 3
E-AB412-PT6T-2
G6AB0168A
Figure 2. Anti-torque hydraulic cylinder bearing inspection tool
67-21-06
Page 4
E-AB412-PT6T-2
67-21-07
ANTI-TORQUE CONTROLS - SERIES ACTUATOR
1. SERIES ACTUATOR - GENERAL
CAUTION
DISASSEMBLY OF SERVO ACTUATOR (5, FIGURE 1) IS NOT PERMITTED.
1. Series actuators are not field repairable and shall be replaced if unserviceable.
2. SERIES ACTUATOR - REMOVAL
CAUTION
1. Remove large round access panel from bottom of aft fuselage. Open access door on right lower side of aft fuselage
(Chapter 52).
2. Remove tailboom assembly (Chapter 53).
4. Remove cotter pin (14), nut (13), washer (12), and remove bolt (9) and washer (10).
5. Remove cotter pin (8), nut (7), washer (6), and bolt (4) with washer (3).
CAUTION
6. Remove series actuator (5).
3. SERIES ACTUATOR - INSTALLATION
CAUTION
1. Establish overall dimensions shown in figure 2.
2. Place servo actuator (5, figure 1) into position with rod end bearing in bellcrank (2).
67-21-07
Rev. 2 Page 1
E-AB412-PT6T-2
3. Install bolt (4), washer (3), washer (6), nut (7) and cotter pin (8).
4. Place forward end of servo actuator (5) on anti-torque controls lever (11).
5. Install bolt (9), washer (10), washer (12), nut (13), and cotter pin (14).
6. Move anti-torque controls through full travel and check for obstructions and binding.
8. Install tailboom assembly (Chapter 53).
CONTROLS").
10. Install large round access panel on bottom of aft fuselage (Chapter 52).
11. Close access door on lower right side of aft fuselage (Chapter 52).
4. SERIES ACTUATOR - INSPECTION
1. Inspect series actuator (5, figure 1) (E-AB412-PT6T-3).
CAUTION
67-21-07
Page 2 Rev. 2
E-AB412-PT6T-2
1. Directional hydraulic flight 8. Cotter pin

control cylinder 9. Bolt
2. Bellcrank 10. Aluminum washer
3. Aluminum washer 11. Anti-torque controls lever
4. Bolt 12. Aluminum washer
5. Servo actuator 13. Nut
6. Aluminum washer 14. Cotter pin
7. Nut 15. Connector
G6AB0169B
Figure 1. Directional series actuator
67-21-07
Rev. 2 Page 3
E-AB412-PT6T-2
1. Bearing
2. Washer
3. Washer
4. Directional series actuator
5. Clevis
6. Lockwire
7. Nut
8. Nut
9. Lockwire
NOTES:
1 Length shown is with actuator at mid-position.
2 Nut to have engagement of threads.

3. Actuator length is 63.062 to 63.112 in (1601.775 to 1603.045 mm) fully extended. Minimum length is 62.668 to 62.718 in
(1591.767 to 1593.073 mm) fully retracted.
G6AB0170B
Figure 2. Directional series actuator assembly
67-21-07
Page 4 Rev. 2
E-AB412-PT6T-2
67-21-08
ANTI-TORQUE CONTROLS - WALKING BEAM AND FRICTION CLAMP
1. WALKING BEAM AND FRICTION CLAMP - REMOVAL
1. Remove access panel from center of aft cabin floor. Remove access panel from bottom of helicopter under walking
beam (19, figure 1) (Chapter 52).
2. Disconnect flight control tube (24) by removing cotter pin (23), nut (22), washer (21). Remove bolt (26) and washer
(25).
3. Disconnect flight control tube (14) by removing cotter pin (16), nut (17), and washer (15). Remove bolt (12) and
washer (13).
4. Remove nut (11) and washer (10). Remove bolt (4) and washer (5).
5. Remove cotter pin (28), nut (27), and washer (29). Remove bolt (3) and washer (2).
6. Remove walking beam (19) and friction clamp (8) with spacer (9).
7. Loosen screw (6) and remove clamp (8) from walking beam (19).
2. WALKING BEAM AND FRICTION CLAMP - INSTALLATION
1. Place friction clamp (8, figure 1) onto walking beam (19). Place walking beam and clamp into structure (1). Install bolt
(3) and washer (2) to hold walking beam in position.
2. Install bolt (4), washer (5), spacer (9), washer (10), and nut (11). Install washer (29), nut (27), and cotter pin (28) on
bolt (3).
3. Place tube (24) on walking beam (19). Install bolt (26), washer (25), washer (21), nut (22), and cotter pin (23).
4. Disconnect force gradient (module 67-21-11 paragraph "1. Force gradient - removal").
5. Adjust friction screw (6) in clamp (8) until force of 4.25 to 4.75 lbs (18.90 to 21.13 N) is measured at pedals when
moved through neutral position.
6. Install force gradient (module 67-21-11 paragraph "2. Force gradient - installation").
7. Place tube (14) onto walking beam (19). Install bolt (12), washer (13), washer (15), nut (17), and cotter pin (16).
8. With anti-torque pedals in central position, locate aft end of boot (31, figure 2) on control tube (19) 9.6 in (243.3 mm)
aft of bulkhead attachment for the boot. Tighten the clamp (32).
CONTROLS").
11. Install access panel on bottom of helicopter under walking beam (19) (Chapter 52).
67-21-08
Rev. 2 Page 1
E-AB412-PT6T-2
12. Install access panel in center of aft cabin floor (Chapter 52).
3. WALKING BEAM AND FRICTION CLAMP - INSPECTION
1. Inspect walking beam (19, figure 1) for mechanical and corrosion damage. Superficial mechanical and corrosion
damage is acceptable if repaired (E-AB412-PT6T-3).
2. Elongated bolt hole damage which can be detected visually is cause to replace walking beam.
3. Inspect bearings for secure installation in beam and for wear (Appendix I).
4. Inspect friction clamp (8) for mechanical and corrosion damage and for elongated bolt holes.
4. WALKING BEAM AND FRICTION CLAMP - REPAIR
Repair walking beam (19, figure 1) and clamp (8) in accordance with E-AB412-PT6T-3.
67-21-08
Page 2 Rev. 2
E-AB412-PT6T-2
1. Structure
2. Aluminum washer
3. Bolt
4. Bolt
5. Aluminum washer
6. Screw
7. Steel washer
8. Friction clamp
9. Spacer
10. Aluminum washer
11. Nut
12. Bolt
13. Aluminum washer
14. Flight control tube
15. Aluminum washer
16. Cotter pin
17. Nut
18. Nut
19. Walking beam
20. Steel washer
21. Aluminum washer
22. Nut
23. Cotter pin
24. Flight control tube
25. Aluminum washer
26. Bolt
27. Nut
28. Cotter pin
29. Aluminum washer
G6AB0171B
Figure 1. Walking beam and friction clamp assembly
67-21-08
Rev. 2 Page 3
E-AB412-PT6T-2
1. Tail rotor 17. Series actuator

2. Crosshead 18. Lever
3. Pitch link 19. Control tube
4. Control tube 20. Lever (walking beam)
5. Lever 21. Control tube
6. Link 22. Adjuster knob
7. Bellcrank 23. Pilot pedal
9. Bellcrank 25. Pedal adjuster
10. Control tube 26. Transducer
11. Walking beam 27. Force gradient
12. Control tube 28. Magnetic brake
13. Bellcrank 29. Friction clamp
14. Control tube 30. Friction screw
15. Cylinder and support 31. Boot
16. Bellcrank 32. Clamp
G6AB0163B
67-21-08
Page 4 Rev. 2
E-AB412-PT6T-2
67-21-09
ANTI-TORQUE CONTROLS - MAGNETIC BRAKE
1. MAGNETIC BRAKE - REMOVAL
3. Remove cotter pin (2) and nut (3).
4. Lift force gradient (1) off arm (10).
5. Remove four bolts (9) with washers (8).
6. Remove magnetic brake (7) from structure (5).
2. MAGNETIC BRAKE - INSTALLATION
1. Inspect magnetic brake (7, figure 1) to ensure arm (10) is installed on magnetic brake with letter “D” positioned in
relation to index mark (11) (detail B). Reposition arm (10) on magnetic brake (7) if index mark (11) is not properly
aligned.
2. Position magnetic brake (7) on structure (5). Install four bolts (9) and washers (8) as follows:
a. Install washer (8) with each bolt (9).
NOTE
Three different length bolts are required. Install bolts of correct length to obtain
proper thread engagement.
b. Install bolts (9) with drilled heads in two inboard holes in magnetic brake (7).
3. Adjust length of force gradient (1) (module 67-11-03 "FLIGHT CONTROLS RIGGING - ANTI-TORQUE
CONTROLS", rigging instructions). After force gradient (1) length is set, position force gradient on arm (10). Install
nut (3) and cotter pin (2).
4. Install electrical connector (6).
5. Move anti-torque controls through full travel and check for binding and obstructions.
6. Verify anti-torque rigging is within limits; refer to module 67-11-03 "FLIGHT CONTROLS RIGGING -
ANTI-TORQUE CONTROLS".
67-21-09
Page 1
E-AB412-PT6T-2
3. MAGNETIC BRAKE - INSPECTION
MATERIALS REQUIRED.
NUMBER NOMENCLATURE
C-320 SEALANT
1. Inspect magnetic brake (7, figure 1) for mechanical and corrosion damage. Superficial mechanical damage is
acceptable without repair. Mechanical damage in excess of superficial and/or corrosion damage is not acceptable.
2. Inspect stud (4) for damaged threads. No damage that can be visually detected is acceptable.
3. Inspect electrical receptacle for bent pins and damaged threads. Superficial damage is acceptable without repair.
4. Check directional control pedals for freedom of movement.
5. If evidence of stiffness and/or binding are found, perform following inspection:
a. Gain access to the anti-torque flight control system magnetic brake (Refer to Chapter 52).
b. Using a mirror and a flashlight, inspect each magnetic brake installed to determine if it is manufactured by
Memcor Truohm, Inc. by identifying the P/N MP498-3. If the magnetic brake is P/N MP498-3 continue with
step c. below. If the magnetic brake is not manufactured by Memcor Truohm, Inc. no other action is required.
Proceed to step l. below.
c. Remove anti-torque magnetic brake from helicopter in accordance with paragraph "1. Magnetic brake -
removal".
d. Inspect arm assembly (3) for mechanical damage created by screws.
NOTE
If mechanical damage is found, the depth shall not exceed 0,762 mm (0.030 inch).
Acceptable damage may be smoothed with 240 grit sandpaper. Treat area with
protective film (C-100).
e. Remove screws (1, figure 2) and stop limits (2) from magnetic brake (4).
f. Clean screw holes and screws (1) with Methyl Ethyl Ketone (C-309) or equivalent and dry with compressed air.
g. Apply adhesive (C-320) to screws treads and install in magnetic brake (4) hand tight.
h. Adjust the stop limits (2) to achieve the arm assembly shaft travel as per dimensions in module 67-11-03
"FLIGHT CONTROLS RIGGING - ANTI-TORQUE CONTROLS".
i. Once shaft travel is obtained, torque screws (1) 5,8 to 11,5 Kg.cm (5 to 10 in-lbs).
j. Apply torque seal inspection ink (999-9900-02-4 yellow, or equivalent) to screws (1) and to stop limits (2).
NOTE
If maintenance is required and screws (1) is to be removed, re-install screws in
accordance with steps f. to j. above.
k. Re-install anti-torque magnetic brake in accordance with paragraph "2. Magnetic brake - installation".
67-21-09
Page 2
E-AB412-PT6T-2
l. Re-install anti-torque magnetic brake access panel (Refer to Chapter 52).
NOTE
Inspect magnetic brake for screws (1) movements, at each 100 Hour/12 calendar
month inspection (Type A) or 600 Hour/12 month inspection (Type B).
4. MAGNETIC BRAKE - REPAIR
1. Refer to E-AB412-PT6T-3 for magnetic brake repair instructions.
G6AB0173A
Figure 1. Magnetic brake
67-21-09
Page 3
E-AB412-PT6T-2
G6AB0833A
Figure 2. Magnetic brake assembly P/N 204-001-376-3
67-21-09
Page 4
E-AB412-PT6T-2
67-21-10
ANTI-TORQUE CONTROLS - CONTROL TRANSDUCER
1. CONTROL TRANSDUCER - REMOVAL
3. Remove cotter pin (20, figure 1), nut (19) with washer (21) and remove bolt (11) and spacer (12).
4. Remove bolt (14) and washer (15) by removing cotter pin (18), nut (17), and spacer (16). Remove transducer (13).
2. CONTROL TRANSDUCER - INSTALLATION
1. Place transducer (13, figure 1) into helicopter onto airframe structure. Install bolt (14) with washer (15), washer (16),
nut (17), and secure with cotter pin (18).
2. Place spacer (22) and rod end bearing of transducer on pedal adjuster assembly (23). Install bolt (11), spacer (12),
washer (21), nut (19) and cotter pin (20).
NOTE
If not previously accomplished, perform transducer adjustment. Refer to module
67-11-03 "FLIGHT CONTROLS RIGGING - ANTI-TORQUE CONTROLS".
4. Install access panel on floor under pilot seat (Chapter 52).
3. CONTROL TRANSDUCER - INSPECTION
4. CONTROL TRANSDUCER - REPAIR
1. Transducer is unrecoverable and shall be replaced when unserviceable.
67-21-10
Page 1
E-AB412-PT6T-2
24. Clevis
25. Nut
G6AB0172A
Figure 1. Control transducer and force gradient
67-21-10
Page 2
E-AB412-PT6T-2
67-21-11
ANTI-TORQUE CONTROLS - FORCE GRADIENT
1. FORCE GRADIENT - REMOVAL
NOTE
The following procedure is applicable to anti-torque force gradients not
incorporating a detent switch for anti-torque force gradients (incorporating a detent
switch) used when the optional 4-axis AFCS/Flight Director kit is installed.
2. Remove cotter pin (10, figure 1), nut (9), washer (8), and bolt (1) with washer (2) from pedal adjuster (23).
3. Remove cotter pin (5) and nut (4) from stud (6).
4. Remove force gradient (3) from magnetic brake (7).
5. Record length of force gradient assembly.
6. Loosen nut (25) and remove clevis (24).
2. FORCE GRADIENT - INSTALLATION
MATERIALS REQUIRED
NUMBER NOMENCLATURE
C-405 LOCKWIRE
NOTE
Force gradient (3, figure 1) is similar in appearance to force gradients used in cyclic
controls but has a different part number. Ensure correct part number force gradient is
installed for anti-torque control system. Refer to E-AB412-PT6T-4.
1. If not previously accomplished, adjust spring preload on force gradient as follows:
a. Cut and remove lockwire from cap (3, figure 2).
b. Remove cap (3) and spring assembly (1) from housing (2).
d. Position spring assembly (1) in housing (2). Install cap (3). Tighten cap (3) until end play of spring (1) is
eliminated. Secure cap (3) as illustrated with lockwire (C-405) to prevent turning in either direction.
67-21-11
Page 1
E-AB412-PT6T-2
CAUTION
ENSURE FORCE GRADIENT LENGTH IS ADJUSTED PRIOR TO

INSTALLATION ON MAGNETIC BRAKE.
2. Install clevis (13, figure 1) on shaft of force gradient (3), adjust to previously recorded length, and secure with nut (25).
3. Position force gradient (3) on pedal adjuster assembly (23).
4. Install bolt (1), washer (2), washer (8), nut (9), and cotter pin (10).
5. If not previously accomplished, adjust length of force gradient as outlined in rigging instructions (module 67-11-03
"FLIGHT CONTROLS RIGGING - ANTI-TORQUE CONTROLS").
6. Position force gradient (3) on stud (6) of magnetic brake (7). Install nut (4) and cotter pin (5).
7. Move anti-torque controls through full travel and check for obstructions and binding.
8. Verify anti-torque rigging is within limits; refer to module 67-11-03 "FLIGHT CONTROLS RIGGING -
ANTI-TORQUE CONTROLS".
3. FORCE GRADIENT - INSPECTION
1. Inspect force gradient assembly (figure 2) for corrosion and mechanical damage. Superficial mechanical damage is
acceptable without repair. Mechanical damage in excess of superficial and/or corrosion damage is not acceptable and
shall be repaired or unit replaced.
2. Inspect bearing (5, figure 2) and sleeve (4) for secure installation in housing (2) and for wear (Appendix I).
3. Inspect two nuts (6) for secure installation. If adjustment of nuts (6) (spring preload) is suspected of being incorrect,
adjust spring preload as outlined in paragraph "2. Force gradient - installation".
4. Inspect cap (3) for correct two way lockwire installation.
4. FORCE GRADIENT - REPAIR
Repair of force gradient consists of replacement of unserviceable components and adjustment of spring preload in
accordance with paragraph "2. Force gradient - installation". Refer to E-AB412-PT6T-3.
67-21-11
Page 2
E-AB412-PT6T-2
24. Clevis
25. Nut
G6AB0172A
Figure 1. Control transducer and force gradient
67-21-11
Page 3
E-AB412-PT6T-2
G6AB0174A
Figure 2. Force gradient assembly
67-21-11
Page 4
E-AB412-PT6T-2
67-21-12
ANTI-TORQUE CONTROLS - PEDAL ADJUSTER ASSEMBLY
1. PEDAL ADJUSTER ASSEMBLY - REMOVAL
2. Remove access panel from bottom of helicopter under pilot cyclic control stick (Chapter 52).
3. Remove pilot cyclic stick boot (module 67-13-26 paragraph "1. Cyclic stick boot - removal").
4. Disconnect flight control tube (3, figure 1) from anti-torque control pedal adjuster assembly (41) as follows:
a. Remove cotter pin (6), nut (5) and aluminum washer (4).
b. Remove bolt (1) with aluminum washer (2) and disconnect tube (3).
5. Disconnect force gradient tube (9) as follows:
a. Remove cotter pin (11), nut (12), and washer (10).
b. Remove bolt (7) with aluminum washer (8) and disconnect force gradient tube (9).
6. Disconnect transducer (15) from adjuster as follows:
b. Remove bolt (13), spacer (14), and spacer (21). Disconnect transducer (15).
7. Disconnect flight control tube (32) as follows:
b. Remove bolt (22) with washer (23) and disconnect tube (32).
8. Disconnect flight control tube (35) as follows:
a. Remove cotter pin (36), nut (40), and aluminum washer (37).
b. Remove bolt (39) with aluminum washer (38) and disconnect tube (35).
9. Remove nuts (24), washers (25 and 33), and bolts (34).
10. Remove pedal adjuster assembly (41) from helicopter.
2. PEDAL ADJUSTER ASSEMBLY - INSTALLATION
1. Place adjuster assembly (41, figure 1) in position in helicopter. Install four bolts (34), washers (33 and 25), and nuts
(24).
2. Place tubes (35 and 32) in pedal adjuster assembly (41). Install bolts (39 and 22), washers (38 and 23), washers (37
and 26), nuts (40 and 27), and cotter pins (36 and 30).
67-21-12
Page 1
E-AB412-PT6T-2
3. Place force gradient (9) on adjuster assembly (41). Install bolt (7), washers (8 and 10), nut (12), and cotter pin (11).
4. Place control tube (3) on pedal adjuster assembly (41). Install bolt (1), washers (2 and 4), nut (5), and cotter pin (6).
5. Place spacer (21) and rod end bearing of transducer (15) on pedal adjuster assembly (41). Install bolt (13), spacer (14),
washer (28), nut (29) and cotter pin (31).
6. Install pilot cyclic stick boot (module 67-13-26 paragraph "2. Cyclic stick boot - installation").
CONTROLS").
9. Install access panel on bottom of helicopter below pilot seat (Chapter 52).
10. Install access panel on cabin floor under plot seat (Chapter 52).
3. PEDAL ADJUSTER ASSEMBLY - INSPECTION
1. Inspect components of adjuster assembly (41, figure 1) for mechanical and corrosion damage (E-AB412-PT6T-3).
2. Inspect chain for wear. Wear that can be detected visually is not acceptable.
3. Inspect gears for wear. Wear that can be detected visually is not acceptable.
4. Inspect bearings for secure installation and for wear (Appendix I).
5. Inspect bolt holes for elongation. Elongation that can be detected visually is not acceptable.
67-21-12
Page 2
E-AB412-PT6T-2
G6AB0175A
Figure 1. Pedal adjuster
67-21-12
Page 3
E-AB412-PT6T-2
67-21-12
Page 4
E-AB412-PT6T-2
67-21-13
ANTI-TORQUE CONTROLS - PEDALS
1. PEDALS - DESCRIPTION
NOTE
Maintenance procedure for anti-torque control right pedal is given. The procedure
for left pedal is similar.
2. PEDALS - REMOVAL
1. Remove cotter pin (4, figure 1), nut (5), washer (3), and bolt (12) with washer (13).
2. Remove cotter pin (8), nut (7), washer (6) and bolt (11) with washer (10). Remove anti-torque control pedal (1).
3. PEDALS - INSTALLATION
1. Place pedal (1, figure 1) on anti-torque pedal support (9). Install bolt (11), washers (10 and 6), nut (7), and cotter pin
(8).
2. Place tube (2) into pedal (1). Install bolt (12), washers (13 and 3), nut (5), and cotter pin (4).
4. PEDALS - INSPECTION
1. Inspect pedal (1, figure 1) for mechanical and corrosion damage. Superficial mechanical damage is acceptable without
repair. Superficial corrosion damage is acceptable if repaired (E-AB412-PT6T-3).
2. Inspect bushings for elongation and security. Damage that can be detected visually is not acceptable.
67-21-13
Page 1
E-AB412-PT6T-2
G6AB0176A
Figure 1. Anti-torque pedals
67-21-13
Page 2
E-AB412-PT6T-2
67-26-01
AERODYNAMICALLY ACTUATED ELEVATOR SYSTEM
1. AERODYNAMICALLY ACTUATED ELEVATOR SYSTEM - DESCRIPTION
The aerodynamically actuated elevator installation (figure 1) consists of left and right elevator assemblies (2 and 17), a horn
assembly (15), two horn support sets (10 and 26), and spring-loaded control tube (20). The horn is mounted in the support
set which secures horn to tailboom structure and permits horn to move to the extent allowed by the spring-loaded control
tube. Each elevator is built up on a spar tube which is inserted into end of horn and is secured by two bolts (27). Each of the
two bolts is installed into holes drilled through both the elevator spar and the horn assembly to provide a fail safe condition
for the elevator.
67-26-01
Page 1
E-AB412-PT6T-2
G6AB0181A
Figure 1. Aerodynamically actuated elevator and horn
67-26-01
Page 2
E-AB412-PT6T-2
67-26-02
AERODYNAMICALLY ACTUATED ELEVATOR
1. AERODYNAMICALLY ACTUATED ELEVATOR - REMOVAL
NOTE
Perform inspections described in steps 1. through 4. of paragraph "3.
Aerodynamically actuated elevator - inspection" prior to removing elevators.
1. Remove access panels from tailboom in area below elevators (Chapter 52).
2. Remove bolt (3, figure 1) and washer (4).
3. Remove cotter pin (30), nut (29), washers (28), bolt (27) and washer (31) from horn (15).
4. Pull elevator (2) straight outboard until spar tube (5) disengages from elevator horn (15).
5. Remove elevator (17) in same manner outlined in steps 2, 3, and 4.
6. Remove cotter pin (23), nut (22), washer (21), and bolt (18) with washer (19). Disconnect tube (20).
CAUTION
HANDLE SUPPORTS (10 AND 26) WITH CARE AFTER REMOVAL TO AVOID
DAMAGE TO BUSHINGS THAT ARE BONDED TO SUPPORTS.
7. Remove self-locking nuts (13), washers (12) and bolts (8) and washers (9). Remove bolts (24) and washers (25).
8. Remove supports (10 and 26) and shims (7 and 11). Index shims (7 and 11) and supports (10 and 26) for installation
as set in same location.
9. Remove supports on opposite end of horn (15). Index shims and supports as a set in same manner outlined in step 8.
10. Remove horn (15) from helicopter.
67-26-02
Page 1
E-AB412-PT6T-2
G6AB0181A
Figure 1. Aerodynamically actuated elevator and horn
67-26-02
Page 2
E-AB412-PT6T-2
2. AERODYNAMICALLY ACTUATED ELEVATOR - INSTALLATION
MATERIALS REQUIRED
NUMBER NOMENCLATURE
C-201 PRIMER
C-202 PRIMER
C-204 PRIMER
C-304 SOLVENT
C-309 SOLVENT
NUMBER NOMENCLATURE
T81 PUSH-PULL DIAL GAGE (SPRING SCALE)
NOTE
If horn (15, figure 1) and control tube (20) were previously installed, proceed to step
12.
1. Place horn (15) in tailboom with horn arm on right side and pointing down as illustrated.
CAUTION
HANDLE SUPPORTS (10 AND 26) CAREFULLY TO AVOID DAMAGE TO

BUSHINGS, THAT ARE BONDED TO SUPPORTS.
2. Install supports (10 and 26), and shims (11) on horn (15) with two bolts (8), washers (9 and 12), and nuts (13). Install
nuts snugly but do not torque at this time.
3. Install supports and shims on opposite end of horn in same manner outlined in step 2.
4. Position shim set (7) and supports (10 and 26) on bracket (6) and install bolts (24) and washers (25). Install bolts snugly
but do not torque at this time.
5. Install supports and shims on opposite end of horn (15) in same manner outlined in step 4.
6. Measure axial play of horn (15) as outlined in paragraph "3. Aerodynamically actuated elevator - inspection", step 2.
If play is not within acceptable limits, adjust thickness of shim set (7). Snug bolts (24) but do not torque at this time.
7. Install two nuts (13). Loosen two similar nuts in opposite end of horn (15).
67-26-02
Page 3
E-AB412-PT6T-2
8. Attach spring scale to hole in arm of horn (15) where control tube (20) is normally installed. Pull scale at right angle
to arm and record force required to rotate horn. Acceptable force is 13 to 16 lbs. (57,82 to 71,17 N). If force is not
within limits, adjust thickness of shims (11) (add shims if force is too great, subtract shims if force is less than
acceptable).
9. After shims (11) are adjusted within acceptable limits, tighten two nuts corresponding to nut (13), but on left end of
horn (15).
10. Repeat force check with spring scale as outlined in step 8., but now acceptable force to rotate horn with both supports
tight is 26 to 32 lbs. (115,65 to 142,34 N). If force is not within limits, adjust thickness of shims on left end of horn
(15) that are opposite shims (11) (add shims if force is too great, subtract shims if force is less than acceptable).
11. After shims (11) are adjusted within acceptable limits as specified in step 10., torque bolts (24) 50 to 70 in.-lbs. (5,7
to 7,9 Nm).
NOTE
If forward end of control tube (20) has not been previously installed on tube support
fitting on bulkhead, install tube (20) on fitting (paragraph "2. Aerodynamically
actuated elevator - installation").
12. Position control tube (20) on elevator horn (15). Install bolt (18), washers (19 and 21), and nut (22). Install cotter pin
(23).
NOTE
The only authorized organic finishes for elevator spar tubes (5) are primer (C-202)
and primer (C-204).
13. Prior to installation, clean both elevator spar tubes (5) and horn (15) as follows:
a. If either tube (5) has been erroneously painted or primed with primer (C-201) or any material other than primer
(C-202) or primer (C-204), remove all traces of existing paint or primer with clean cloth moistened with MEK
(C-309). Also, clean portion of horn (15) that is contacted by either tube (5). If bare metal is exposed, touch up
with primer (C-202) or primer (C-204). Allow primer to thoroughly and completely dry before installing
elevator into horn.
b. If tubes (5) are coated only with primer (C-202), clean tubes (5) and portion of horn (15) that is contacted by
either tube (5) with solvent (C-304).
14. Apply thin coat of corrosion preventive compound (C-104) to spar tube (5) on elevators and to internal surfaces of
horn (15).
15. Insert spar tube (5) into horn and align horn mounting lug (14) for bolt (3). Install bolt (3) and washer (4). Torque bolt
100 to 140 in.-lbs. (11,3 to 15,8 Nm).
16. Install bolt (27) with washer from horn (15), washer (28), and nut (29). Torque nut (29) to 10,0 in.-lbs. (1,13 Nm)
maximum. Install cotter pin (30).
17. Install elevator (17) in same manner outlined in steps 13. through 16.
18. Inspect spring action of control tube (20) (paragraph "3. Aerodynamically actuated elevator - inspection").
19. Install access doors on bottom of tailboom below elevators (Chapter 52).
67-26-02
Page 4
E-AB412-PT6T-2
3. AERODYNAMICALLY ACTUATED ELEVATOR - INSPECTION
NOTE
Prior to removal of elevator, perform inspection outlined in steps 1. through 4.
1. Inspect for loose rivets and/or cracks in skin at attachment points for bracket (6, figure 1) and similar bracket on
opposite side. Press down on each elevator (2 and 17) trailing edge to cause elevator to defect maximum of 0,040 in.
(1,02 mm) and at same time inspect for loose rivets. It is recommended that a dial indicator be used to measure
deflection. If loose rivets or cracks are found, refer to paragraph "4. Aerodynamically actuated elevator - repair" for
repair procedure.
2. Measure axial play of elevator horn (15) as follows:
a. Mount dial indicator on tailboom so stylus of indicator touches inboard edge of elevator near bolt (3).
b. Apply light force to move elevator inboard and outboard spanwise as shown in figure 2. Record dial indicator
reading. Acceptable axial play is 0,005 to 0,030 in. (0,127 to 0,762 mm). If axial play is not within limits, adjust
shims (7, figure 1) as outlined in paragraph "2. Aerodynamically actuated elevator - installation".
c. Remove dial indicator.
3. Measure radial play at elevator horn (15) as follows:
a. Mount dial indicator on tailboom, so stylus of indicator touches upper surface of elevator (2) near bolt (3).
NOTE
Do not use heavy force to move elevator up and down when accomplishing
following step or false dial indicator readings will result.
b. Apply light force to move elevator up and down to measure radial play as shown on figure 2. Record dial
indicator reading. Maximum acceptable radial play is 0,010 in. (0,254 mm).
c. Measure radial play on opposite elevator in same manner outlined in steps a. and b. Remove dial indicator.
d. If radial play on either elevator exceeds limits, adjust shims (11) as outlined in paragraph "2. Aerodynamically
actuated elevator - installation".
4. Inspect spring action of control tube assembly (20). Refer to paragraph "3. Aerodynamically actuated elevator -
inspection" for inspection procedure.
5. Inspect elevators (2 and 17) as follows:
a. Inspect for loose and/or missing rivets, cracks, and holes in skin. Minor damage, that does not result in distortion
of elevator surface, is acceptable if repaired as outlined in paragraph "2. Aerodynamically actuated elevator -
installation".
b. Inspect tip cap (1) and similar tip cap on left elevator for security.
6. For detailed inspection criteria, refer to the E-AB412-PT6T-3.
67-26-02
Page 5
E-AB412-PT6T-2
4. AERODYNAMICALLY ACTUATED ELEVATOR - REPAIR
MATERIALS REQUIRED
NUMBER NOMENCLATURE
C-306 TOLUENE
C-310 ADHESIVE
1. Repair minor damage to skins and structure. Refer to E-AB412-PT6T-3 for materials.
2. Repair loose or missing elevator tip cap (1, figure 1) and similar tip cap on elevator (17) as follows:
a. Clean bonding area on elevator tip using aliphatic naphtha (C-305).
b. Clean inside of tip cap using toluene (C-306).
c. Brush thin coat of thermosetting adhesive (C-310) about 0,010 in. (0,254 mm) thick inside tip cap.
d. Allow about one hour drying time for adhesive to get tacky, then install tip cap (1).
e. Hold tip cap in place at least 15 seconds.
f. Allow to dry at least 24 hours prior to flight or operation.
67-26-02
Page 6
E-AB412-PT6T-2
G6AB0182A
Figure 2. Elevator inspection (installed)
67-26-02
Page 7
E-AB412-PT6T-2
67-26-02
Page 8
E-AB412-PT6T-2
67-26-03
AERODYNAMICALLY ACTUATED ELEVATOR - ELEVATOR CONTROL
TUBE
1. ELEVATOR CONTROL TUBE - REMOVAL
1. Remove access door from tailboom in area below elevators (Chapter 52).
2. Remove cotter pin (14, figure 1), nut (15), washer (16) and bolt (2) and washer (3).
3. Remove cotter pin (11), nut (10), washer (12), bolt (4), and washer (5) and remove control tube (13) from helicopter.
2. ELEVATOR CONTROL TUBE - INSTALLATION
MATERIALS REQUIRED
NUMBER NOMENCLATURE
1. If control tube (13, figure 1) was not previously installed in same helicopter, adjust length of control tube (13) to
dimensions shown on detail A. Align clevis (17) and clevis (20) so bolt holes are parallel. Tighten nut (19) but do not
install lockwire (22) at this time.
2. Apply corrosion preventive compound (C-102) to nut (19) and adjacent threads.
3. Position tube (13) in tailboom with non-adjustable clevis (20) on elevator horn (1). Install bolt (2), washers (3 and 16)
and nut (15). Install cotter pin (14).
4. Align adjustable clevis (17) on tube support (9) and install bolt (4), washers (5 and 12), and nut (10). Do not install
cotter pin (11) at this time.
5. Rig elevator controls (module 67-11-04 paragraph "1. Aerodynamically actuated elevator - description").
6. After rigging is complete, ensure cotter pins (11 and 14) and lockwires (21 and 22) are installed.
7. Install access doors (Chapter 52).
67-26-03
Page 1
E-AB412-PT6T-2
G6AB0183A
Figure 1. Elevator control tube
67-26-03
Page 2
E-AB412-PT6T-2
3. ELEVATOR CONTROL TUBE - INSPECTION
NOTE
Perform inspections described in step 1. of paragraph "1. Elevator control tube -
removal" prior to removing elevators.
1. Inspect operation of tube (13, figure 1). Move elevator to approximately 3° nose down position and slowly release.
Spring action of tube (13) should return elevator to original position. Failure to return to original position, binding,
and/or lock-up are not acceptable. If any of these conditions exist, adjust length of tube as shown in detail A. If this
does not correct discrepancy, replace tube (13).
2. Inspect support (9, figure 1) (E-AB412-PT6T-3).
67-26-03
Page 3
E-AB412-PT6T-2
67-26-03
Page 4
E-AB412-PT6T-2
CHAPTER 71 - POWER PLANT

Module Page
Number Title Number
71-00-00 POWER PLANT
1. Power plant - general .............................................................................................................................. 1
71-01-01 POWER PLANT MAINTENANCE
1. Power plant maintenance - description ................................................................................................... 1

2. Power plant maintenance - priming - power plant lubrication system ................................................... 1
3. Power plant maintenance - pre-oil - reduction (combining) gearbox ..................................................... 1
4. Power plant maintenance - priming - power plant fuel system .............................................................. 1
5. Power plant maintenance - wet motoring run - power plant ................................................................... 2
6. Power plant maintenance - alignment - engine to transmission [A][B][C] ............................................. 3
7. Power plant maintenance - alignment - engine to transmission [D]........................................................ 7
71-01-02 POWER PLANT - COMPRESSOR WASH
1. Compressor wash - description ............................................................................................................... 1

2. Compressor wash - troubleshooting ....................................................................................................... 1
3. Compressor wash - operational check .................................................................................................... 1
71-02-01 ENGINE ASSEMBLY
1. Engine assembly - description ................................................................................................................ 1

2. Engine assembly - removal ..................................................................................................................... 1
3. Engine assembly - installation ............................................................................................................... 13
71-02-02 ENGINE ASSEMBLY - ENGINE POWER SECTION
1. Engine power section - removal ............................................................................................................. 1

2. Engine power section - installation.......................................................................................................... 4
71-02-03 ENGINE ASSEMBLY - REDUCTION (COMBINING) GEARBOX
1. Reduction (combining) gearbox - description ........................................................................................ 1

2. Reduction (combining) gearbox - removal ............................................................................................. 1
3. Reduction (combining) gearbox - installation ........................................................................................ 2
71-11-01 COWLING
1. Cowling - description .............................................................................................................................. 1

2. Cowling - forward and aft transmission pylon fairing ............................................................................ 1
2-1. Forward and aft transmission pylon fairing - removal .................................................................. 1
2-2. Forward and aft transmission pylon fairing - installation .............................................................. 1
2-3. Forward and aft transmission pylon fairing - inspection and repair .............................................. 1
71-Index
Rev. 2 Page 1
E-AB412-PT6T-2

Module Page
Number Title Number
71-11-02 COWLING - TRANSMISSION FAIRING AND ENGINE AIR INLET COWLING
1. Transmission fairing and engine air inlet cowling - removal ..................................................................1

2. Transmission fairing and engine air inlet cowling - installation .............................................................1
3. Transmission fairing and engine air inlet cowling - inspection and repair .............................................1
71-11-03 COWLING - ENGINE COWLING
1. Engine cowling - removal .......................................................................................................................1

2. Engine cowling - installation ...................................................................................................................1
71-11-04 COWLING - REDUCTION (COMBINING) GEARBOX COWLING
1. Reduction (combining) gearbox cowling - removal ...............................................................................1

2. Reduction (combining) gearbox cowling - installation ...........................................................................1
3. Reduction (combining) gearbox cowling - inspection and repair ...........................................................1
71-11-05 COWLING - OIL COOLER AIRSCOOP COWLING
1. Oil cooler airscoop cowling - removal ....................................................................................................1

2. Oil cooler airscoop cowling - installation ...............................................................................................1
3. Oil cooler airscoop cowling - inspection and repair ...............................................................................1
71-21-01 ENGINE MOUNTS
1. Engine mount - description .....................................................................................................................1

2. Engine mount - forward mount ...............................................................................................................1
2-1. Forward mount - removal ...............................................................................................................1
2-2. Forward mount - installation ..........................................................................................................1
2-3. Forward mount - inspection and repair ..........................................................................................2
71-21-02 ENGINE MOUNT - FORWARD MOUNT FITTINGS
1. Forward mount fittings - removal ...........................................................................................................1

2. Forward mount fittings - installation .......................................................................................................1
3. Forward mount fittings - inspection and repair .......................................................................................1
71-21-03 ENGINE MOUNT - FORWARD MOUNT DECK FITTINGS
1. Forward mount deck fittings - removal ...................................................................................................1

2. Forward mount deck fittings - installation ..............................................................................................1
3. Forward mount deck fittings - inspection and repair ...............................................................................2
71-21-04 ENGINE MOUNT - AFT LEFT MOUNT TRIPOD
1. Aft left mount tripod - removal ...............................................................................................................1

2. Aft left mount tripod - installation ..........................................................................................................1
3. Aft left mount tripod - inspection and repair ...........................................................................................1
71-Index
Page 2 Rev. 2
E-AB412-PT6T-2

Module Page
Number Title Number
71-21-05 ENGINE MOUNT - AFT LEFT MOUNT TRIPOD DECK FITTINGS
1. Aft left mount tripod deck fittings - removal .......................................................................................... 1

2. Aft left mount tripod deck fittings - installation ..................................................................................... 1
3. Aft left mount tripod deck fittings - inspection and repair ...................................................................... 2
71-21-06 ENGINE MOUNT - AFT LEFT AND RIGHT MOUNT ENGINE BEARINGS
1. Aft left and right mount engine bearings - removal ................................................................................ 1

2. Aft left and right mount engine bearings - installation ........................................................................... 1
3. Aft left and right mount engine bearings - inspection and repair ........................................................... 1
71-21-07 ENGINE MOUNT - AFT RIGHT MOUNT BIPOD
1. Aft right mount bipod - removal ............................................................................................................. 1

2. Aft right mount bipod - installation ........................................................................................................ 1
3. Aft right mount bipod - inspection and repair ........................................................................................ 1
71-21-08 ENGINE MOUNT - AFT RIGHT MOUNT BIPOD DECK FITTINGS
1. Aft right mount bipod deck fittings - removal ........................................................................................ 1

2. Aft right mount bipod deck fittings - installation ................................................................................... 1
3. Aft right mount bipod deck fittings - inspection and repair .................................................................... 2
71-31-01 ENGINE FIREWALLS
1. Engine firewalls - description ................................................................................................................. 1

2. Engine firewalls - air inlet cowling firewall assembly ........................................................................... 1
2-1. Air inlet cowling firewall assembly - removal .............................................................................. 1
2-2. Air inlet cowling firewall assembly - installation .......................................................................... 1
2-3. Air inlet cowling firewall assembly - inspection ........................................................................... 1
71-31-02 ENGINE FIREWALLS - MIDDLE FIREWALL ASSEMBLY
1. Middle firewall assembly - removal ....................................................................................................... 1

2. Middle firewall assembly - installation .................................................................................................. 2
3. Middle firewall assembly - inspection .................................................................................................... 6
71-31-03 ENGINE FIREWALLS - CENTERLINE FIREWALL ASSEMBLY
1. Centerline firewall assembly - removal .................................................................................................. 1

2. Centerline firewall assembly - installation ............................................................................................. 1
3. Centerline firewall assembly - inspection ............................................................................................... 2
71-31-04 ENGINE FIREWALLS - AFT FIREWALL ASSEMBLY
1. Aft firewall assembly - removal ............................................................................................................. 1

2. Aft firewall assembly - installation ......................................................................................................... 1
3. Aft firewall assembly - inspection .......................................................................................................... 2
71-Index
Rev. 2 Page 3
E-AB412-PT6T-2

Module Page
Number Title Number
71-61-01 ENGINE AIR MANAGEMENT SYSTEM
1. Air management system - description .....................................................................................................1

2. Air management system - ejectors ..........................................................................................................4
2-1. Ejectors - removal ..........................................................................................................................4
2-2. Ejectors - installation ......................................................................................................................4
2-3. Ejectors - inspection .......................................................................................................................8
2-4. Ejectors - repair ...............................................................................................................................9
71-61-02 AIR MANAGEMENT SYSTEM - TRANSITION DUCTS
1. Transition ducts - removal .......................................................................................................................1

2. Transition ducts - installation ..................................................................................................................1
3. Transition ducts - inspection ...................................................................................................................1
4. Transition ducts - repair ..........................................................................................................................2
71-61-03 AIR MANAGEMENT SYSTEM - VALVE ASSEMBLY
1. Valve assembly - removal .......................................................................................................................1

2. Valve assembly - installation ..................................................................................................................1
3. Valve assembly - inspection ....................................................................................................................4
4. Valve assembly - repair ...........................................................................................................................4
71-61-04 AIR MANAGEMENT SYSTEM - FORWARD DUCTS
1. Forward ducts - removal .........................................................................................................................1

2. Forward ducts - installation .....................................................................................................................1
3. Forward ducts - inspection ......................................................................................................................2
71-61-05 AIR MANAGEMENT SYSTEM - INDUCTION BAFFLES
1. Induction baffles - removal .....................................................................................................................1

2. Induction baffles - installation .................................................................................................................1
71-61-06 AIR MANAGEMENT SYSTEM - EXHAUST DUCTS
1. Exhaust duct - removal ............................................................................................................................1

2. Exhaust duct - installation .......................................................................................................................1
3. Exhaust duct - inspection ........................................................................................................................1
4. Exhaust duct - repair ...............................................................................................................................2
71-81-01 ENGINE ACCESSORIES - GAS PRODUCER TACHOMETER GENERATOR
1. Gas producer tachometer generator - description ....................................................................................1

2. Gas producer tachometer generator - removal ........................................................................................1
3. Gas producer tachometer generator - installation ....................................................................................1
71-81-02 ENGINE ACCESSORIES - POWER TURBINE TACHOMETER GENERATOR
1. Power turbine tachometer generator - description ..................................................................................1

2. Power turbine tachometer generator - removal .......................................................................................1
3. Power turbine tachometer generator - installation ..................................................................................1
71-Index
Page 4 Rev. 2
E-AB412-PT6T-2

Module Page
Number Title Number
71-81-03 ENGINE ACCESSORIES - DIFFERENTIAL PRESSURE INDICATOR
1. Differential pressure indicator - description ........................................................................................... 1

2. Differential pressure indicator - removal ................................................................................................ 1
3. Differential pressure indicator - installation ........................................................................................... 1
71-81-04 ENGINE ACCESSORIES - TORQUE PRESSURE TRANSMITTERS
1. Torque pressure transmitter - description ............................................................................................... 1

2. Torque pressure transmitter - removal .................................................................................................... 1
3. Torque pressure transmitter - installation ............................................................................................... 1
71-81-05 ENGINE ACCESSORIES - POWER SECTION OIL PRESSURE SWITCH
1. Power section oil pressure switch - description ...................................................................................... 1

2. Power section oil pressure switch - removal .......................................................................................... 1
3. Power section oil pressure switch - installation ...................................................................................... 1
71-81-06 ENGINE ACCESSORIES - REDUCTION (COMBINING) GEARBOX OIL PRESSURE SWITCH
1. Reduction (combining) gearbox oil pressure switch - description ......................................................... 1

2. Reduction (combining) gearbox oil pressure switch - removal .............................................................. 1
3. Reduction (combining) gearbox oil pressure switch - installation ......................................................... 1
71-81-07 ENGINE ACCESSORIES - REDUCTION (COMBINING) GEARBOX OIL TEMPERATURE

BULB
1. Reduction (combining) gearbox oil temperature bulb - description ....................................................... 1

2. Reduction (combining) gearbox oil temperature bulb - removal ........................................................... 1
3. Reduction (combining) gearbox oil temperature bulb - installation ....................................................... 1
71-81-08 ENGINE ACCESSORIES - REDUCTION (COMBINING) GEARBOX OIL PRESSURE

TRANSMITTER
1. Reduction (combining) gearbox oil pressure transmitter - description .................................................. 1

2. Reduction (combining) gearbox oil pressure transmitter - removal ....................................................... 1
3. Reduction (combining) gearbox oil pressure transmitter - installation .................................................. 1
71-81-09 ENGINE ACCESSORIES - POWER SECTION OIL PRESSURE TRANSMITTER
1. Power section oil pressure transmitter - description ............................................................................... 1

2. Power section oil pressure transmitter - removal .................................................................................... 1
3. Power section oil pressure transmitter - installation ............................................................................... 1
71-81-10 ENGINE ACCESSORIES - POWER SECTION OIL TEMPERATURE BULB
1. Power section oil temperature bulb - description ................................................................................... 1

2. Power section oil temperature bulb - removal ........................................................................................ 1
3. Power section oil temperature bulb - installation ................................................................................... 1
71-Index
Rev. 2 Page 5
E-AB412-PT6T-2

Module Page
Number Title Number
71-81-11 ENGINE ACCESSORIES - STARTER-GENERATOR
1. Starter-generator - description .................................................................................................................1

2. Starter-generator - removal .....................................................................................................................1
3. Starter-generator - installation .................................................................................................................1
4. Starter-generator - inspection ..................................................................................................................4
5. Starter-generator - cleaning .....................................................................................................................5
71-Index
Page 6 Rev. 2
E-AB412-PT6T-2
FIGURES
Figure Page
Number Title Number
Figure 1. Tool application - transmission leveling jacks (T30) ..................................................................................... 5

Figure 2. Tool application - engine to transmission alignment (T37) [A] [B] [C] ........................................................ 6
Figure 3. Transmission leveling................................................................................................................................... 10
Figure 4. Engine to transmission alignment [D] .......................................................................................................... 11
Figure 5. Engine high................................................................................................................................................... 14
Figure 6. Engine low .................................................................................................................................................... 14
Figure 7. Engine yawed left ......................................................................................................................................... 15
Figure 8. Engine offset left .......................................................................................................................................... 16
Figure 9. Engine offset slightly right ........................................................................................................................... 16
Figure 1. Compressor wash fitting ................................................................................................................................. 2
Figure 1. Engine installation connections (sheet 1 of 4)................................................................................................ 4

Figure 2. Engine electrical connections (sheet 1 of 4) ................................................................................................... 8
Figure 3. Tool application - engine sling (SWE-13833) (sheet 1 of 2) ....................................................................... 14
Figure 4. Engine mount connections............................................................................................................................ 16
Figure 1. Tool application - engine sling (SWE-13833) (sheet 1 of 2) ......................................................................... 2
Figure 1. Tool application - engine sling (SWE-13833) (sheet 1 of 2) ......................................................................... 3
71-11-01 COWLING
Figure 1. Transmission and engine cowling (sheet 1 of 2) ............................................................................................ 2

Figure 2. Forward and aft transmission pylon fairing.................................................................................................... 4
71-11-02 COWLING - TRANSMISSION FAIRING AND ENGINE AIR INLET COWLING
Figure 1. Transmission fairings and engine air inlet cowling........................................................................................ 2
71-11-03 COWLING - ENGINE COWLING

Figure 2. Lower engine cowling .................................................................................................................................... 4
71-11-04 COWLING - REDUCTION (COMBINING) GEARBOX COWLING
71-Index
Rev. 2 Page 7
E-AB412-PT6T-2
FIGURES (CONT.D)
Figure Page
Number Title Number
71-11-05 COWLING - OIL COOLER AIRSCOOP COWLING
Figure 1. Transmission and engine cowling (sheet 1 of 2).............................................................................................2

Figure 2. Oil cooler air scoop cowling ...........................................................................................................................4
Figure 1. Engine mounts.................................................................................................................................................3

Figure 2. Forward mount tube ........................................................................................................................................4
Figure 1. Forward mount fitting .....................................................................................................................................2
Figure 1. Forward mount deck fitting.............................................................................................................................2
Figure 1. Aft left mount tripod .......................................................................................................................................2
Figure 1. Aft left mount tripod deck fitting ....................................................................................................................2
Figure 1. Aft left and right mount engine bearing..........................................................................................................2
Figure 1. Aft right mount bipod......................................................................................................................................2
Figure 1. Aft right mount bipod deck fitting ..................................................................................................................2
Figure 1. Engine firewalls ..............................................................................................................................................2

Figure 2. Forward firewall..............................................................................................................................................3
Figure 1. Middle firewall (sheet 1 of 2)..........................................................................................................................3

Figure 2. Engine firewalls ..............................................................................................................................................5
Figure 3. Middle firewall assembly................................................................................................................................7
71-Index
Page 8 Rev. 2
E-AB412-PT6T-2
FIGURES (CONT.D)
Figure Page
Number Title Number
Figure 1. Centerline firewall .......................................................................................................................................... 3

Figure 2. Centerline firewall assembly .......................................................................................................................... 4
Figure 1. Aft firewall ..................................................................................................................................................... 3

Figure 2. Aft firewall assembly...................................................................................................................................... 4
Figure 1. Engine air management system ...................................................................................................................... 2

Figure 2. Air management system schematic ................................................................................................................ 3
Figure 3. Ejector (sheet 1 of 3) ...................................................................................................................................... 5
Figure 4. Exhaust ejector repair (sheet 1 of 11) ........................................................................................................... 11
Figure 1. Transition duct ................................................................................................................................................ 3

Figure 2. Transition duct repair (sheet 1 of 2) ............................................................................................................... 4
Figure 1. Transition duct ................................................................................................................................................ 2

Figure 2. Air management system valve........................................................................................................................ 3
Figure 3. Air management valve assembly repair.......................................................................................................... 6
Figure 1. Forward duct................................................................................................................................................... 3

Figure 2. Engine air management system ...................................................................................................................... 4
Figure 3. Transmission fairings and engine air inlet cowling........................................................................................ 5
Figure 4. Air management system valve........................................................................................................................ 6
Figure 1. Exhaust duct ................................................................................................................................................... 3

Figure 2. Exhaust duct repair ......................................................................................................................................... 4
Figure 1. Gas producer tachometer generator ................................................................................................................ 2
Figure 1. Power turbine tachometer generator............................................................................................................... 2
Figure 1. Differential pressure indicator ........................................................................................................................ 2
71-Index
Rev. 2 Page 9
E-AB412-PT6T-2
FIGURES (CONT.D)
Figure Page
Number Title Number
Figure 1. Torque pressure transmitter (sheet 1 of 2) ......................................................................................................2
Figure 1. Power section oil pressure switch ...................................................................................................................2
Figure 1. Reduction (combining) gearbox oil pressure switch.......................................................................................2
71-81-07 ENGINE ACCESSORIES - REDUCTION (COMBINING) GEARBOX OIL TEMPERATURE

BULB
Figure 1. Reduction (combining) gearbox oil temperature bulb ....................................................................................2
71-81-08 ENGINE ACCESSORIES - REDUCTION (COMBINING) GEARBOX OIL PRESSURE

TRANSMITTER
Figure 1. Reduction (combining) gearbox oil pressure transmitter................................................................................2
Figure 1. Engine power section oil pressure transmitter ................................................................................................3
Figure 1. Engine power section oil temperature bulb.....................................................................................................2
Figure 1. Starter-generator..............................................................................................................................................3
Figure 2. Starter-generator electrical cable.....................................................................................................................5
Figure 3. Starter-generator brush installation .................................................................................................................7
71-Index
Page 10 Rev. 2
E-AB412-PT6T-2
TABLES
Table Page
Number Title Number
Table 1. Situation matrix, vertical plane..................................................................................................................... 17

Table 2. Situation matrix, horizontal plane ................................................................................................................ 18
Table 3. Situation matrix ............................................................................................................................................ 19
71-Index
Rev. 2 Page 11
E-AB412-PT6T-2
71-Index
Page 12 Rev. 2
E-AB412-PT6T-2
71-0 -0 POWER PLANT
71-00-00
POWER PLANT
1. POWER PLANT - GENERAL
The power plant is the overall power package. Major components in this chapter are the engine assembly (consisting of two
power sections), mounts, firewalls, accessories, and air management system.
The power plant is the canadian UACL-PT6T consisting essentially of two turbine engines coupled together.
The fuel system that supplies the two engines is automatically controlled to ensure that each engine provides the same
torque.
The air intake has an integral foreign particle separator while the lubrication system is divided into two independent circuits
for each engine and its accessory gearbox.
The air intakes are also provided with a special ring and nozzles to allow rapid flushing of the compressor.
The two engines are connected to the reduction gearbox through a fee-wheeling unit to allow the reduction gearbox to
operate normally. The reduction gearbox is connected to the main transmission by a shaft, provided with flexible end
couplings, and a free-wheeling unit.
71-00-00
Page 1
E-AB412-PT6T-2
71-00-00
Page 2
E-AB412-PT6T-2
71-01-01
POWER PLANT MAINTENANCE
1. POWER PLANT MAINTENANCE - DESCRIPTION
The fuel system maintenance data is contained in Chapter 28.
The engine oil system maintenance data is contained in Chapter 79.
2. POWER PLANT MAINTENANCE - PRIMING - POWER PLANT LUBRICATION

SYSTEM
NOTE
The following procedure shall be accomplished when a power section or reduction
(combining) gearbox lubrication system or oil cooler has been drained.
1. Open access doors.
2. Fill oil reservoir to specified level (Chapter 12).
3. With qualified personnel at controls, perform dry motoring run (E-AB412-PT6T-1).
4. After completion of motoring run, refill oil reservoir to specified level.
5. Close access doors.
3. POWER PLANT MAINTENANCE - PRE-OIL - REDUCTION (COMBINING) GEARBOX
1. Open access doors.
2. Fill gearbox oil reservoir (Chapter 12).
3. Turn main driveshaft a minimum of 20 revolutions in direction of normal rotation by using main rotor turned by hand.
4. Check gearbox oil level. Visually check oil level to full mark on indicator. Service gearbox as necessary.
5. Close access doors.
4. POWER PLANT MAINTENANCE - PRIMING - POWER PLANT FUEL SYSTEM
1. Disconnect fuel inlet tube from fuel flow divider and connect suitable drainage tubes to inlet tube open ends. Provide
a suitable container to catch displaced fuel and/or preservative.
2. Perform a wet motoring run on each power section (paragraph "5. Power plant maintenance - wet motoring run - power
plant").
3. Verify fuel flows freely from each drainage line.
71-01-01
Rev. 2 Page 1
E-AB412-PT6T-2
NOTE
If power section fuel systems have been preserved, ensure all preservative fluid is
cleared. Repeat wet motoring run if necessary.
4. Disconnect drainage tubes.
5. Connect fuel inlet tube to flow divider. Torque 90 to 100 in-lbs (10.17 to 11.30 Nm).
5. POWER PLANT MAINTENANCE - WET MOTORING RUN - POWER PLANT
WARNING
RESIDUAL VOLTAGE IN IGNITION EXCITER MAY BE DANGEROUSLY

HIGH. ALWAYS DISCONNECT CABLE COUPLING NUTS AT IGNITION
EXCITER END FIRST.
USE INSULATED TOOLS TO REMOVE CABLE COUPLING NUTS. DO NOT

TOUCH EXCITER OUTPUT CONNECTORS OR CABLE COUPLING NUTS
WITH BARE HANDS.
NOTE
The following procedures should be accomplished as a functional check of fuel
system components as well as to depreserve and preserve fuel system.
1. Disconnect input source of power to igniter exciter box on power section no. 1 or power section no. 2, whichever is
applicable, or both.
2. With qualified personnel at controls, fully close throttles.
3. Place BATTERY BUS 1 and BATTERY BUS 2 switches ON, and appropriate power section GOV switch to AUTO.
CAUTION
DO NOT EXCEED STARTER LIMITATIONS (E-AB412-PT6T-1).
4. Actuate START switch to ENG 1 or ENG 2, whichever is applicable, and after gas generator (GAS PROD) rpm attains
12%, position throttle to idle detent.
5. While starter is engaged, close throttle, position GOV switch to MANUAL, and open throttle to idle detent.
6. Return throttle to OFF, and release START switch.
7. Allow power section to coast down and position BATTERY BUS 1 and BATTERY BUS 2 switches to OFF.
71-01-01
Page 2 Rev. 2
E-AB412-PT6T-2
6. POWER PLANT MAINTENANCE - ALIGNMENT - ENGINE TO

TRANSMISSION [A][B][C]
MATERIALS REQUIRED
NUMBER NOMENCLATURE
C-317 ADHESIVE
C-447 LOCKWIRE
C-452 ANTISEIZE COMPOUND
NUMBER NOMENCLATURE
T30 TRANSMISSION LEVELING
T37 ALIGNMENT TOOL
T59 CLEVIS
NOTE
When engine is replaced, alignment check is not required provided engine mount
and/or shim stack-up is not changed.
1. Engine to transmission alignment is required when any of the following conditions exist:
a. Main driveshaft misalignment is suspected for any reason.
b. Excessive wear of driveshaft crowned-tooth coupling.
c. Indications of excessive driveshaft coupling heating.
d. Deleted.
e. Hard landings.
f. Replacement of any engine mount or mount component.
g. Major repair or replacement of components is required in center fuselage, or pylon support structure.
2. Make alignment check with helicopter resting on skids on a level surface, and with engine and pylon assembly installed
in a normal manner and with main rotor untied.
3. Remove main driveshaft, leaving adapter installed in end of engine output shaft (Chapter 63).
4. Remove cotter pins, nuts, and washers from both lift link bolts (figure 1).
5. Position transmission with leveling jacks (T30) as follows:
a. Using hoist and clevis (T59), raise transmission to point where lift link bolts may be turned freely by hand
(figure 1). Replace bolt if binding occurs due to corrosion or galling. Apply antiseize compound (C-452) to bore
and OD of bolt.
b. Install four jacks (T30) between transmission support case and pylon structure. Use jacks to hold transmission
at height where lift link bolts turn freely.
71-01-01
Rev. 2 Page 3
E-AB412-PT6T-2
NOTE
Use shim plates on jacks if necessary to obtain proper height.
c. Use depth gage to measure distance at each corner mount between top side of support case and pylon structure.
d. The four depth gage measurements should be within 0.020 in (0.508 mm) of each other. Adjust jacks as required
to achieve this measurement.
e. If the four measurements cannot be brought within tolerance, average the two front corner measurements and
adjust aft corners to be within 0.020 in (0.508 mm) of the average. Recheck lower lift link bolt for freedom of
movement (step a.).
6. Perform engine to transmission alignment check as follows:
a. Using tool (T37, figure 2), install support assembly (3) to blower drive pads (4) (detail A). Install beam assembly
(2) to support assembly (3) and oil pressure transmitter pad (5). Loosely install knurled bolt (1).
b. Use a length of lockwire (C-447) for alignment wire (7), long enough to reach from installed target plate (8) to
installed knurled bolt (1). Tie a knot in one end of wire and thread wire through target plate with knot on inner
(counterbored) side of target plate.
NOTE
Target plate (8) must be installed in vertical position, with stamp TOP at top.
c. Install target plate (8) to transmission input drive quill (9).

d. Guide alignment wire (7) through center hole of beam assembly bracket (6) and attach to knurled bolt (1) (detail B).
e. Tighten knurled bolt (1) as required to remove all slack, kinks or bends from alignment wire (7). Alignment is
correct if wire does not touch edge of hole in beam assembly bracket (6) (detail C).
f. If alignment wire (7) touches edge of hole in beam assembly bracket (6), alignment is not correct. Change
alignment by adjusting thickness of laminated shim(s) beneath work deck engine mount fitting(s) as necessary.
Refer to module 71-21-03 "ENGINE MOUNT - FORWARD MOUNT DECK FITTINGS", module 71-21-05
"ENGINE MOUNT - AFT LEFT MOUNT TRIPOD DECK FITTINGS" and module 71-21-08 "ENGINE
MOUNT - AFT RIGHT MOUNT BIPOD DECK FITTINGS" for removal of engine mount deck fitting.
NOTE
The maximum amount of shim allowed under any fitting is 0.188 in (4.775 mm). If
more shim is required, fabricate a plate of 2024-T4 aluminum alloy 0.10 in
(2.54 mm) thick, same outside dimensions as shim stock. Structurally bond plate
to engine service deck with adhesive (C-317). Total thickness of shim and
plate under any engine mount fitting shall not exceed 0.288 in (7.315 mm).
7. Remove transmission jacks, hoist, and clevis.
8. Install washer and nut on upper lift link bolt. Torque nut 60 to 80 ft-lbs (81 to 108 Nm) and secure with cotter pin.
9. Install washer and nut on lower lift link bolt. Torque nut 108 to 125 ft-lbs (147 to 169 Nm) and secure with cotter pin.
10. Install main driveshaft (Chapter 63).
71-01-01
Page 4 Rev. 2
E-AB412-PT6T-2
G6AB0206A
Figure 1. Tool application - transmission leveling jacks (T30)
71-01-01
Rev. 2 Page 5
E-AB412-PT6T-2
NOTE:
1 Alignment wire (C-447) must not touch edge of hole.
1. Knurled bolt (T101579-17)

2. Beam assembly (T101579-3)
3. Support assembly (T101579-5)
4. Blower drive pad (2 Reqd)
5. Oil pressure transmitter pad
6. Bracket
7. Wire (MS20995C41)
8. Target plate (T101579-19)
9. Transmission input drive quill
10. Blower (installed)
G6AB0207B
Figure 2. Tool application - engine to transmission alignment (T37) [A] [B] [C]
71-01-01
Page 6 Rev. 2
E-AB412-PT6T-2
7. POWER PLANT MAINTENANCE - ALIGNMENT - ENGINE TO TRANSMISSION [D]
MATERIALS REQUIRED
NUMBER NOMENCLATURE
C-108 BRUSH CADMIUM PLATING SOLUTION
NUMBER NOMENCLATURE
T30 TRANSMISSION LEVELING JACKS
T59 LIFTING CLEVIS
T92 TOOL SET, DRIVESHAFT ALIGNMENT-TRANSMISSION

TO ENGINE
T106 DEPTH MICROMETER
NOTE
When engine is replaced, alignment check is not required provided engine mount
and/or shim stack-up is not changed.
1. Engine to transmission alignment is required when any of the following conditions exist:
a. Main driveshaft misalignment is suspected for any reason.
b. Excessive wear of driveshaft crowned-tooth coupling.
c. Indications of excessive driveshaft coupling heating.
d. Hard landings.
e. Major repair or replacement of components is required in center fuselage, tailboom, or pylon support structure.
2. During engine-to-transmission alignment procedure, the following conventions should be observed:
a. Clocking conventions as it applies to dial indicator sweeps on engine and transmission adapters is as the adapter
is viewed looking into the face; i.e., transmission adapter viewed looking forward and engine adapter viewed
looking aft.
b. Dial indicator supplied with alignment tool (T92) can be read in 0.001 in (0.0254 mm) units. A fourth decimal
place should be estimated as accurately as possible.
c. Movement of indicator probe into dial shall be considered as producing positive (+) indicator deflection.
d. Movement of indicator probe away from dial shall be considered as producing negative (–) indicator deflection.
3. Level transmission as follows:
a. Make alignment check with helicopter resting on skids on level surface, and with engine and pylon
assembly installed in a normal manner with main rotor unrestrained.
b. Remove transmission and engine cowlings.
c. Remove main driveshaft assembly (Chapter 63).
71-01-01
Rev. 2 Page 7
E-AB412-PT6T-2
d. Position transmission with leveling jacks as follows:
(1) Remove the four pylon isolation mount bolts (1, figure 2) and washers (2 and 3).
(2) Remove cotter pin (6), nut (7), and thin steel washer (8) from lower lift link bolt (9). Do not remove bolt.
(3) Using hoist and lifting clevis (T59) raise transmission to point where lift link bolt may turned freely by
hand.
(4) Install four leveling jacks (T30) between transmission support case and pylon support structure (see
figure 1). Using the jack shim plates if necessary to obtain proper height.
NOTE
The leveling jacks will not lower simply by rotating the jack screw
counterclockwise. To lower jack precise amount, rotate jack screw counterclockwise
1/2 turn past the desired point, then tap lightly on end of jack screw to drive in
wedge within jack. Rotate jack screw 1/2 turn clockwise to obtain elevation desired.
(5) Carefully adjust four leveling jacks equally so that transmission is held at height where lift link bolt turns
freely.
(6) Determine that transmission support points are all at same height above support structure by measuring at
each pylon mount with a depth micrometer (see figure 1).
CAUTION
THE TRANSMISSION JACKS (T30) ARE TO BE USED TO PITCH

TRANSMISSION FORE OR AFT AND ROLL TRANSMISSION LEFT OR
RIGHT TO PROPER LEVEL ASSEMBLY FOR DRIVESHAFT ALIGNMENT
CHECKS. EXTREME CARE MUST BE TAKEN WHEN RAISING A JACK NOT
TO DEFORM PYLON SUPPORT STRUCTURE. THIS CAN BE AVOIDED BY
LOWERING JACK OR JACKS OF OPPOSITE SIDE OR END OF
TRANSMISSION SAME AMOUNT AS A PARTICULAR JACK IS RAISED. IT
IS ALSO IMPORTANT TO DETERMINE DEGREE OF LIFT LINK BOLT
LOOSENESS ANY TIME A JACK IS ADJUSTED. IF DURING ROTATION OF
LIFT LINK BOLT, THE BOLT APPEARS TO GET TIGHTER AFTER A JACK
MOVE, STOP. MOVE WAS IN WRONG DIRECTION OR A FAILURE TO
MAKE OPPOSITE MOVE ON OPPOSITE JACK OR JACKS HAS OCCURRED.
(7) Use depth micrometer to measure from top surface of each transmission support case mounting washer to
top of pylon support structure. Measure at each of the four mount locations; measurements should be equal
within 0.010 in (0.254 mm). Adjust jacks to achieve required tolerance. After each adjustment, recheck lift
link bolt for freedom of movement. If four measurements cannot be brought within tolerance, average two
forward corner measurements and adjust aft corners to be within 0.010 in (0.254 mm) of this average.
(8) Upon completion of transmission leveling, recheck lift link bolt to make sure it can be turned freely by
hand.
4. Install alignment tool for transmission-end alignment check.
a. The T92 tool set (figure 4) is supplied with two T101743-127 adapters. Inspect tool adapters and mating flanged
adapters on transmission and engine for contamination and raised material on interfacing surfaces. Clean as
required and remove any raised material flush with surrounding surfaces using a fine india stone. Brush
cadmium plate any damage to cadmium plated surfaces with brush cadmium plating solution (C-108).
b. Using a permanent ink marker, mark a 12 o'clock, 3 o'clock, 6 o'clock, and a 9 o'clock position on face of each
adapter (2 and 5). Label each position.
71-01-01
Page 8 Rev. 2
E-AB412-PT6T-2
c. Install one adapter (5) on engine adapter (9), install other adapter (2) on transmission adapter (1). Secure using
bolts (6), washers (7) and nuts (8). Torque nuts 50 to 70 in-pounds (5.65 to 7.91 Nm).
d. Insert tooling ball on adjustable end of support assembly (4) in pivot hole in adapter (5). Push aft against adapter
(5) to compress plunger in support assembly (4) and insert tooling ball at opposite end in adapter (2) pivot hole.
Dial indicator mounting bracket should be at transmission end of support assembly (4).
e. Rotate transmission end adapter (2) so that 12 o'clock mark is at 12 o'clock position.
f. Install dial indicator (3) on support assembly (4). Position so that indicator is at approximately mid range of
travel and tighten thumb screw.
5. Take indicator readings at transmission end.
6. Transmission end vertical alignment check. Take indicator readings in the vertical plane, 12 o'clock and 6 o'clock
positions, as follows:
NOTE
Because of the sensitivity of dial indicator measurements of extraneous pylon
motion, only personnel actually involved in the measurement operations are to be
allowed on helicopter. Care must be taken not to lean or otherwise exert side loads
on engine, transmission or support assembly (4) as measurements are being taken.
a. Zero dial indicator at 12 o'clock position on transmission end adapter (2) by rotating dial indicator bezel. Lock
bezel in place.
b. To aid tracking direction of indicator needle travel, particularly when indicator is viewed with mirror, coat half
the indicator lens (180) in the area swept by initial negative indicator travel with red permanent ink felt tipped
marker.
c. While holding support assembly (4) stationary with dial indicator at 12 o'clock position, rotate transmission
adapter (1) until the 6 o'clock mark on adapter (2) is in 12 o'clock position. Record indicator reading as 6 o'clock
transmission adapter runout and note whether reading is positive (+) or negative (–). The adapter runout reading
is amount of runout inherent in the assembly and must be accounted for when determining actual amount of
misalignment.
d. Rotate adapter (2) to return the 12 o'clock mark to the 12 o'clock position. Rezero indicator if required.
e. With dial indicator zeroed at 12 o'clock position and holding transmission adapter stationary, rotate tool support
until dial indicator probe is at 6 o'clock position. Record dial indicator reading as 6 o'clock transmission
alignment, noting whether reading is positive (+) or negative (–).
71-01-01
Rev. 2 Page 9
E-AB412-PT6T-2
1. Bolt 7. Nut
2. Washer 8. Thin steel washer
3. Washer 9. Bolt
4. Isolation mount 10. Lift beam lift link fitting
5. Damper 11. Lift link
6. Cotter pin
G6AB1037A
Figure 3. Transmission leveling
71-01-01
Page 10 Rev. 2
E-AB412-PT6T-2
1. Transmission adapter
2. Adapter (T101743-127)
3. Dial indicator
4. Support assembly (T101743-107)
5. Adapter (T101743-127)
6. Bolt (6 each)
7. Washer (12 each)
8. Nut (6 each)
9. Engine adapter
G6AB0208B
Figure 4. Engine to transmission alignment [D]
71-01-01
Rev. 2 Page 11
E-AB412-PT6T-2
7. Transmission end horizontal alignment check. Take indicator readings in the horizontal plane (3 and 9 o'clock
positions) as follows:
a. With adapter (2) still positioned with 12 o'clock mark at 12 o'clock position, rotate the support assembly (4) and
zero the indicator at 3 o'clock mark.
b. While holding support assembly (4) stationary with indicator at 3 o'clock position, rotate transmission input quill
adapter (1) until 9 o'clock mark on adapter is in 3 o'clock position. Record indicator reading as 9 o'clock
transmission adapter runout and note whether reading is positive (+) or negative (–).
c. Return 3 o'clock mark on adapter to 3 o'clock position. Rezero indicator, if required.
d. With indicator zeroed at 3 o'clock position and holding input quill adapter stationary rotate support assembly (4)
until indicator probe is at 9 o'clock position. Record indicator reading as 9 o'clock transmission alignment, noting
whether reading is positive (+) or negative (–).
8. Remove and reinstall alignment tool for engine end alignment check.
a. Remove dial indicator from support tube. Disengage and remove support tube by compressing engine end of
tube and lifting out transmission end from transmission end adapter.
b. Reinstall support assembly (4) with indicator end at engine end adapter. Insert tooling ball of adjustable end of
support assembly (4) in pivot hole in transmission end adapter (2). Push forward against transmission end
adapter to compress plunger mechanism in support assembly (4) and insert tooling ball at opposite end in engine
and adapter pivot hole.
NOTE
Rotating engine end adapter counterclockwise (as viewed looking aft) requires less
effort than rotating it clockwise. Free wheeling clutches within engine combining
gearbox disengage much of the gearbox drive train as well as engine output shafts
when adapter is rotated counterclockwise.
c. Rotate engine end adapter counterclockwise so that 12 o'clock mark on adapter is at 12 o'clock position.
d. Install dial indicator on support assembly (4). Position indicator so that indicator is about mid range of its travel
and tighten thumb screw.
9. Take indicator readings at engine end.
10. Engine end vertical alignment check. Take indicator readings in the vertical plane (12 and 6 o'clock positions) as follows:
a. Zero indicator at 12 o'clock position on engine end adapter (2, figure 4) by rotating indicator bezel. Lock bezel
in place.
b. While holding support assembly (4) stationary with indicator at 12 o'clock position, rotate engine adapter
counterclockwise until 6 o'clock mark on adapter is in 12 o'clock position. Record indicator reading as 6 o'clock
engine adapter runout and note whether reading is positive (+) or negative (–).
c. Rotate adapter (5) to return 12 o'clock mark on adapter to the 12 o'clock position. Rezero the indicator if
required.
d. With indicator zeroed at 12 o'clock position and holding engine shaft adapter (9) stationary, rotate support
assembly (4) until indicator probe is at 6 o'clock position. Record indicator reading as 6 o'clock engine
alignment, noting whether reading is positive (+) or negative (–).
11. Engine end horizontal alignment check. Take indicator readings in the horizontal plane (3 and 9 o'clock positions) as
follows:
a. With adapter still positioned with 12 o'clock mark at 12 o'clock position, rotate support assembly (4) and zero
indicator at 3 o'clock mark.
71-01-01
Page 12 Rev. 2
E-AB412-PT6T-2
b. While holding support assembly (4) stationary with indicator at 3 o'clock position, rotate engine shaft adapter
(5) counterclockwise until 9 o'clock mark on adapter is in 3 o'clock position. Record indicator reading as 9
o'clock engine adapter runout and note whether reading is positive (+) or negative (–).
c. Return the 3 o'clock mark on adapter (5) to the 3 o'clock position. Rezero indicator if required.
d. With indicator zeroed at 3 o'clock position and holding engine adapter (2) stationary, rotate the support assembly
(4) until indicator probe is at 9 o'clock position. Record indicator reading as 9 o'clock engine alignment, noting
whether reading is positive (+) or negative (–).
12. Adjust indicator readings. All indicator readings required to properly evaluate magnitude of any misalignment
between transmission and engine assembly are now available.
Indicator readings for transmission and engine misalignment measured in steps 6.e, 7.d, 8.d and 11.d must be adjusted
to cancel a portion of misalignment readings caused by transmission and engine adapter runouts.
NOTE
In adjusting the various indicator readings, it is very important that algebraic signs of
runout and misalignment readings be included.
Adjust measured alignment indicators by subtracting algebraically the
corresponding adapter runout readings.
13. Vertical alignment. If engine is within acceptable alignment with transmission in the vertical plane, adjusted 6 o'clock
indicator readings should be within (+) or (–) 0.012 in (0.3048 mm) at transmission end and within (+) or (–) 0.040 in
(1.0160 mm) at the engine end.
a. Example (see figure 5).
(1) Suppose the 6 o'clock transmission alignment measured in step 6.e. is (–) 0.015 in (0.3810 mm) and the 6
o'clock adapter runout measured in step 6.c. is (+) 0.002 in (0.0050 mm):
TRANSMISSION (–) 0.015 in (0.3810 mm).

ALIGNMENT
ADAPTER RUNOUT – (+) 0.002 in (0.0508 mm).
(–) 0.017 in (0.4318 mm).
(2) The magnitude of adjusted 6 o'clock transmission alignment reading in the vertical plane is (–) 0.017 in
(0.4318 mm).
b. Example (see figure 6).
(1) Suppose the 6 o'clock transmission alignment measured in step 6.e. is (+) 0.022 in (0.5588 mm) and the 6
o'clock adapter runout measured in step 6.c. is (–) 0.003 in (0.0762 mm):
TRANSMISSION (+) 0.022 in (0.5588 mm).

ALIGNMENT
ADAPTER RUNOUT – (–) 0.003 in (0.0762 mm).
(+) 0.025 in (0.6350 mm).
(2) Now, (+) 0.025 in (0.6350 mm) is the magnitude of adjusted 6 o'clock transmission alignment reading in
the vertical plane.
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E-AB412-PT6T-2
G6AB0209A
Figure 5. Engine high
G6AB0210A
Figure 6. Engine low
71-01-01
Page 14 Rev. 2
E-AB412-PT6T-2
14. Horizontal alignment. If engine is within acceptable alignment with transmission in horizontal plane adjusted 9 o'clock
indicator readings should be between (+) 0.005 in (0.1270 mm) and (+) 0.035 in (0.8890 mm) at the transmission end
and between (+) 0.044 in (1.1176 mm) and (–) 0.032 in (0.8128 mm) at the engine end.
The readings for acceptable alignment in horizontal plane will not be evenly disposed about zero as in vertical plane
because transmission assembly is rotated slightly to the right to compensate for torsional wind up.
a. Example (see figure 7 and figure 8).
(1) Suppose the 9 o'clock engine alignment measured in step 11.b. is (+) 0.120 in (0.3048 mm) and the runout
measured in step 11.b. is (–) 0.0015 in (0.0387 mm):
ENGINE (+) 0.120 in (0.3048 mm)

ALIGNMENT
ADAPTER RUNOUT – (–) 0.0015 in (0.038 mm)
(+) 0.0135 in (0.3429 mm)
(2) Now, (+) 0.0135 in (0.3429 mm) is the magnitude of adjusted 9 o'clock engine alignment reading in the
horizontal plane.
b. Example (see figure 9).
(1) Suppose the 9 o'clock transmission alignment measured in step 7.d. is (–) 0.002 in (0.00508 mm) and the
adapter runout measured in step 7.b. is (+) 0.005 in (0.01270 mm):
TRANSMISSION (–) 0.002 in (0.05 mm).

ALIGNMENT
ADAPTER RUNOUT – (+) 0.005 in (0.13 mm).
(–) 0.007 in (0.18 mm).
(2) Now, (–) 0.007 in (0.18 mm) is the magnitude of adjusted 9 o'clock transmission alignment reading in the
horizontal plane.
G6AB0211A
Figure 7. Engine yawed left
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E-AB412-PT6T-2
G6AB0212A
Figure 8. Engine offset left
G6AB0213A
Figure 9. Engine offset slightly right
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Page 16 Rev. 2
E-AB412-PT6T-2
15. Adjust alignment. Review adjusted alignment readings at transmission and engine end together using table 1 and
table 2 to determine which engine situation is causing misalignment. Refer to table 3 to estimate shim changes required
to correct vertical and horizontal misalignment.
a. Adjust alignment by adding or removing laminated shims beneath engine deck fittings. Shim changes at mount
locations shown in table 3 will move pivot hole in engine adapter the indicated amount and result in the tabulated
change in indicator reading. All shim changes in table 3 are shown in 0.010 in (0.2540 mm) increments. Shim
removal will result in motions exactly opposite in direction but identical in magnitude.
b. Recheck vertical and horizontal alignment after any shim change.
c. After alignment is complete, remove alignment tool, transmission jacks, hoist, and clevis.
d. Install thin steel washer (8, figure 3) and nut (7) on lower lift link bolt (9). Torque nut 108 to 125 foot-pounds
(146 to 169 Nm) and secure with cotter pin (6).
e. Install four pylon isolation mount bolts (1) and washers (2 and 3).
f. Torque four pylon isolation mount bolts (1) 90 to 105 foot-pounds (122 to 142 Nm).
16. Install main driveshaft (Chapter 63).
Table 1. Situation matrix, vertical plane
CONDITION VISUALIZATION SITUATION
ADJUSTED 6 O’CLOCK LOOKING INBOARD

INDICATOR READING L/H SIDE
TRANSMISSION ENGINE
END END
OUT OF WITHIN ENGINE IS LOW AND

TOLERANCE (+) LIMITS POSSIBLY PITCHED
NOSE-UP
OUT OF WITHIN ENGINE IS HIGH AND

TOLERANCE (–) LIMITS POSSIBLY PITCHED
NOSE-DOWN
OUT OF OUT OF ENGINE IS LOW AND

TOLERANCE (+) TOLERANCE PITCHED NOSE-UP
(+)
OUT OF OUT OF ENGINE IS LOW AND

TOLERANCE (+) TOLERANCE POSSIBLY PITCHED
(–) NOSE-DOWN
OUT OF OUT OF ENGINE IS HIGH AND

TOLERANCE (–) TOLERANCE POSSIBLY PITCHED
(+) NOSE-UP
OUT OF OUT OF ENGINE IS HIGH AND

TOLERANCE (–) TOLERANCE PITCHED
(–) NOSE-DOWN
71-01-01
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E-AB412-PT6T-2
(Cont.d)
ADJUSTED 6 O’CLOCK LOOKING INBOARD

INDICATOR READING L/H SIDE
TRANSMISSION ENGINE
END END
WITHIN LIMITS OUT OF ENGINE IS PITCHED

TOLERANCE NOSE-UP AND POSSI-
(+) BLY IS LOW
WITHIN LIMITS OUT OF ENGINE IS PITCHED

TOLERANCE NOSE-DOWN AND
(–) POSSIBLY IS HIGH
Table 2. Situation matrix, horizontal plane
ADJUSTED 9 O’CLOCK LOOKING DOWN

INDICATOR READING fACING INBOARD
FROM L/H SIDE
TRANSMISSION ENGINE
END END
GREATER THAN WITHIN ENGINE IS TRANS-

(+) .035 IN (0.8890 mm) LIMITS LATED LEFT AND
YAWED RIGHT
LESS THAN WITHIN ENGINE IS TRANS-

(+) .005 IN (0.1270 mm) LIMITS LATED RIGHT AND
YAWED LEFT
OR (–)
GREATER THAN OUT OF ENGINE IS TRANS-

(+) .035 IN (0.8890 mm) TOLERANCE LATED LEFT OR
YAWED LEFT OR
(+)
BOTH
GREATER THAN OUT OF ENGINE IS TRANS-

(+) .035 IN (0.8890 mm) TOLERANCE LATED LEFT AND
YAWED RIGHT
(–)
LESS THAN OUT OF ENGINE IS TRANS-

(+) .005 IN (0.1270 mm) TOLERANCE LATED RIGHT AND
YAWED LEFT
OR (–) (+)
71-01-01
Page 18 Rev. 2
E-AB412-PT6T-2
(Cont.d)
ADJUSTED 9 O’CLOCK LOOKING DOWN

INDICATOR READING fACING INBOARD
FROM L/H SIDE
TRANSMISSION ENGINE
END END
LESS THAN OUT OF ENGINE IS TRANS-

(+) .005 IN (0.1270 mm) TOLERANCE LATED RIGHT OR
YAWED RIGHT OR
OR (–) (–)
BOTH
WITHIN LIMITS OUT OF ENGINE IS YAWED

TOLERANCE LEFT AND POSSI-
BLY TRANSLATED
(+)
RIGHT
WITHIN LIMITS OUT OF ENGINE IS YAWED

TOLERANCE RIGHT AND POSSI-
BLY TRANSLATED
(–)
LEFT
Table 3. Situation matrix
CHANGE IN INDICA- ADJUSTED READING

TOR
MOUNT MOVEMENT OF PIVOT

LOCATION HOLE IN ENGINE END 3 4
ADAPTER REF 6 o'clock 9 o'clock
Fwd monopod UP 0.0023 (0.05842 mm) XMSN END -0.0002 in (0.00508 mm) 0
mounts
AFT 0.0033 (0.08382 mm) ENG END +0.0014 in (0.03556 mm) 0
Fwd leg, UP 0.0015 (0.03810 mm) XMSN END -0.0001 in (0.00254 mm) -0.0002 in (0.00508 mm)
bipod mount
AFT 0.0058 (0.14732 mm) ENG END +0.0001 in (0.00254 mm) -0.0028 in (0.07112 mm)
RT 0.0023 (0.05842 mm)
Aft leg, bipod UP 0.0035 (0.08890 mm) XMSN END -0.0004 in (0.01016 mm) +0.0008 in (0.002032 mm)
mount
FWD 0.0058 (0.14732 mm) ENG END +0.0004 in (0.01016 mm) +0.003 in (0.00762 mm)
LFT 0.0078 (0.19812 mm)
Fwd leg, tri- UP 0.0015 (0.03810 mm) XMSN END -0.0001 in (0.00254 mm) +0.0002 in (0.00508 mm)
pod
AFT 0.0058 (0.14732 mm) ENG END +0.0001 in (0.00254 mm) +0.0026 in (0.06604 mm)
LFT 0.0023 (0.05842 mm)
71-01-01
Rev. 2 Page 19
E-AB412-PT6T-2
(Cont.d)
CHANGE IN INDICA- ADJUSTED READING
TOR
MOUNT MOVEMENT OF PIVOT

LOCATION HOLE IN ENGINE END 3 4
ADAPTER REF 6 o'clock 9 o'clock
Aft, inbrd leg, UP 0.0003 (0.00762 mm) XMSN END 0 +0.0012 in (0.03048 mm)
tripod mount
LFT 0.0103 (0.261762 mm) ENG END 0 +0.0012 in (0.03048 mm)
Aft, outbrd UP 0.0025 (0.06350 mm) XMSN END -0.0004 in (0.01016 mm) -0.0018 in (0.04572 mm)
leg, tripod
mount
FWD 0.0061 (0.15494 mm) ENG END +0.0004 in (0.01016 mm) -0.0044 in (0.11176 mm)
RT 0.0169 (0.42926 mm)
All UP 0.0100 (0.2540 mm) XMSN END -0.0012 in (0.03048 mm) 0
ENG END +0.0012 in (0.03048 mm) 0
NOTES:
1. Small pitch alignment errors may be cancelled by relevelling transmission within limits. The transmission may not be repositioned
again to meet vertical alignment requirements.
2. The maximum amount of shim allowed under any fitting is 0.188 in (4.775 mm). If more shim is required, fabricate a plate of
2024-T4 aluminum alloy 0.100 in (2.540 mm) thick, same outside dimensions as shim stock. Seal the faying surfaces of the plate
and engine deck with sealant (C-559). Total thickness of shim and plate under any engine mount fitting must not exceed 0.288 in
(7.320 mm).
3 Indicator is assumed to be zeroed at 12 o'clock.
4 Indicator is assumed to be zeroed at 3 o'clock.
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E-AB412-PT6T-2
71-01-02
POWER PLANT - COMPRESSOR WASH
1. COMPRESSOR WASH - DESCRIPTION
CAUTION
CONNECT ENGINE MANIFOLD FUEL DRAIN HOSES AFTER FIRST

DRYING RUN.
PLACE A SUITABLE CONTAINER BENEATH MANIFOLD VALVE ON EACH

POWER SECTION TO CONTAIN FUEL WHICH WILL BE DUMPED UPON
ENGINE STARTUP OR SHUTDOWN DURING DRYING RUN.
There are two types of compressor wash procedures for cleaning compressor section; desalination wash (to remove salt
deposits) and performance recovery wash (removal of dirt and other deposits). Connections for compressor wash are located
in upper forward induction baffles (figure 1). Refer to Pratt and Whitney Aircraft of Canada PT6T-3 Series engine
maintenance manual for compressor wash.
CAUTION
HELICOPTERS CODE [D], AND ANY MODEL 412 MODIFIED TO RETURN

DUMPED FUEL BACK TO FUEL CELLS, REQUIRES DISCONNECTION OF
FUEL MANIFOLD DRAIN HOSES FROM MANIFOLD VALVE ON EACH
POWER SECTION WHEN ACCOMPLISHING AN ENGINE COMPRESSOR
WASH OR MOTORING WASH.
2. COMPRESSOR WASH - TROUBLESHOOTING
Refer to Pratt and Whitney Aircraft of Canada PT6T-3 Series engine maintenance manual for troubleshooting procedures.
3. COMPRESSOR WASH - OPERATIONAL CHECK
CAUTION
AFTER POWER PLANT CHANGE AND/OR DISCONNECTING ENGINE OIL

INLET HOSE, PRIME OIL PUMP PRIOR TO ENGINE START.
1. Prior to engine starting, motor engine (E-AB412-PT6T-1) until oil pressure is indicated. If an indication of oil pressure
is not indicated in 30 seconds, cease starter operation and determine cause.
2. Perform engine check run (E-AB412-PT6T-1). Refer to Pratt and Whitney Aircraft of Canada PT6T-3 Series engine
maintenance manual.
71-01-02
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E-AB412-PT6T-2
G6AB0214A
Figure 1. Compressor wash fitting
71-01-02
Page 2
E-AB412-PT6T-2
71-02-01
ENGINE ASSEMBLY
1. ENGINE ASSEMBLY - DESCRIPTION
The engine assembly consists of a PT6T-3B or PT6T-3D engine and adapting parts to connect engine to related systems and
helicopter airframe.
The PT6T-3 Series engine consists of two identical, free-turbine, twinned-turboshaft power sections driving a single output
shaft through identical gear trains in a common reduction (combining) gearbox.
NOTE
Refer to Pratt and Whitney Aircraft of Canada, Ltd., PT6T-3 Series engine
maintenance manual for engine maintenance data.
2. ENGINE ASSEMBLY - REMOVAL
MATERIALS REQUIRED
NUMBER NOMENCLATURE
C-405 LOCKWIRE
C-308 ADHESIVE
NUMBER NOMENCLATURE
T7 ENGINE SLING
2. Open forward transmission fairing.
3. Remove left and right engine air inlet cowling (module 71-11-03 paragraph "1. Engine cowling - removal").
4. Remove left and right engine lower cowling (module 71-11-03 paragraph "1. Engine cowling - removal").
5. Remove left and right engine upper cowl.
6. Remove left and right twin gearbox cowl.
7. Remove ejector on each side of engine (module 71-61-01 paragraph "2-1. Ejectors - removal").
NOTE
Center section of aft firewall will be removed with engine.
71-02-01
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E-AB412-PT6T-2
8. Remove upper aft firewall (module 71-31-04 paragraph "1. Aft firewall assembly - removal"). Remove screws to
detach center section of aft firewall from lower section and from flange of centerline firewall.
9. Remove main driveshaft and adapter (Chapter 63).
10. Remove upper web (trough) of centerline firewall (module 71-31-03).
11. Remove air management system, valve assembly and transition duct from each side of engine (module 71-61-02
paragraph "1. Transition ducts - removal" and module 71-61-03 paragraph "1. Valve assembly - removal").
12. Remove induction baffle from each side of engine (module 71-61-05 paragraph "1. Induction baffles - removal").
13. Remove upper section of middle firewall from each side of engine (module 71-31-02 paragraph "1. Middle firewall
assembly - removal").
CAUTION
DO NOT DEFLECT FIREWALL OR INDUCTION BAFFLE MORE THAN

NECESSARY TO EFFECT REMOVAL.
14. Deflect left and right inboard ears of lower middle firewall and induction baffle forward, to allow engine removal
clearance, and secure with lockwire (C-405).
15. Remove bulged access doors from aft cabin bulkhead at each side of pylon support.
16. Place suitable container under oil drain line and open valves (9 and 10, figure 1) and valve on deck aft of reduction
(combining) gearbox. Close valves (9 and 10).
17. Place suitable container under drain line and open valves (6 and 13) to drain fuel filters. Close valves (6 and 13).
18. Remove nuts and washers from tachometer generators and remove bonding straps (1 and 2).
19. Disconnect hoses (3, 4, 5, 7, 8, 11, 12, 14, 15, and 16).
20. Disconnect the following items at left side of engine, disconnect the same items at right side of engine unless otherwise
noted.
a. Disconnect the bleed air tube (38, figure 1) from the adapter (34) and the bleed air tube assembly (23).
b. On left side only, remove the clamp (24) with attaching hardware.
c. Remove the bleed air tube (38).
d. If necessary, remove the bleed air tube connector assembly (23) and the gasket (41).
(1) Remove and discard the lockwire from the bolts (39).
(2) Remove the bolts (39) and the washers (40).
(3) Remove the bleed air tube connector assembly (23) and the gasket (41).
(4) Put protective caps on all open ends.
e. Loosen screws (25) and slide oil cooler blower boot (26) aft from oil cooler blower.
f. On left side of engine only, remove cotter pin (31), nut (18), washer (19), and bolt (21); separate link (22) from
lever (20).
g. Disconnect hoses (35 and 36 or 37).
71-02-01
Page 2
E-AB412-PT6T-2
NOTE
On right side of engine, a control tube is installed instead of link (22).
h. Remove coter pin (17), nut (18), washer (19), and bolt (21); separate link (22) from lever (20).
21. At rear of engine, disconnect hoses (38, 39, 46, 47, 48, 49, 50, 51, and 52, figure 1).
22. Disconnect electrical connections at front of engine (figure 2).
a. Disconnect electrical leads (9) from solenoid (7). Remove clamps (8 and 10) with attaching hardware.
b. Disconnect electrical connector (12) from transmitter (11).
c. Disconnect cable (13).
d. Disconnect electrical leads (14), remove clamp (16).
e. Disconnect cable (1).
f. Disconnect electrical connector (2) from transmitter (3). Remove clamp (4) with attaching hardware.
g. Disconnect electrical leads (6) from solenoid (5).
23. Disconnect electrical connectors at left side of engine (figure 2).
a. Disconnect starter generator cable (28). Remove clamp (29) with attaching hardware.
b. Disconnect electrical connectors (21, 23 and 24).
c. Disconnect electrical connector (19). Remove clamp (20).
WARNING

EXCITER END FIRST. USE INSULATED TOOLS TO REMOVE CABLE
COUPLING NUTS. DO NOT TOUCH EXCITER OUTPUT CONNECTORS OR
CABLE COUPLING NUTS WITH BARE HANDS.
d. Disconnect electrical connector (27). Remove screws, washers, and nuts (25). Secure exciter (26) to engine with
tape or equivalent.
71-02-01
Page 3
E-AB412-PT6T-2
G6AB0215A
Figure 1. Engine installation connections (sheet 1 of 4)
71-02-01
Page 4
E-AB412-PT6T-2
G6AB0216A
71-02-01
Page 5
E-AB412-PT6T-2
G6AB0217A
71-02-01
Page 6
E-AB412-PT6T-2
G6AB0218A
71-02-01
Page 7
E-AB412-PT6T-2
G6AB0219A
Figure 2. Engine electrical connections (sheet 1 of 4)
71-02-01
Page 8
E-AB412-PT6T-2
G6AB0220A
71-02-01
Page 9
E-AB412-PT6T-2
Tachometer generator
G6AB0221A
71-02-01
Page 10
E-AB412-PT6T-2
G6AB0222A
71-02-01
Page 11
E-AB412-PT6T-2
24. Disconnect electrical connectors at right side of engine (figure 2, sheet 3).
a. Disconnect starter generator cable (33). Remove clamp (32) with attaching hardware.
b. Disconnect fire detector connectors (34).
WARNING

EXCITER END FIRST. USE INSULATED TOOLS TO REMOVE CABLE
COUPLING NUTS. DO NOT TOUCH EXCITER OUTPUT CONNECTORS OR
CABLE COUPLING NUTS WITH BARE HANDS.
c. Disconnect electrical connector (37). Remove screws, washers, and nuts (35). Secure exciter (36) to engine with
tape or equivalent.
d. Disconnect electrical connectors (38, 39, and 41).
25. Inspect engine area. Ensure all hoses, electrical connectors, and controls are disconnected from engine.
26. Install engine sling (figure 3) (T7).
CAUTION
LIFTING CAPACITY OF HOIST SHALL BE 2,000 POUNDS (908 KG) OR

GREATER.
27. Attach hoist (minimum 2000 pounds (908 kg) capacity) to sling and take up slack in sling cables without placing load
on engine mount bolts.
28. Disconnect engine mounts as follows (figure 4).
a. Remove cotter pin (24), nut (25), washer (26), and bolt (27) attaching bipod (23) or tripod (28) to bearing (2 or 3).
b. Remove cotter pin (11), nut (12), washers (13 and 15), and bolt (16). Separate tube (10) from bellcrank (14).
c. Remove cotter pin (21), nut (20), washers (19 and 18), and bolt (17).
29. Lift engine assembly clear of helicopter.
30. Remove cotter pin (9), nut (8), washers (7 and 6), bolt (5), and tube (10) from fitting (1).
31. Remove center section of aft firewall between power sections (module 71-31-04 paragraph "1. Aft firewall assembly
- removal").
32. Install engine assembly in suitable stand and remove hoist.
NOTE
Refer to E-AB412-PT6T-3 manual for build-up of replacement engine.
71-02-01
Page 12
E-AB412-PT6T-2
3. ENGINE ASSEMBLY - INSTALLATION
MATERIALS REQUIRED
NUMBER NOMENCLATURE
C-021 SOLID FILM LUBRICANT
C-405 LOCKWIRE
1. Install engine sling (T7) (See sheet 2 of figure 3 for cable usage and engine attachment points).
2. Position center section of aft firewall between power sections (module 71-21-08 paragraph "2. Aft right mount bipod
deck fittings - installation").
CAUTION

GREATER.
3. Attach hoist to sling and remove engine from stand.
4. Connect tube (10, figure 4) to fitting (1) with bolt (5), washers (6 and 7), nut (8), and cotter pin (9).
5. Lower engine carefully into place, checking position as follows:
a. Bearings (2 and 3) aligns with bipod (23) and tripod (28).
b. Tube (22) aligns with fitting (4) and tube (10) aligns with bellcrank (14).
c. Forward engine fireshield is aft of lower induction baffle (module 71-21-08 paragraph "2. Aft right mount bipod
deck fittings - installation").
d. Middle engine fireshield is aft of lower middle firewall.
e. Aft engine fireshield is forward of lower aft firewall.
6. Install bolt (27), washer (26), nut (25), and cotter pin (24) to connect bipod (23) and tripod (28) to bearings (2 and 3).
9. Remove hoist and sling.
10. Connect electrical components at right side of engine (figure 2, sheet 3).
a. Connect electrical connectors (38, 39 and 41).
b. Position exciter (36) on firewall flange, install screws, washers, and nuts (35). Connect electrical connector (37).
c. Connect fire detector connectors (34).
d. Connect starter generator cable (33). Install clamp (32) using screw spacer, washer, and nut (31).
71-02-01
Page 13
E-AB412-PT6T-2
G6AB0223A
Figure 3. Tool application - engine sling (SWE-13833) (sheet 1 of 2)
71-02-01
Page 14
E-AB412-PT6T-2
G6AB0224A
71-02-01
Page 15
E-AB412-PT6T-2
G6AB0225A
Figure 4. Engine mount connections
71-02-01
Page 16
E-AB412-PT6T-2
11. Connect electrical components at left side of engine (figure 2, sheet 2).
a. Connect electrical connectors (21, 23 and 24).
b. Connect electrical connector (19). Install clamp (20) using existing hardware.
c. Position exciter (26) on firewall flange. Install screws, washers, and nuts (25). Connect electrical connector (27).
d. Connect starter generator cable (28). Install clamp (29) using screw, spacer, washer, and nut (30).
12. Connect electrical components at front of engine (figure 2, sheet 1).
a. Connect electrical leads (9). Install clamps (8 and 10) with screw, washer, and nut.
b. Connect electrical connectors (12 and 13).
c. Connect electrical leads (14). Install clamp (16) using existing hardware.
d. Connect electrical leads (6). Install clamp (4) with screw, washer, and nut.
e. Connect electrical connector (2) and cable (1).
13. Connect the following items at left side of engine, connect same items at right side of engine unless otherwise noted
(figure 1).
a. If removed, install the bleed air tube connector assembly (23, figure 1) as follows:
(1) Remove the protective caps from all open ends.
(2) Put the gasket (41) and the bleed air tube connector assembly (23) in the correct position.
(3) Install the washers (40) and the bolts (39).
(4) Torque the bolts (39).
b. Install lockwire (C-405) on the bolts (39).
c. Apply solid film lubricant (C-021) to the threads of bleed air tube connector assembly (23) and the nut (42).
d. Make sure that the orifice is in the correct position in the nut (42).
e. Connect the bleed air tube (38) to the bleed air tube connector assembly (23) and the adapter (34).
f. On the left side only, install the clamp (24) with attaching hardware.
g. Connect the electrical connector (19, figure 1).
h. Position oil cooler blower boot (26, figure 1) around oil cooler blower. Tighten screw (25) to secure boot.
i. On left side of engine only, connect actuator (30) to jackshaft (27) using bolt (29), washers (28 and 33), nut (32),
j. Connect hoses (35 and 36 or 37).
NOTE
On right side of engine, a control tube is installed instead of link (22).
k. Connect link (22) to lever (20) using bolt (21), washer (19), nut (18), and cotter pin (17).
14. At rear of engine, connect hoses (38, 39, 46, 47, 48, 49, 50, 51, and 52) shown on sheet 3 of figure 1.
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E-AB412-PT6T-2
15. Connect the following items at front of engine (figure 1, sheet 1).
a. Connect hoses (3, 4, 5, 7, 8, 11, 12, 14, 15, and 16).
b. Remove nuts and washers from tachometer generator where bonding straps (1 and 2) mount. Clean area, if
necessary, to ensure a good electrical ground. Install bonding straps (1 and 2), washers, and nuts.
16. Install upper section of middle firewall and induction baffle (module 71-21-04 paragraph "2. Aft left mount tripod -
installation") on each side of engine.
17. Install air management system valve assembly and transition duct (module 71-61-03 paragraph "2. Valve assembly -
installation" and module 71-61-02 paragraph "2. Transition ducts - installation") on each side of engine.
18. Install upper web (trough) of centerline firewall (module 71-31-03 paragraph "2. Centerline firewall assembly -
installation").
19. Install main driveshaft adapter and main driveshaft (Chapter 63).
20. Install upper aft firewall (module 71-31-04 paragraph "2. Aft firewall assembly - installation").
21. Install ejector on each side of engine (module 71-61-01 paragraph "2-2. Ejectors - installation").
22. Install left and right twin gearbox cowl.
23. Service engine and reduction gearbox (Chapter 12).
24. Install left and right engine top cowl.
25. Install left and right engine lower cowling.
26. Install left and right engine air inlet cowling (module 71-11-03 paragraph "2. Engine cowling - installation").
27. Perform T5 resistance check on each power section (Chapter 76).
28. Prime power plant lubrication system (module 71-01-01 paragraph "2. Power plant maintenance - priming - power
plant lubrication system").
29. Pre-oil reduction gearbox (module 71-01-01 paragraph "3. Power plant maintenance - pre-oil - reduction (combining)
gearbox").
30. Perform wet motoring run (module 71-01-01 paragraph "5. Power plant maintenance - wet motoring run - power
plant").
31. Prime power plant fuel system (module 71-01-01 paragraph "4. Power plant maintenance - priming - power plant fuel
system").
32. Rig power lever controls (Chapter 76).
33. Rig droop compensator controls (Chapter 76).
34. Check torque limiter adjustment (Chapter 76).
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E-AB412-PT6T-2
71-02-02
ENGINE ASSEMBLY - ENGINE POWER SECTION
1. ENGINE POWER SECTION - REMOVAL
NOTE
Either left or right power section may be removed and installed by procedures
outlined below, with opposite power section and reduction (combining) gearbox
remaining in place.
NUMBER NOMENCLATURE
T7 ENGINE SLING
1. Perform steps 1. through 24. of module 71-02-01 paragraph "2. Engine assembly - removal" as applicable for power
section being removed.
2. Install engine sling (T7) (see sheet 2 of figure 1 for cable usage and power section attachment points).
CAUTION

GREATER.
3. Attach hoist (minimum 2000 pounds (908 kg) capacity) to sling and take up slack without placing load on engine
mount bolts.
4. Disconnect engine mount from applicable power section (module 71-02-01 paragraph "2. Engine assembly - removal",
step 28.).
5. Disconnect power section from engine. Refer to Pratt and Whitney Aircraft of Canada PT6T-3 Series maintenance
manual.
6. Inspect power section to ensure all connections are separated from engine and helicopter airframe.
7. Move power section approximately 1,0 in. (25,4 mm) forward until clear of reduction (combining) gearbox.
8. Lift power section vertically until clear of helicopter. Watch all sides to ensure adequate clearance.
9. Place power section on suitable stand. Disconnect hoist and sling.
10. Cover openings on power section and gearbox.
71-02-02
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G6AB0223A
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G6AB0224A
71-02-02
Page 3
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2. ENGINE POWER SECTION - INSTALLATION
NOTE
Either left or right power section of engine assembly can be installed by procedures
outlined below, with opposite power section and reduction gearbox remaining in
place.
1. Install engine sling (T7) (see sheet 2 of figure 1 for cable usage and power section attachment points).
CAUTION

GREATER.
2. Attach hoist to engine sling and move power section near helicopter.
3. If installing right power section, attach forward engine mount tube to accessory gearbox mount fitting (module
71-02-01 paragraph "3. Engine assembly - installation", step 4.).
4. Ensure new seals are installed on mating flange and oil tubes on rear end of power section. Lubricate seals with engine
oil (Chapter 12).
5. Install power section in helicopter.
a. Position power section above engine compartment and lower until 6,0 in. (150 mm) clearance remains above
firewalls.
b. Route electrical connector and wire connected at lower left and right corner of aft fire shield, through space
below reduction (combining) gearbox.
c. Push middle panel of lower mid firewall at least 1,4 in. (35,5 mm) forward.
d. Carefully lower power section into position while observing the following.
(1) Ensure seals on mating flange and oil tubes on rear of power section are not damaged.
(2) Position mid-fireshield on power section aft of lower middle firewall.
(3) Ensure seal on air induction baffle is forward of fireshield on power section.
6. Mate power section with reduction gearbox and install retaining nuts and washers. Refer to Pratt and Whitney of
Canada, Ltd. PT6T-3 Series maintenance manual.
7. Connect engine mount (module 71-02-01 paragraph "3. Engine assembly - installation").
8. Remove hoist and sling.
9. Connect all attachments between power section and engine. Refer to Pratt and Whitney of Canada, Ltd. PT6T-3 Series
maintenance manual.
10. Perform steps 10. through 34. of module 71-02-01 paragraph "3. Engine assembly - installation", as applicable for
power section being installed.
71-02-02
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E-AB412-PT6T-2
71-02-03
ENGINE ASSEMBLY - REDUCTION (COMBINING) GEARBOX
1. REDUCTION (COMBINING) GEARBOX - DESCRIPTION
NOTE
The reduction (combining) gearbox can be replaced without removing either power
section.
2. REDUCTION (COMBINING) GEARBOX - REMOVAL
NUMBER NOMENCLATURE
T7 ENGINE SLING
2. Open transmission cowling.
3. Remove air inlet cowling (module 71-11-03 paragraph "1. Engine cowling - removal").
4. Remove engine cowling (module 71-11-03 paragraph "1. Engine cowling - removal").
5. Remove air scoop cowling (module 71-11-05 paragraph "1. Oil cooler airscoop cowling - removal").
6. Remove gearbox cowling (module 71-11-04 paragraph "1. Reduction (combining) gearbox cowling - removal").
7. Remove ejectors (module 71-61-01 paragraph "2-1. Ejectors - removal").
8. Remove upper aft firewall (module 71-31-03 paragraph "1. Aft firewall assembly - removal").
9. Remove main driveshaft and adapter (Chapter 63).
10. Remove upper web (trough) of centerline firewall (module 71-31-02 "ENGINE FIREWALLS - MIDDLE FIREWALL
ASSEMBLY").
11. Drain oil from gearbox.
12. Remove oil cooler blowers (Chapter 79).
13. Disconnect hoses, electrical connectors, and engine controls attaching gearbox to helicopter (same as engine removal
module 71-02-01 paragraph "2. Engine assembly - removal").
14. Remove exhaust ducts, cover openings.
15. Disconnect engine connections between gearbox and power sections. Do not remove nuts and washers around
mounting flange. Refer to Pratt and Whitney Aircraft of Canada, Ltd. PT6T-3 Series maintenance manual.
71-02-03
Page 1
E-AB412-PT6T-2
16. Support power sections using a small hydraulic jack at flange C (exhaust duct to gas generator case) or a suitable sling
and hoist.
17. Install engine sling (T7). Refer to sheet 2 of figure 1 for cable usage and gearbox attachment points).
CAUTION

GREATER.
18. Attach hoist (minimum 2000 pounds (908 kg) capacity) to sling and take up slack without placing load on engine
mount bolts.
19. Remove nuts and washers securing gearbox to power sections.
20. Disconnect engine mounts from gearbox (module 71-02-01 paragraph "2. Engine assembly - removal", step 28).
21. Inspect gearbox to ensure all connections are separated from power sections and helicopter airframe.
22. Support weight of gearbox with hoist. Slide gearbox aft approximately 1,0 in. (25,4 mm) to clear power sections.
23. Lift gearbox vertically until clear of helicopter. Watch all sides to ensure adequate clearance.
24. Place gearbox on suitable stand.
25. Cover openings on power sections and reduction (combining) gearbox.
3. REDUCTION (COMBINING) GEARBOX - INSTALLATION
1. Prepare reduction (combining) gearbox for installation.
a. Transfer parts not provided on replacement gearbox from removed gearbox.
b. Install new packings on mating faces and oil transfer tubes.
2. Install engine sling (T7) (see sheet 2, of figure 1 for cable usage and gearbox attachment points).
CAUTION

GREATER.
3. Attach hoist (minimum 2000 pounds (908 kg) capacity) to engine sling and move gearbox into position aft of power
sections.
4. Mate gearbox with power sections and install retaining nuts and washers. Refer to Pratt and Whitney of Canada, Ltd.
PT6T-3 Series maintenance manual.
5. Connect engine mounts (module 71-02-01 paragraph "3. Engine assembly - installation").
6. Remove jacks or sling used to support power sections. Remove engine sling and hoist from gearbox.
7. Connect all attachments between gearbox and power sections. Install exhaust ducts. Refer to Pratt and Whitney of
Canada, Ltd. PT6T-3 Series maintenance manual.
71-02-03
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G6AB0223A
71-02-03
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G6AB0224A
71-02-03
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8. Connect hoses, electrical connectors and engine controls attaching gearbox to helicopter, the same as for engine
installation (module 71-02-01 paragraph "3. Engine assembly - installation").
9. Install oil cooler blowers (Chapter 79).
10. Install upper web (trough) of centerline firewall (module 71-31-03 paragraph "2. Centerline firewall assembly -
installation").
11. Install main driveshaft adapter and driveshaft (Chapter 63).
12. Install upper aft firewall (module 71-31-04 paragraph "2. Aft firewall assembly - installation").
13. Install ejectors (module 71-61-01 paragraph "2-2. Ejectors - installation").
14. Install combining gearbox cowling (module 71-11-04 paragraph "2. Reduction (combining) gearbox cowling -
installation").
15. Install air scoop cowling (module 71-11-05 paragraph "2. Oil cooler airscoop cowling - installation").
16. Install engine cowling (module 71-11-03 paragraph "2. Engine cowling - installation").
17. Install air inlet cowling (module 71-11-03 paragraph "2. Engine cowling - installation").
18. Close transmission cowlings.
19. Service gearbox (Chapter 12).
20. Pre-oil gearbox (module 71-01-01 paragraph "3. Power plant maintenance - pre-oil - reduction (combining) gearbox").
21. Check torque limiter adjustment (Chapter 76).
71-02-03
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E-AB412-PT6T-2
71-02-03
Page 6
E-AB412-PT6T-2
71-1 -01 COWLING
71-11-01
COWLING
1. COWLING - DESCRIPTION
Cowling is utilized to protect and provide easy access to engine, reduction (combining) gearbox air intake, exhaust ejectors
and top of main transmission.
The forward pylon fairing (1, figure 1) is secured with one latch, seven fasteners, and one hinge assembly. The aft pylon
fairing (2) is secured with six latches and six fasteners. The transmission fairing (3) is secured with 19 fasteners. The engine
air inlet cowlings (4) are secured with three fasteners, one latch and screws. The lower and upper engine cowlings (11 and
12) may be constructed of sheet metal or composite materials. The lower engine cowling (11) is secured by two latches, a
cowl lock, and a brace assembly which serves as the hinge. The upper engine cowling is held open with a hold open brace.
The following cowlings are secured by screws; engine top (5), reduction gearbox (6), oil cooler (7), engine oil cooler support
(8), oil cooler air scoop (9) and reduction gearbox side cowling (10). Reduction (combining) gearbox side cowling (10) has
an inspection door in the front half.
2. COWLING - FORWARD AND AFT TRANSMISSION PYLON FAIRING
2-1. FORWARD AND AFT TRANSMISSION PYLON FAIRING - REMOVAL
1. Remove forward pylon fairing (1, figure 2). Press latch (5) open, unfasten fasteners (6) and hinge open. Remove cotter
pins (9), washers (8), pins (7), and remove fairing (1).
2. Remove aft pylon fairing (2). Press latches (4) open, unfasten fasteners (3) and remove fairing (2).
2-2. FORWARD AND AFT TRANSMISSION PYLON FAIRING - INSTALLATION
1. Position aft pylon fairing in place and secure latches (4) and fasteners (3).
NOTE
Washers may be stacked in any combination required on inboard side of bearings.
2. Position forward pylon fairing in hinged open position. Install hinge with pins (7), washers (8), and cotter pins (9).
Close fairing and secure latch (5) and fasteners (6).
2-3. FORWARD AND AFT TRANSMISSION PYLON FAIRING - INSPECTION AND REPAIR
1. Inspect latches, fittings, fasteners, and hinges for wear, damage, and serviceability.
2. Inspect seals for cracks, tears, deterioration, and security of bonding.
3. Replace latches, fittings, and seals if unserviceable.
4. Inspect fairings for dents, cracks, and damage.
71-11-01
Rev. 1 Page 1
E-AB412-PT6T-2
G6AB0257A
Figure 1. Transmission and engine cowling (sheet 1 of 2)
71-11-01
Page 2 Rev. 1
E-AB412-PT6T-2
DETAIL A 1
1. Forward pylon fairing

2. Aft pylon fairing
3. Transmission fairing
4. Engine air inlet cowling
5. Engine top cowling
6. Reduction gearbox cowling
7. Oil cooler cowling
8. Engine oil cooler support cowling
9. Oil cooler side scoop
10. Reduction gearbox side cowling
11. Lower engine cowling
12. Upper engine cowling
13. Stud panel fastener
14. Washer
15. Receptacle panel fastener
16. Main drive aft inspection door
NOTE:
1 Applicable to S/N 25901 and subsequent and helicopter

modified by SB 412-085.
G6AB0258B
71-11-01
Rev. 1 Page 3
E-AB412-PT6T-2

3. Fastener
4. Latch
5. Latch
6. Fastener
7. Pin
8. Washers
9. Cotter pin
G6AB0259B
Figure 2. Forward and aft transmission pylon fairing
71-11-01
Page 4 Rev. 1
E-AB412-PT6T-2
71-1 -02 COWLING - TRANSMISSION FAIRING AND ENGINE AIR INLET COWLING
71-11-02
COWLING - TRANSMISSION FAIRING AND ENGINE AIR INLET COWLING
1. TRANSMISSION FAIRING AND ENGINE AIR INLET COWLING - REMOVAL
1. Remove forward and aft transmission pylon fairings (module 71-11-01 paragraph "2-1. Forward and aft transmission
pylon fairing - removal").
2. Remove transmission fairing (1, figure 1). Unfasten fasteners (3), remove fairing.
3. Remove the left-hand or right hand engine air inlet cowlings (2). Remove two bolts (5) and washers (6) from the
forward duct (14) and forward transition duct (11). Press cowling latch (8), lift forward end of engine air inlet cowling
to clear dowel pin (10), pull forward and remove cowling.
2. TRANSMISSION FAIRING AND ENGINE AIR INLET COWLING - INSTALLATION
1. Install the left-hand or right-hand engine air inlet cowling (2, figure 1), as applicable, as follows:
a. Put the engine air inlet cowling (2) into position with the forward end raised to clear dowel pin (10). Align and
engage dowel pins (4 and 7), and lower on dowel pin (10).
b. Install two bolts (5) and washers (6) to secure the forward transition duct (11) to forward duct (14).
c. Hook cowling latch (8) to cowling latch fitting (9).
2. Position transmission fairing (1) in place and secure fasteners (3).
3. Install forward and aft transmission pylon fairings (module 71-11-01 paragraph "2-2. Forward and aft transmission
pylon fairing - installation").
3. TRANSMISSION FAIRING AND ENGINE AIR INLET COWLING - INSPECTION AND

REPAIR
1. Inspect latches, cowl locks, fittings, fasteners, and hinges for wear, damage, and serviceability.
2. Inspect seals for cracks, tears, deterioration, and security of bonding.
3. Replace latches, cowl locks, fittings, and seals if unserviceable.
4. Inspect cowling, duct and firewall for dents, cracks, and damage. Repair sheet metal cowlings, ducts and firewalls
using maintenance practices in accordance with FAA Publication AC 43.13.1B, Aircraft Inspection and Repair. For
information on damage limits and repairs to composite cowlings, please contact Product Support Engineering for
assistance.
71-11-02
Rev. 1 Page 1
E-AB412-PT6T-2
3. Fastener
4. Dowel pin
5. Bolt
6. Washer
7. Dowel pin
8. Cowling latch
9. Cowling latch fitting
10. Dowel pin
11. Forward transition duct
12. Bolt
13. Washer
14. Forward duct
G6AB0260B
Figure 1. Transmission fairings and engine air inlet cowling
71-11-02
Page 2 Rev. 1
E-AB412-PT6T-2
71-1 -03 COWLING - ENGINE COWLING
71-11-03
COWLING - ENGINE COWLING
1. ENGINE COWLING - REMOVAL
1. Remove engine lower cowling (11, figure 1) as follows:
a. Disengage two latches (2, figure 2) and cowl lock (18), open engine cowling (1).
b. Pull quick release pin (8) from brace (6) and hinge fitting. Remove cowling.
2. Remove top and upper cowling as follows:
a. Disengage latches on engine upper cowling (12, figure 1).
b. Remove screws securing engine top cowling (5) and remove engine top cowling (5) and upper cowling (12)
together.
3. Refer to module 71-11-02 paragraph "3. Transmission fairing and engine air inlet cowling - inspection and repair" for
inspection and repair.
2. ENGINE COWLING - INSTALLATION
NOTE
A combination of sheet metal and composite engine cowlings may be utilized.
Weight differential between the sheet metal and composite cowlings is considered
negligible.
1. Position cowling (5 and 12, figure 1) on helicopter. Align screw holes and install (but do not tighten) screws. Engage
latches on cowling (12) and tighten screws.
2. Position cowling (11, figure 1), on helicopter. Align brace (6, figure 2) to hinge fitting. Install quick release pin (8),
close cowling and engage two latches (2) and cowl lock (18).
71-11-03
Rev. 1 Page 1
E-AB412-PT6T-2
G6AB0257A
71-11-03
Page 2 Rev. 1
E-AB412-PT6T-2
DETAIL A 1

14. Washer
NOTE:

G6AB0258B
71-11-03
Rev. 1 Page 3
E-AB412-PT6T-2
1. Cowl assembly, engine lower 10. Spacer

2. Latch 11. Bolt
3. Bolt 12. Washer
4. Washer 13. Cotter pin
5. Striker 14. Nut
6. Brace 15. Washer
7. Chain 16. Rod end
8. Quick release pin 17. Washer (7)
9. Spacer 18. Cowl lock
G6AB0261B
Figure 2. Lower engine cowling
71-11-03
Page 4 Rev. 1
E-AB412-PT6T-2
71-1 -04 COWLING - REDUCTION (COMBINING) GEARBOX COWLING
71-11-04
COWLING - REDUCTION (COMBINING) GEARBOX COWLING
1. REDUCTION (COMBINING) GEARBOX COWLING - REMOVAL
1. Remove screws around reduction (combining) gearbox side cowling (10, figure 1) and remove cowling.
2. Remove screws around gearbox top cowling (6) and remove cowling.
3. Remove four screws from oil filler adapter. Disconnect antenna, if installed. Remove screws from ends of center top
cowling, remove cowling.
2. REDUCTION (COMBINING) GEARBOX COWLING - INSTALLATION
1. Position center top cowling on helicopter, install four screws in ends of cowling. If installed, connect rotating light and
radio antenna. Install four screws in center top cowling and oil filler adapter.
2. Position reduction gearbox top cowling (6, figure 1) on helicopter, align screw holes, install and tighten screws.
3. Position reduction (combining) gearbox side cowling (10) on helicopter, align screw holes, install and tighten screws.
3. REDUCTION (COMBINING) GEARBOX COWLING - INSPECTION AND REPAIR
Refer to module 71-11-02 paragraph "3. Transmission fairing and engine air inlet cowling - inspection and repair" for
71-11-04
Rev. 1 Page 1
E-AB412-PT6T-2
G6AB0257A
71-11-04
Page 2 Rev. 1
E-AB412-PT6T-2
DETAIL A 1

14. Washer
NOTE:

G6AB0258B
71-11-04
Rev. 1 Page 3
E-AB412-PT6T-2
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E-AB412-PT6T-2
71-1 -05 COWLING - OIL COOLER AIRSCOOP COWLING
71-11-05
COWLING - OIL COOLER AIRSCOOP COWLING
1. OIL COOLER AIRSCOOP COWLING - REMOVAL
1. Remove oil cooler airscoop cowling (9, figure 1). Disengage latches (7, 8, and 9, figure 2). Install hold open strut.
2. Remove nut (5), screw (3), and washers (4) from hinge fitting (2 and 6). Disengage hold open brace, remove cowling
(1).
2. OIL COOLER AIRSCOOP COWLING - INSTALLATION
1. Position oil cooler airscoop cowling (1, figure 2) on helicopter and install hold open strut. Install three AN960JD10L
washers each side of hinge (2 and 6), to equalize gap at fore and aft ends of oil cooler airscoop cowling (1). Install
screw (3), washers (4), and nuts (5). Tighten nuts.
2. Disengage strut, close oil cooler airscoop cowling (1). Check gap between cowling ends. Engage latches (7, 8, and 9).
3. OIL COOLER AIRSCOOP COWLING - INSPECTION AND REPAIR
Refer to module 71-11-02 paragraph "3. Transmission fairing and engine air inlet cowling - inspection and repair" for
71-11-05
Rev. 1 Page 1
E-AB412-PT6T-2
G6AB0257A
71-11-05
Page 2 Rev. 1
E-AB412-PT6T-2
DETAIL A 1

14. Washer
NOTE:

G6AB0258B
71-11-05
Rev. 1 Page 3
E-AB412-PT6T-2
1. Oil cooler airscoop cowling

2. Hinge fitting
3. Screw
4. Washer
5. Nut
6. Hinge fitting
7. Latch
8. Latch
9. Latch
G6AB0262B
Figure 2. Oil cooler air scoop cowling
71-11-05
Page 4 Rev. 1
E-AB412-PT6T-2
71-21-01
ENGINE MOUNTS
1. ENGINE MOUNT - DESCRIPTION
The accessory gearbox on front end of each power section is supported by vertical steel tubes interconnected through
bellcrank fittings to a horizontal steel tube (figure 1). The bearing rod end at top of each vertical tube is attached to a fitting
on accessory gearbox. The other end is attached to a bellcrank fitting, which is pivoted in a deck fitting with movement
restricted by a bellcrank stop. The reduction (combining) gearbox on aft end of engine is supported by a tripod mount on
left side and by a bipod mount on right side. The tripod and bipod have steel tube legs with bearing rod ends, which attach
to fittings on engine deck. The other end has a fitting, which attaches to bearing fittings on reduction gearbox. Laminated
shims under engine deck fittings are used to align engine to transmission.
2. ENGINE MOUNT - FORWARD MOUNT
2-1. FORWARD MOUNT - REMOVAL
CAUTION

GREATER.
1. If engine mount is to be removed while engine is installed, support engine with hoist and engine sling. Refer to module
71-02-01 for procedure to install sling on engine and gain access to forward engine mount tubes.
2. Remove bolt (5, figure 2). Remove bolt (18). Remove tube (11).
3. Remove tube (23) in same manner outlined in preceding step.
4. Remove bolts (36 and 37). Remove stop (34).
5. Remove stop from fitting (20) in same manner outlined in preceding step.
6. Remove bolt (22). Separate tube (19) from fitting (20).
7. Remove bolt and separate tube (19) from fitting (16) in same manner outlined in preceding step. Remove tube (19).
8. Remove bolt (39). Remove fitting (15) and bushing (24).
9. Remove fitting (20) in same manner outlined in preceding step.
2-2. FORWARD MOUNT - INSTALLATION
1. Install bushing (24, figure 2).
2. Install fitting (15) with bolt (39), washers (40 and 25), nut (26), and cotter pin (27).
71-21-01
Page 1
E-AB412-PT6T-2
3. Repeat steps 1. and 2. above to install fitting (20).
4. Install tube (19) with bolt (22), washers (21 and 4), nut (3), and cotter pin (2).
5. Install opposite end of tube (19) in similar manner.
6. Install stop (34) with bolts (36 and 37), washers (35, 33, 38, and 30), nuts (28 and 32), and cotter pins (29 and 31).
7. Install stop in fitting (20) in same manner outlined in preceding step.
8. Install bolt (18), washers (17 and 14), nut (13), and cotter pin (12) into bottom of tube (11).
9. Install bottom of tube (23) in same manner outlined in preceding step.
10. Install bolt (5), washers (6 and 8), nut (9), and cotter pin (10) into top of tube (11).
11. Install top of tube (23) in same manner outlined in preceding step.
2-3. FORWARD MOUNT - INSPECTION AND REPAIR
CAUTION
IF RECORDS OR PHYSICAL APPEARANCE INDICATE ENGINE MOUNT

HAS BEEN INVOLVED IN AN ACCIDENT OR INCIDENT, REFER TO
E-AB412-PT6T-6 FOR CONDITIONAL INSPECTION REQUIREMENTS.
For inspection and repair procedure, refer to E-AB412-PT6T-3 manual.
71-21-01
Page 2
E-AB412-PT6T-2
G6AB0263A
Figure 1. Engine mounts
71-21-01
Page 3
E-AB412-PT6T-2
G6AB0264A
Figure 2. Forward mount tube
71-21-01
Page 4
E-AB412-PT6T-2
71-21-02
ENGINE MOUNT - FORWARD MOUNT FITTINGS
1. FORWARD MOUNT FITTINGS - REMOVAL
1. Remove tubes (2 and 6, figure 1).
2. Remove bolts (10). Remove fitting (7).
3. Remove fitting (1) in same manner outlined in preceding step.
2. FORWARD MOUNT FITTINGS - INSTALLATION
MATERIALS REQUIRED
NUMBER NOMENCLATURE
C-405 LOCKWIRE
NOTE
Fittings (1 and 7, figure 1) are not interchangeable.
1. Install fitting (7) with three bolts (10) and washers (9). Torque bolts 275 to 300 in.lbs. (31,1 to 33,9 Nm).
2. Lockwire bolts (10) together using lockwire (C-405).
3. Install fitting (1) in same manner outlined in steps 1. and 2.
4. Install tubes (2 and 6) (module 71-21-01 paragraph "2-2. Forward mount - installation").
3. FORWARD MOUNT FITTINGS - INSPECTION AND REPAIR
CAUTION

Inspect and repair forward engine mount fittings (1 and 7, figure 1) in accordance with E-AB412-PT6T-3 manual.
71-21-02
Page 1
E-AB412-PT6T-2
G6AB0265A
Figure 1. Forward mount fitting
71-21-02
Page 2
E-AB412-PT6T-2
71-21-03
ENGINE MOUNT - FORWARD MOUNT DECK FITTINGS
1. FORWARD MOUNT DECK FITTINGS - REMOVAL
CAUTION
WHEN FITTINGS (2 OR 4, FIGURE 1) ARE REMOVED, INDEX SHIM (7) OR

SIMILAR SHIM UNDER FITTING (2), FOR REINSTALLATION IN SAME
LOCATION. IF SHIM IS NOT REINSTALLED IN SAME LOCATION, ENGINE
TO TRANSMISSION ALIGNMENT MAY BE AFFECTED. IF SHIMS ARE
LOST OR DAMAGED, ENGINE TO TRANSMISSION ALIGNMENT CHECK IS
REQUIRED (MODULE 71-01-01 PARAGRAPH "6. Power plant maintenance -
alignment - engine to transmission [A][B][C]").
NOTE
Fittings (2 or 4) should be removed only if required for engine to transmission
alignment, or to replace a damaged fitting.
1. Remove tubes (1, 3, and 5, figure 1).
2. Remove four screws (6). Remove fitting (4) and shim (7). Index shim (7) for reinstallation in same location.
3. Remove fitting (2) and index shim in same manner outlined in preceding step.
2. FORWARD MOUNT DECK FITTINGS - INSTALLATION
CAUTION
SHIM (7, FIGURE 1) AND SIMILAR SHIM UNDER FITTING (2) SHOULD
HAVE BEEN INDEXED FOR REINSTALLATION IN SAME LOCATION WHEN
REMOVED. THE SAME SHIMS REMOVED, OR SHIMS OF IDENTICAL
THICKNESS, SHALL BE INSTALLED. IF SHIMS HAVE BEEN LOST,
DAMAGED, OR MIXED, PERFORM ENGINE TO TRANSMISSION
ALIGNMENT CHECK (MODULE 71-01-01 PARAGRAPH "6. Power plant
maintenance - alignment - engine to transmission [A][B][C]" OR PARAGRAPH "7.
Power plant maintenance - alignment - engine to transmission [D]").
1. Install fitting (4, figure 1) and shim (7) with screws (6).
2. Install fitting (2) in same manner outlined in step 1.
3. Install tubes (1, 3, and 5) (module 71-21-01 paragraph "2-2. Forward mount - installation").
71-21-03
Page 1
E-AB412-PT6T-2
3. FORWARD MOUNT DECK FITTINGS - INSPECTION AND REPAIR
CAUTION
IF RECORDS OR PHYSICAL APPEARANCE INDICATES MOUNT HAS BEEN

INVOLVED IN AN ACCIDENT OR INCIDENT, REFER TO E-AB412-PT6T-6
FOR CONDITIONAL INSPECTION REQUIREMENTS.
For inspection and repair, refer to E-AB412-PT6T-3 manual.
G6AB0266A
Figure 1. Forward mount deck fitting
71-21-03
Page 2
E-AB412-PT6T-2
71-21-04
ENGINE MOUNT - AFT LEFT MOUNT TRIPOD
1. AFT LEFT MOUNT TRIPOD - REMOVAL
CAUTION
LIFTING CAPACITY OF ENGINE HOIST SHALL BE 2,000 LBS (908 KG) OR

GREATER.
1. If the engine mount tripod is to be removed while engine is installed, support engine with hoist and engine sling
(module 71-02-01 paragraph "2. Engine assembly - removal").
2. Remove bolt (2, figure 1). Remove bolts (4, 9, and 18).
2. AFT LEFT MOUNT TRIPOD - INSTALLATION
1. Install tripod (3, figure 1), with bolt (9), washer (11), nut (12), and cotter pin (13).
2. Install bolt (4), washer (6), nut (7), and cotter pin (8).
3. Install bolt (18), washer (16), nut (15) and cotter pin (14).
4. Install bolt (2) through tripod mount (3) and engine mount bearing (1). Install washer (19), nut (20), and cotter pin (21).
3. AFT LEFT MOUNT TRIPOD - INSPECTION AND REPAIR
CAUTION
IF RECORDS OR PHYSICAL APPEARANCE INDICATES MOUNT HAS BEEN

INVOLVED IN AN ACCIDENT OR INCIDENT, REFER TO CHAPTER 5 OF
AB412-MPM FOR CONDITIONAL INSPECTION REQUIREMENTS.
For inspection and repair of mount tripod, refer to E-AB412-PT6T-3 manual.
71-21-04
Page 1
E-AB412-PT6T-2
G6AB0267A
Figure 1. Aft left mount tripod
71-21-04
Page 2
E-AB412-PT6T-2
71-21-05
ENGINE MOUNT - AFT LEFT MOUNT TRIPOD DECK FITTINGS
1. AFT LEFT MOUNT TRIPOD DECK FITTINGS - REMOVAL
CAUTION
WHEN FITTINGS (3, 10, AND 16, FIGURE 1) ARE REMOVED, INDEX SHIMS
(4, 5, 11, 17, AND 18) FOR REINSTALLATION IN SAME LOCATION. IF
SHIMS ARE NOT REINSTALLED IN SAME LOCATION, ENGINE TO
TRANSMISSION ALIGNMENT MAY BE AFFECTED. IF SHIMS ARE LOST
OR DAMAGED, ENGINE TO TRANSMISSION ALIGNMENT PROCEDURE
SHALL BE ACCOMPLISHED.
NOTE
Fittings (3, 10, and 16) should be removed only if required to perform engine to
transmission alignment, or to replace a damaged fitting.
1. Remove engine mount tripod (module 71-21-04 paragraph "1. Aft left mount tripod - removal").
2. Remove inboard fitting (3, figure 1) (detail A).
3. Remove forward fitting (10) (detail B).
4. Remove aft fitting (16) (detail C).
2. AFT LEFT MOUNT TRIPOD DECK FITTINGS - INSTALLATION
CAUTION
SHIMS (4, 5, 11, 17, AND 18, FIGURE 1) SHALL BE SAME SHIMS AS
REMOVED, OR SHIMS OF IDENTICAL THICKNESS. IF SHIMS HAVE BEEN
LOST, DAMAGED OR MIXED, PERFORM ENGINE TO TRANSMISSION
1. Install inboard fitting (3, figure 1) and shims (4 and 5) (detail A).
2. Install forward fitting (10) and shim (11) as shown (detail B).
3. Install aft fitting (16) and shims (17 and 18) (detail C).
4. Install engine mount tripod (module 71-21-04 paragraph "2. Aft left mount tripod - installation").
71-21-05
Page 1
E-AB412-PT6T-2
3. AFT LEFT MOUNT TRIPOD DECK FITTINGS - INSPECTION AND REPAIR
CAUTION
IF RECORDS OR PHYSICAL APPEARANCE INDICATE DECK FITTINGS

HAVE BEEN INVOLVED IN AN ACCIDENT OR INCIDENT, REFER TO
For inspection and repair of fittings, refer to E-AB412-PT6T-3 manual.
G6AB0268A
Figure 1. Aft left mount tripod deck fitting
71-21-05
Page 2
E-AB412-PT6T-2
71-21-06
ENGINE MOUNT - AFT LEFT AND RIGHT MOUNT ENGINE BEARINGS
1. AFT LEFT AND RIGHT MOUNT ENGINE BEARINGS - REMOVAL
1. Remove engine mount tripod (module 71-21-04 paragraph "1. Aft left mount tripod - removal").
2. Remove engine mount bipod (module 71-21-07 paragraph "1. Aft right mount bipod - removal").
2. AFT LEFT AND RIGHT MOUNT ENGINE BEARINGS - INSTALLATION
MATERIALS REQUIRED
NUMBER NOMENCLATURE
C-405 LOCKWIRE
1. Install bearing (12, figure 1) with bolts (14) and washers (13).
2. Torque bolts (14) 275 to 300 in.lbs. (31,1 to 33,9 Nm). Secure bolts in pairs with lockwire (C-405).
3. Install bearing (2) in same manner outlined in preceding steps 1. and 2.
4. Install engine mount tripod (module 71-21-04 paragraph "2. Aft left mount tripod - installation").
5. Install engine mount bipod (module 71-21-07 paragraph "2. Aft right mount bipod - installation").
3. AFT LEFT AND RIGHT MOUNT ENGINE BEARINGS - INSPECTION AND REPAIR
CAUTION

BEARINGS HAVE BEEN INVOLVED IN AN ACCIDENT OR INCIDENT,
REFER TO E-AB412-PT6T-6 FOR CONDITIONAL INSPECTION
REQUIREMENTS.
For inspection and repair of mount bearings, refer to E-AB412-PT6T-3 manual.
71-21-06
Page 1
E-AB412-PT6T-2
G6AB0269A
Figure 1. Aft left and right mount engine bearing
71-21-06
Page 2
E-AB412-PT6T-2
71-21-07
ENGINE MOUNT - AFT RIGHT MOUNT BIPOD
1. AFT RIGHT MOUNT BIPOD - REMOVAL
CAUTION
LIFTING CAPACITY OF ENGINE HOIST SHALL BE 2,000 POUNDS (908 KG)

OR GREATER.
1. If engine mount bipod is to be removed while engine is installed, support engine with hoist and engine sling (module
71-02-01 paragraph "2. Engine assembly - removal").
4. Remove bipod (15).
2. AFT RIGHT MOUNT BIPOD - INSTALLATION
1. Install bipod (15, figure 1).
3. AFT RIGHT MOUNT BIPOD - INSPECTION AND REPAIR
CAUTION
IF RECORDS OR PHYSICAL APPEARANCE INDICATE BIPOD HAS BEEN

INVOLVED IN AN ACCIDENT OR INCIDENT, REFER TO CHAPTER 5 OF
AB412-MPM FOR CONDITIONAL INSPECTION REQUIREMENTS.
For inspection and repair of bipod, refer to E-AB412-PT6T-3 manual.
71-21-07
Page 1
E-AB412-PT6T-2
G6AB0270A
Figure 1. Aft right mount bipod
71-21-07
Page 2
E-AB412-PT6T-2
71-21-08
ENGINE MOUNT - AFT RIGHT MOUNT BIPOD DECK FITTINGS
1. AFT RIGHT MOUNT BIPOD DECK FITTINGS - REMOVAL
CAUTION
WHEN FITTINGS (3 AND 9, FIGURE 1) ARE REMOVED, INDEX SHIMS (4,

10, AND 11) UNDER FITTINGS FOR REINSTALLATION IN SAME
LOCATION. IF SHIMS ARE NOT REINSTALLED IN SAME LOCATION,
ENGINE TO TRANSMISSION ALIGNMENT MAY BE AFFECTED. IF SHIMS
ARE LOST, DAMAGED, OR MIXED, ENGINE TO TRANSMISSION
ALIGNMENT (MODULE 71-01-01 PARAGRAPH "6. Power plant maintenance -
alignment - engine to transmission [A][B][C]" OR PARAGRAPH "7. Power plant
maintenance - alignment - engine to transmission [D]") IS REQUIRED.
NOTE
Fittings (3 and 9) should be removed only to perform engine to transmission
alignment or to replace a damaged fitting.
1. Remove engine mount bipod (module 71-21-07 paragraph "1. Aft right mount bipod - removal").
2. Remove forward fitting (3) as shown (detail A).
3. Remove aft fitting (9) as shown in (detail B).
2. AFT RIGHT MOUNT BIPOD DECK FITTINGS - INSTALLATION
CAUTION
SHIMS (4, 10 AND 11, FIGURE 1) MUST BE THE SAME SHIMS REMOVED,
OR SHIMS OF IDENTICAL THICKNESS. IF SHIMS HAVE BEEN LOST,
DAMAGED, OR MIXED, PERFORM ENGINE TO TRANSMISSION
1. Install forward fitting (3) and shim (4) (detail A).
2. Install aft fitting (9) and shims (10 and 11) (detail B).
3. Install engine mount bipod (module 71-21-07 paragraph "2. Aft right mount bipod - installation").
71-21-08
Page 1
E-AB412-PT6T-2
3. AFT RIGHT MOUNT BIPOD DECK FITTINGS - INSPECTION AND REPAIR
CAUTION

For inspection and repair, refer to E-AB412-PT6T-3 manual.
G6AB0271A
Figure 1. Aft right mount bipod deck fitting
71-21-08
Page 2
E-AB412-PT6T-2
71-31-01
ENGINE FIREWALLS
1. ENGINE FIREWALLS - DESCRIPTION
The forward, middle, centerline, and aft firewall assemblies (1, 2, 3 and 4, figure 1) are provided to isolate both power
sections, combustion chambers, combining gearbox areas, and main driveshaft tunnel in case of fire in the engine
compartment.
2. ENGINE FIREWALLS - AIR INLET COWLING FIREWALL ASSEMBLY
The left-hand and right-hand air inlet cowling firewalls (2 and 3, figure 2) are integral parts of the left-hand and right-hand
engine air inlet cowlings. The maintenance of the left-hand and right-hand air inlet cowling firewalls are covered in the
cowlings section (module 71-11-02 "COWLING - TRANSMISSION FAIRING AND ENGINE AIR INLET COWLING").
2-1. AIR INLET COWLING FIREWALL ASSEMBLY - REMOVAL
1. Remove the forward and aft pylon fairings (module 71-11-01 paragraph "2-1. Forward and aft transmission pylon
fairing - removal").
2. Remove the transmission fairing and the left-hand and right-hand engine air inlet cowlings (module 71-11-02
paragraph "1. Transmission fairing and engine air inlet cowling - removal").
2-2. AIR INLET COWLING FIREWALL ASSEMBLY - INSTALLATION
1. Install the left-hand and right-hand engine air inlet cowlings and the transmission fairing (module 71-11-02
paragraph "2. Transmission fairing and engine air inlet cowling - installation").
2. Install the forward and aft pylon fairings (module 71-11-01 paragraph "2-2. Forward and aft transmission pylon fairing
- installation").
2-3. AIR INLET COWLING FIREWALL ASSEMBLY - INSPECTION
1. Inspect lower forward firewall (1, figure 2) for distortion, holes and cracks.
2. Inspect for loose and/or missing attaching screws and nut plates. No missing attaching parts are acceptable.
3. Inspect seals for secure installation and deterioration.
71-31-01
Page 1
E-AB412-PT6T-2
G6AB0297A
Figure 1. Engine firewalls
71-31-01
Page 2
E-AB412-PT6T-2
G6AB0298A
Figure 2. Forward firewall
71-31-01
Page 3
E-AB412-PT6T-2
71-31-01
Page 4
E-AB412-PT6T-2
71-31-02
ENGINE FIREWALLS - MIDDLE FIREWALL ASSEMBLY
1. MIDDLE FIREWALL ASSEMBLY - REMOVAL
NOTE
Instructions in this paragraph are for removal of upper left induction baffle and
upper portion of middle firewall assemblies which must be removed and installed
when engine is removed and installed. Removal procedures for upper right middle
firewall assembly and upper right induction baffle (not illustrated) are same.
1. Remove forward and aft pylon fairings (module 71-11-01 paragraph "2-1. Forward and aft transmission pylon fairing
- removal").
2. Remove transmission fairing and left-hand and right-hand engine air inlet cowlings (module 71-11-02
3. Remove centerline firewall (module 71-31-03 paragraph "1. Centerline firewall assembly - removal").
4. Remove transition duct (module 71-61-02 paragraph "1. Transition ducts - removal").
5. Remove valve assembly (module 71-61-03 paragraph "1. Valve assembly - removal").
6. Disconnect engine power section accessory case vent hose (not illustrated) from forward side of elbow (2, figure 1).
Remove vent line (not illustrated) from aft side of elbow (2).
8. Disconnect hose (25) from engine compressor wash manifold.
13. Remove screw (32). Remove induction baffle (43) and duct (24) as an assembly.
14. Remove right induction baffle and forward duct (not illustrated) in same manner outlined in steps 1. through 11.
15. Disconnect brace (3) from fastener (12).
16. Remove screws (4, 9, 23, 6, 21, and 18).
17. Remove middle upper firewall (1).
71-31-02
Page 1
E-AB412-PT6T-2
CAUTION
DO NOT DEFLECT FIREWALL OR INDUCTION BAFFLE MORE THAN

NECESSARY TO ACCOMPLISH ENGINE REMOVAL.
18. If engine is to be removed, deflect section of firewall adjacent to screw (21) forward. Deflect section of induction baffle
adjacent to bolt (42) aft. Secure these parts together with wire.
19. Remove right upper firewall (not illustrated) in same manner.
2. MIDDLE FIREWALL ASSEMBLY - INSTALLATION
MATERIALS REQUIRED
NUMBER NOMENCLATURE
NOTE
Instructions in this paragraph are for installation of upper left induction baffle and
upper portion of middle firewall assembly (2, figure 2) which must be removed and
installed when engine is removed and installed. Installation procedures for upper
right middle firewall and upper right induction baffle (not illustrated) are the same.
NOTE
Use of beeswax, paste-type drill and tap lubricant, or bar soap on bolts and screws
will reduce damage to nutplates and make installation easier.
1. If not previously accomplished, deflect section of firewall adjacent to screw (21, figure 1) forward. Deflect section of
induction baffle adjacent to bolt (42) aft. Secure these parts together with wire. This will allow engine to be lowered
vertically into position unless aft firewall has been removed. Remove wire securing induction baffle and firewall after
engine is installed.
2. If removed, install screws (17) and washers (16).
3. Position upper firewall (1) on lower firewall (10).
4. Install screw (21) and washer (20).
6. Install screw (23) and washer (22).
9. Secure brace (3) with fastener (12).
10. Install right induction baffle (not illustrated) in same manner.
71-31-02
Page 2
E-AB412-PT6T-2
G6AB0299A
Figure 1. Middle firewall (sheet 1 of 2)
71-31-02
Page 3
E-AB412-PT6T-2
G6AB0300A
Figure 1. Middle firewall (sheet 2 of 2)
71-31-02
Page 4
E-AB412-PT6T-2
G6AB0297A
Figure 2. Engine firewalls
71-31-02
Page 5
E-AB412-PT6T-2
11. If not previously accomplished, install hose (25) on fitting (28).
NOTE
Ensure correct part number duct (24) is installed in following step.
12. If not previously accomplished, install forward duct (24) on induction baffle (43) and install screws (26) and washers
(27).
13. Position induction baffle (43) and duct (24) on forward side of firewall (1).
17. Install bolts (40) and washer (39).
18. Attach hose (25) to engine compressor wash manifold (not illustrated).
20. Secure wires (29 and 13) with clamp and bracket (30), washer (31) and screw (32).
21. Install engine power section accessory case vent hose (not illustrated) on forward side of elbow (2). Install vent line
(not illustrated) on aft side of elbow (2).
22. Install right induction baffle and forward duct (not illustrated) in same manner outlined in steps 11. through 21.
23. Install valve assembly (module 71-61-03 paragraph "2. Valve assembly - installation").
24. Install transition duct (module 71-61-02 paragraph "2. Transition ducts - installation").
25. Install centerline firewall assembly (module 71-31-03 paragraph "2. Centerline firewall assembly - installation").
26. Seal any small openings in firewalls with sealing compound (C-353).
27. Install left-hand and right-hand engine air inlet cowlings and transmission fairing (module 71-11-02
paragraph "2. Transmission fairing and engine air inlet cowling - installation").
28. Install forward and aft pylon fairings (module 71-11-01 paragraph "2-2. Forward and aft transmission pylon fairing -
installation").
3. MIDDLE FIREWALL ASSEMBLY - INSPECTION
1. Inspect middle firewall assembly (2, figure 2) for distortion, holes, and cracks. Minor damage is acceptable if repaired
by standard sheet metal repair procedures.
2. Inspect for loose and/or missing attaching screws and nutplates. No missing attaching parts are acceptable.
3. Inspect brace (3, figure 3) and latch (4) for secure installation, distortion, and cracks. Damage affecting function is not
acceptable.
4. Inspect seals (1, 5 and 6) for condition and security.
71-31-02
Page 6
E-AB412-PT6T-2
G6AB0301A
Figure 3. Middle firewall assembly
71-31-02
Page 7
E-AB412-PT6T-2
71-31-02
Page 8
E-AB412-PT6T-2
71-31-03
ENGINE FIREWALLS - CENTERLINE FIREWALL ASSEMBLY
1. CENTERLINE FIREWALL ASSEMBLY - REMOVAL
1. Remove engine to transmission driveshaft (Chapter 63).
2. Remove engine to driveshaft adapter (Chapter 63).
3. Remove screws (17, figure 1), screws (20), and washers (19). Remove forward cover (18).
4. Remove screws (not illustrated) on each side directly above aft cover (8).
5. Remove screws (13) and washer (12) on each side securing middle firewall (10) to centerline firewall assembly (3).
6. Remove screws and washers (not illustrated) on each side securing centerline firewall (3) to left middle firewall (10)
and to right middle firewall assembly (not illustrated).
7. Remove screws (4) and washers (5) securing aft cover (8).
8. Remove screws (1) and washers (2) on each side securing centerline firewall assembly (3) to induction baffle (15).
9. Remove screws (4) and washers (5) securing centerline firewall assembly (3) to web (9).
10. Remove electrical connector (inside) at front of firewall (3).
11. Remove two hoses on each side (outside) of firewall (3).
12. Remove centerline firewall assembly (3).
14. Remove aft cover (8).
2. CENTERLINE FIREWALL ASSEMBLY - INSTALLATION
NOTE
1. Position aft cover (8, figure 1) on web (9). Install screws (6) and washers (7) at lower aft holes. Do not install screws
at locations for screws (4) that also pass through centerline firewall assembly (3).
2. Position centerline firewall assembly (3) between middle firewall (10) and forward firewall (not illustrated).
3. Install screws (4) and washers (5) to secure centerline firewall to web (9).
4. Install screws (1) and washers (2) on each side to secure centerline firewall assembly (3) to induction baffle (15).
5. Install screws (4) and washers (5) to complete installation of aft cover (8).
71-31-03
Page 1
E-AB412-PT6T-2
6. Install screws (not illustrated) on each side to secure centerline firewall (3) to left middle firewall (10) and to right
middle firewall (not illustrated).
7. Install screws (13) and washer (12) on each side to secure middle firewall (10) to centerline firewall assembly (3).
8. Install screws and washer (not illustrated) on each side directly above aft cover (8).
9. Position forward cover (18) on centerline firewall assembly (3). Install screws (20) and washers (19). Install
countersunk screws (17).
10. Install electrical connector.
11. Install hoses on outside of each side of centerline firewall.
12. Install engine to driveshaft adapter (Chapter 63).
13. Install engine to transmission driveshaft (Chapter 63).
3. CENTERLINE FIREWALL ASSEMBLY - INSPECTION
1. Inspect centerline firewall assembly (1, figure 2) for distortion, holes, and cracks.
3. Inspect seals (2, 3 and 4) for condition and security.
71-31-03
Page 2
E-AB412-PT6T-2
G6AB0302A
Figure 1. Centerline firewall
71-31-03
Page 3
E-AB412-PT6T-2
G6AB0303A
Figure 2. Centerline firewall assembly
71-31-03
Page 4
E-AB412-PT6T-2
71-31-04
ENGINE FIREWALLS - AFT FIREWALL ASSEMBLY
1. AFT FIREWALL ASSEMBLY - REMOVAL
NOTE
Instructions in this paragraph are for removal of left upper section (4, figure 1) and
center section (15) which must be removed and installed when engine is removed
and installed. Removal procedure for the right upper section is the same.
1. Remove ejector (module 71-61-01 paragraph "2-1. Ejectors - removal").
2. Remove torque transmitter (module 71-81-04 paragraph "2. Torque pressure transmitter - removal").
3. Remove screws (7, 6, and 3).
4. Remove screws (9) and stiffener (16).
7. Remove right upper section (not illustrated) in same manner outlined in steps 1. through 8.
8. Remove engine (module 71-02-01 paragraph "2. Engine assembly - removal"), if desired. Firewall center section (15)
will remain with engine.
9. Bend firewall center section (15) into a U shape and remove from engine.
2. AFT FIREWALL ASSEMBLY - INSTALLATION
NOTE
Instructions in this paragraph are for installation of left upper section (4, figure 1)
and center section (15) which must be removed and installed when engine is
removed and installed.
NOTE
Use of beeswax, paste-type drill and tap lubricant or bar soap on bolts and screws
1. Install a piece of flexible wire (or string) approximately 18 in. (460 mm) long in bottom center hole of aft firewall
center section (15, figure 1).
NOTE
Accomplish step 2. with engine installed on stand.
71-31-04
Page 1
E-AB412-PT6T-2
2. Bend firewall center section (15) into “U” shape and position firewall between engine power sections immediately
forward of engine combining gearbox.
3. Secure wire (or string) installed in step 1. to manual fuel control linkage jackshaft to hold firewall center section (15)
aft (preventing interference with lower firewall section (11) when engine is installed).
4. Carefully position engine in helicopter and ensure firewall center section (15) engages lower section (11). Secure
engine in engine mounts (module 71-02-01 paragraph "3. Engine assembly - installation").
5. Remove wire (or string) installed in step 3.
6. Position stiffener (17) on lower section (11) and forward of engine fireshield (not illustrated). Install screws (12) and
washers (13).
7. Position stiffener (18) under clip (14) forward of engine fireshield. Install screws (3) and washers (2).
8. Position stiffener (16) on firewall. Install screws (9) and washers (10) through firewall lower section (11).
9. Position firewall upper section (4) on lower section (11). Install screws (6) and washers (5). Install screws (7) and
washers (8).
10. Install screws (9) and washers (10). Do not install top screws at this time. Top screws will be installed with ejector.
11. Install ejector (module 71-61-01 paragraph "2-2. Ejectors - installation").
12. Install torque transmitter (module 71-81-04 paragraph "3. Torque pressure transmitter - installation").
3. AFT FIREWALL ASSEMBLY - INSPECTION
1. Inspect aft firewall assembly (2, figure 2) for distortion, holes, and cracks.
3. Inspect seals (1, 3, 4, and 5) for secure installation and for deterioration.
71-31-04
Page 2
E-AB412-PT6T-2
G6AB0304A
Figure 1. Aft firewall
71-31-04
Page 3
E-AB412-PT6T-2
G6AB0305A
Figure 2. Aft firewall assembly
71-31-04
Page 4
E-AB412-PT6T-2
71-61-01
ENGINE AIR MANAGEMENT SYSTEM
1. AIR MANAGEMENT SYSTEM - DESCRIPTION
The air management system (figure 1) consists of a series of ducts located within the engine cowling. Inlet air flows through
two separate duct systems (figure 2) to each of two engine power sections. During normal operation, air is drawn in through
forward ducts (4 and 7, figure 1) and forward transition ducts (5 and 6) by combined action of engine power section
compressors, exhaust flow through ejectors (1 and 11) or ejector/deflector assemblies and ram effect of forward movement
of the helicopter. Doors (13) in valve assemblies (3 and 9) are normally open. Part of the air, with any foreign particles
present, passes through valve assemblies (3 and 9), transition ducts (2 and 10), and out through ejectors (1 and 11). The
remaining air makes a sharp turn downward into induction baffles (8 and 12). Most of the airborne particles cannot make
the sharp turn, but continue aft through the valve assemblies. The clean air passes from induction baffles (8 and 12) into
engine power sections then out through exhaust ducts (14) and ejectors (1 and 11).
Doors (13), in valve assemblies (3 and 9), are positioned either full open or full closed by actuators. Electrical power for the
actuators is furnished by the 28 Vdc essential bus. The electrical circuits are connected through circuit breakers, ENG 1
PART SEP and ENG 2 PART SEP. The electrical actuators are operated either automatically (by the engine low rpm warning
system) or manually (by pulling either FIRE PULL handle). When the actuators are operated to close the doors, either
automatically or manually, the caution panel segment PART SEP OFF will illuminate and all intake air is directed to the
power section.
The forward transition ducts (5 and 6, figure 1) are integral parts of the engine air inlet cowlings.
71-61-01
Rev. 2 Page 1
E-AB412-PT6T-2
1. Left ejector or ejector/deflector

assembly
2. Left transition duct
3. Left valve assembly
4. Left froward duct
5. Left forward transition duct
6. Right forward transition duct
7. Right forward duct
8. Right induction baffle
9. Right valve assembly
10. Right transition duct
11. Right ejector or ejector/deflector
assembly
12. Left induction baffle
13. Valve assembly door
14. Right exhaust duct
15. Engine exhaust flange
G6AB0272B
Figure 1. Engine air management system
71-61-01
Page 2 Rev. 2
E-AB412-PT6T-2
G6AB0273A
Figure 2. Air management system schematic
71-61-01
Rev. 2 Page 3
E-AB412-PT6T-2
2. AIR MANAGEMENT SYSTEM - EJECTORS
2-1. EJECTORS - REMOVAL
NOTE
Maintenance procedures for ejectors (1 and 5, figure 3) is the same except as noted
in text.
1. Remove engine cowling, aft pylon fairing, and tailpipe fairing.
NOTE
Step 2. is applicable to left ejector (1). Step 3. is applicable to right ejector (5).
2. Remove hoses (17 and 18) from fittings on left ejector (1).
3. Remove hose (51) from fitting on right ejector (5).
4. Disconnect drain line (19) from fitting (20).
NOTE
Step 5. is applicable to left ejector. Step 6. is applicable to right ejector.
5. If ejector will not be reinstalled, remove fittings (27 and 28) from left ejector (1).
6. If ejector will not be reinstalled, remove fitting from right ejector (5) that is similar to fitting (28) on left ejector (1).
7. Remove screws (9, 11 and 13, figure 3) and remove oil cooler support frame (7)
8. Remove screws (14) attaching left ejector (1) to firewall.
10. Remove left ejector (1).
2-2. EJECTORS - INSTALLATION
MATERIALS REQUIRED
NUMBER NOMENCLATURE
C-405 LOCKWIRE
NOTE
Maintenance procedures for both ejectors (1 and 5, figure 3) are the same except as
noted in text.
Steps 1. and 2. are applicable to left ejector (1). Step 3. is applicable to right ejector
(5).
71-61-01
Page 4 Rev. 2
E-AB412-PT6T-2
G6AB0274A
Figure 3. Ejector (sheet 1 of 3)
71-61-01
Rev. 2 Page 5
E-AB412-PT6T-2
G6AB0275B
71-61-01
Page 6 Rev. 2
E-AB412-PT6T-2
1. Left ejector 32. Nut

2. Aft firewall 33. Bolt
3. Left transition duct 34. Washer (AN960C10L)
4. Right transition duct 35. Washer (AN960C10L)
5. Right ejector 36. Link
6. Oil cooler cowling 37. Bracket
7. Oil cooler support frame 38. Spacer
8. Washer 39. Washer (AN960C10L)
9. Screw 40. Washer (AN960C10L)
10. Washer 41. Nut
11. Screw 42. Bolt
12. Washer 43. Washer (AN960C10L)
13. Screw 44. Washer
14. Screw 45. Bracket
15. Washer (AN960C10L) 46. Spacer
16. Seal 47. Link
17. Vent hose (left power section accessory gearbox) 48. Washer
18. Vent hose (combining gearbox) 49. Washer
19. Drain line 50. Nut
20. Drain line fitting 51. Vent hose (right power section accessory gearbox)
21. Exhaust duct 52. Union
22. Elbow 53. Elbow
23. Union 54. Bolt
24. Nut 55. Washer
25. Thin steel washer 56. Washer
26. Thin steel washer 57. Nut
27. Fitting 58. Bolt
28. Fitting 59. Washer
29. Thin steel washer 60. Washer
30. Thin steel washer 61. Nut
31. Nut
71-61-01
Rev. 2 Page 7
E-AB412-PT6T-2
1. If not previously accomplished, position fitting (27) and washer (26) in left ejector (1) from inside. Install washer (25)
and nut (24).
2. If not previously accomplished, position fitting (28) and washer (29) in left ejector (1) from inside. Install washer (30) and
nut (31). Secure nut (31) to nut (24) as shown on view B with lockwire (C-405). Install nut (32), elbow (22), and union (23).
3. If not previously accomplished, install elbow (53) on right ejector (5) in same manner that elbow (22) was installed in
preceding step 2. Apply lockwire (C-405) as illustrated.
4. Position the ejector (1 or 5) into the end of the transmission duct (3 or 4).
5. If required, attach the link (47) to the bracket (45) with the bolt (58), washers (59 and 60), and nut (61). Tighten the nut.
6. Position spacer (46) and link (47) in bracket on bottom of ejector. Install bolt (42), washers (43, 44, 48, and 49), and
nut (50). Tighten the nut.
7. If required, attach the link (36) to the bracket (37) with the bolt (54), washers (55 and 56), and nut (57). Tighten the nut.
8. Position spacer (38) and link (36) in bracket on side of ejector. Install bolt (33), washers (34, 35, 39, 40), and nut (41).
Tighten the nut.
9. Install two screws (14) and washers (15). Check clearance between duct (21) and ejector. Acceptable clearance is
0.10 to 0.40 in (2.54 to 10.16 mm). Trim ejector as required.
10. Install remaining screws (14) and washers (15).
11. Connect drain line (19) to drain line fitting (20).
NOTE
Steps 10. and 11. are applicable to left ejector. Step 12. is applicable to right ejector.
12. Install hose (18) on fitting (27).
13. Loosen nut (32) and position elbow (22) for installation of hose (17). Tighten nut (32) and install hose (17).
14. Position elbow (53) in same manner outlined in preceding step and install hose (51).
15. Position frame (7) on oil cooler cowling (6). Install screws (9, 11, and 13) and washers (8, 10, and 12).
16. Install engine cowling, aft pylon fairing and tailpipe fairing.
2-3. EJECTORS - INSPECTION
1. Inspect ejectors (1 and 5, figure 3) for evidence of overheating, distortion, cracks, and holes.
2. Inspect ejectors for secure installation of attaching bolts (33 and 42) and screws (14).
3. Inspect drain line (19) on each ejector for security and condition.
4. Inspect vent hoses (17, 18, and 51) for security and condition.
5. Inspect for proper clearance between ejectors (1 and 5) and exhaust ducts (21) (paragraph "2-2. Ejectors -
installation").
71-61-01
Page 8 Rev. 2
E-AB412-PT6T-2
2-4. EJECTORS - REPAIR
CAUTION
ANY REPAIRS REQUIRING WELDING SHOULD ONLY BE CARRIED OUT

BY COMPETENT CERTIFIED WELDERS USING PROPER EQUIPMENT.
NOTE
All repairs addressed are designed to be accomplished either with ejectors installed
or on the bench without the aid of extensive equipment.
1. Dents, small cracks in inner and outer skins are repaired as follows (figure 4):
a. Dents may be worked out using standard sheet metal methods; however, care must be exercised not to crack the
metal which is titanium.
b. Repair cracks in ejector skins which do not exceed 3.0 in in length by stop drilling with 0.094 in diameter drill
and install a doubler patch 4.5 X 4.5 in (114.3 X 114.3 mm) or 4.5 in (114.3 mm) dia. X 0.025 in (0.635 mm)
thick titanium per MIL-T-9046-CP2 (formerly known as MIL-T-9046, TYP1, Comp C).
c. Install patch to outer surface of outer skin using NAS1738M4 monel rivets and/or to outer surface of inner skin
using MS20615-3M monel rivets with rivet manufactured head on exhaust gas side of inner skin, rivet spacing
to be 0.75 in (19.05 mm) minimum to 1.0 in (25.4 mm) maximum. TIG welding may be used in lieu of rivets.
d. Cracks and holes contained in an area of 0.50 in (12.7 mm) diameter may be repaired (sheets 2 and 3). Patch to
be fabricated from titanium per MIL-T-9046. Patch may be welded in place.
2. Cracks in intercostal members are repaired as follows:
a. Cracks in intercostal members which are confined to one flange only may be repaired as shown in sheet 4. If
crack exceeds 1.0 in (25.4 mm) in length, member must be replaced or repaired in accordance with sheet 5.
Doubler used in sheet 4 or sheet 5 should be fabricated from titanium per MIL-T-9046.
b. Cracks in intercostal members affecting both flanges cannot be repaired with doublers defined in sheet 6,
intercostal members shall be replaced.
3. Make repair to large areas as follows:
a. Outer Skin — Repair of areas larger than 16.0 sq-in (103.2 sq-cm) and not greater than 8.0 in (203.2 mm) x 12.0
in (304.8 mm) may be repaired as shown in sheet 6. Patch doubler may be fabricated from titanium per
MIL-T-9046. Number of repairs of this size shall not exceed three per ejector. Consideration should be taken to
combine adjacent small repairs into one large patch.
b. Inner Skin — Repair of areas larger than 16.0 sq-in (103.2 sq-cm) and not greater than 8.0 in (203.2 mm) x 12.0
in (304.8 mm) may be repaired as shown in sheet 7. Fabricate a patch from titanium per MIL-T-9046 using monel
rivets (MS20615-3M) at each corner to locate patch. Number of repairs of this size shall not exceed two per
ejector.
4. Frame Repairs:
a. Cracks in frames may be repaired as shown in sheets 8, 9, or 10. Cracks up to 1.5 in (38.1 mm) (Dim. A, sheet
10) may be welded. Cracks up to 5.0 in (127 mm) long (Dim. A) may be repaired by welding a 0.032 in
(0.813 mm) thick titanium per MIL-T-9046 patch over crack. Patch shall extend 0.50 in (12.7 mm) beyond
stop-drill holes and completely cover cracked area. Fillet weld around edges of frame.
b. When cracks extend into vertical flanges, repair as shown in sheet 8 using 0.025 in (0.635 mm) thick titanium
per MIL-T-9046. When cracks extend to attachment flanges, repair as shown in sheet 9 using 0.025 in
(0.635 mm) thick titanium per MIL-T-9046.
71-61-01
Rev. 2 Page 9
E-AB412-PT6T-2
c. Rivet spacing (where used) shall be 0.75 in (19.05 mm) minimum to 1.0 in (25.4 mm) maximum. When crack
extends through attachment flanges, frame may have only one repair in an 18.0 in (457.2 mm) length of frame
and no closer than 8.0 in (203.2 mm) to any airframe attachment fitting.
d. Support clips may have cracks in vertical flange weld repaired once, subsequent repairs require replacement of
clip which may be fabricated from same thickness titanium per MIL-T-9046.
e. Repair attachment flange as follows:
(1) All loose nutplate attaching rivets are to be replaced using monel rivets (MS20427M3).
(2) Cracks originating from rivet or bolt holes may be welded one weld per nutplate. Cracks which run from
hole to hole within a nutplate pattern shall be reinforced by welding a doubler 0.025 in (0.635 mm) thick
titanium per MIL-T-9046 over hole pattern and redrilling holes.
(3) Cracks in attachment flange in between attachment holes may be welded and weld finished smooth. When
crack runs across both flanges, a doubler 0.025 in (0.635 mm) thick titanium per MIL-T-9046 should be
used. Crack in attachment flange is to be welded and finished smooth. Since other flange is attached to
ejector, weld as far as practical. Attach doubler and weld. Repairs of this nature shall be restricted to rivet
per ejector and shall be no closer to other repairs by length of doubler.
71-61-01
Page 10 Rev. 2
E-AB412-PT6T-2
G6AB0278A
Figure 4. Exhaust ejector repair (sheet 1 of 11)
71-61-01
Rev. 2 Page 11
E-AB412-PT6T-2
NOTE:
All dimensions are in inches.
G6AB0279B
71-61-01
Page 12 Rev. 2
E-AB412-PT6T-2
NOTE:
G6AB0280B
71-61-01
Rev. 2 Page 13
E-AB412-PT6T-2
NOTE:
G6AB0281B
71-61-01
Page 14 Rev. 2
E-AB412-PT6T-2
NOTE:
G6AB0282B
71-61-01
Rev. 2 Page 15
E-AB412-PT6T-2
NOTE:
G6AB0283B
71-61-01
Page 16 Rev. 2
E-AB412-PT6T-2
G6AB0284B
71-61-01
Rev. 2 Page 17
E-AB412-PT6T-2
NOTE:
G6AB0285B
71-61-01
Page 18 Rev. 2
E-AB412-PT6T-2
G6AB0286A
71-61-01
Rev. 2 Page 19
E-AB412-PT6T-2
G6AB0287A
71-61-01
Page 20 Rev. 2
E-AB412-PT6T-2
NOTE:
G6AB0288B
71-61-01
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E-AB412-PT6T-2
71-61-01
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E-AB412-PT6T-2
71-61-02
AIR MANAGEMENT SYSTEM - TRANSITION DUCTS
1. TRANSITION DUCTS - REMOVAL
NOTE
The removal procedure for right transition duct is given. The removal procedure for
left transition duct is the same.
1. Remove engine cowling, aft pylon fairing, and tailpipe fairing.
2. Remove ejector (1, figure 1) (module 71-61-01 paragraph "2-1. Ejectors - removal").
3. Remove screws (3 and 7).
4. Remove transition duct (2).
2. TRANSITION DUCTS - INSTALLATION
NOTE
The installation procedure for right transition duct is given. The installation
procedure for left transition duct is the same.
NOTE
1. Position duct (2, figure 1) over duct (8).
2. Align forward flanges of duct (2) with valve assembly (5).
3. Install screws (3 and 7) and washers (4 and 6) in locations shown on Section A-A.
4. Inspect clearance between duct (2) and duct (8). Clearance must be 0,10 to 0,70 in (2,54 to 17,78 mm).
5. Install ejector (1) (module 71-61-01 paragraph "2-2. Ejectors - installation").
6. Install engine cowling, aft pylon fairing and tailpipe fairing.
3. TRANSITION DUCTS - INSPECTION
NOTE
The inspection procedure for right transition duct is given. The inspection procedure
for left transition duct is the same.
1. Inspect duct (2, figure 1) for distortion, cracks, and holes.
71-61-02
Rev. 1 Page 1
E-AB412-PT6T-2
2. Inspect duct (2) for secure installation of attaching screws.
3. Inspect duct (2) for proper clearance with duct (8). Clearance must be 0,10 to 0,70 in (2,6 to 17,7 mm).
4. Inspect duct (2) for secure installation with ejector (1).
4. TRANSITION DUCTS - REPAIR
MATERIALS REQUIRED
NUMBER NOMENCLATURE
C-204 PRIMER
1. Repair transition duct (2, figure 1) as follows:
a. Local dings, dents, or bumps not exceeding 0,25 in (6,35 mm) in depth and 2,0 in (50,8 mm) in diameter may
be ignored or worked out at operator discretion.
b. Dings, dents, and bumps exceeding 0,25 in (6,35 mm) in diameter shall be worked out to original contour.
c. All dings, dents, and bumps penetrating the surface shall be worked out to original contour and treated as a crack.
d. All cracks up to 3,0 in (76,2 mm) in length shall be stop-drilled (0,094 in (2,387 mm) diameter), cracks cleaned
out, and patch applied to outside surface (figure 2, view A). Use adhesive (C-308).
e. All holes up to 3,0 in (76,2 mm) in diameter shall be cleaned and a patch applied to the outside surface (view B).
Use adhesive (C-308).
f. Repair cracks in flanges per view C. Only one repair on each side permitted. Use adhesive (C-308).
g. Repairs to seal retainer shall be limited to stop-drilling cracks (0,094 in (2,387 mm) diameter) and adding a
doubler as shown in view D. Use adhesive (C-308).
h. Repairs to duct requiring a patch shall have patch applied to outside surface except in area of seal retainer (aft
end of duct) where patches on internal surface is the only practical surface on which to apply patches.
i. All scratches, scores, and surface penetrations shall be buffed out and primer (C-204) applied.
2. No more than four patches are allowed per duct.
71-61-02
Page 2 Rev. 1
E-AB412-PT6T-2
1. Ejector
2. Transition duct
3. Screw
5. Valve assembly
7. Screw
8. Exhaust duct
G6AB0289B
Figure 1. Transition duct
71-61-02
Rev. 1 Page 3
E-AB412-PT6T-2
NOTE
ALL DIMENSIONS ARE IN INCHES
G6AB0290B
Figure 2. Transition duct repair (sheet 1 of 2)
71-61-02
Page 4 Rev. 1
E-AB412-PT6T-2
G6AB0291A
Figure 2. Transition duct repair (sheet 2 of 2)
71-61-02
Rev. 1 Page 5
E-AB412-PT6T-2
71-61-02
Page 6 Rev. 1
E-AB412-PT6T-2
71-61-03
AIR MANAGEMENT SYSTEM - VALVE ASSEMBLY
1. VALVE ASSEMBLY - REMOVAL
NOTE
Instructions in this paragraph are for removal of right valve assembly. Removal
procedures for left valve assembly are the same.
1. Remove transition duct (2, figure 1) (module 71-61-02 paragraph "1. Transition ducts - removal").
2. Remove screws (6, figure 2). Remove cover (38).
3. Remove bolt (36).
4. Remove screws (8). Remove valve body (37).
NOTE
Accomplish steps 5. and 6. only if it is necessary to remove actuator (9).
5. Disconnect electrical connector (11). Remove jamnut and separate electrical lead of actuator (9) from firewall.
6. Remove bolt (18). Remove actuator (9).
NOTE
Accomplish steps 7. and 8. only if it is necessary to remove fitting (27).
7. Remove screws (26). Remove fitting (27).
8. If shims (21 and 24) are present, index shims for reinstallation in same location.
2. VALVE ASSEMBLY - INSTALLATION
NOTE
Instructions in this paragraph are for installation of right valve assembly. Installation
procedures for left valve assembly are the same.
NOTE
Use of beeswax, paste type drill and tap lubricant, or bar soap on screws and bolts
1. Remove valve cover (38, figure 2) from valve body (37).
2. Position valve body (37) on firewall (3). Install washers (7) and screws (8).
71-61-03
Rev. 1 Page 1
E-AB412-PT6T-2
1. Ejector
2. Transition duct
3. Screw
5. Valve assembly
7. Screw
8. Exhaust duct
G6AB0289B
Figure 1. Transition duct
71-61-03
Page 2 Rev. 1
E-AB412-PT6T-2
1. Engine air management 8. Screw 19. Thin steel washer 30. Electrical wire
system valve assembly 9. Actuator 20. Thin steel washer 31. Cotter pin
(left) 10. Actuator mount lug 21. Shim 32. Nut
2. Transition duct 11. Electrical connector 22. Nut 33. Thin steel washer
3. Middle firewall 12. Washer 23. Cotter pin 34. Thin steel washer
4. Engine air management 13. Screw 24. Shim 35. Thin steel washer
system valve assembly 14. Door 25. Thin steel washer 36. Bolt
(right) 15. Rod end 26. Screw 37. Valve body
5. Washer 16. Jam nut 27. Fitting 38. Valve cover
6. Screw 17. Thin steel washer 28. Thin steel washer
7. Thin steel washer 18. Bolt 29. Actuator mount lug
G6AB0294B
Figure 2. Air management system valve
71-61-03
Rev. 1 Page 3
E-AB412-PT6T-2
NOTE
Shims (21 and 24) are required only if interference occurs between actuator (9) and
door (14).
3. Position fitting (27) on firewall (3). Install washers (25) and screws (26).
4. Position actuator (9) on fitting (27). Install bolt (18), washers (17, 19, 20, and 28), and nut (22) as illustrated. Install
cotter pin (23).
5. Position actuator (9) on door (14). Install bolt (36), washers (33, 34, and 35), and nut (32). Install cotter pin (31).
6. Position electrical lead of actuator (9) through firewall and install jamnut.
NOTE
Use suitable electrical work aid to accomplish steps 7. and 8.
7. Operate actuator (9) to full retract position. Measure dimension between door (14) and valve body (37) as shown in
section A-A. If door is not flush within 0,03 in (0,76 mm), adjust rod end (15) to obtain proper door position.
8. Operate actuator (9) through full throw in both directions and check for binding and interference. If actuator touches
edge of door (14), install shims (21 and 24) as required.
9. After actuator is adjusted, install electrical connector (11).
10. Position cover (38) on body (37) and install washers (5) and screws (6).
3. VALVE ASSEMBLY - INSPECTION
NOTE
The inspection procedure for right valve assembly is given. Inspection procedure for
left valve assembly is the same.
1. Inspect valve (4, figure 2) for distortion, cracks, and holes.
2. Inspect door (14) for distortion, cracks, and proper adjustment in accordance with section A-A.
3. Inspect actuator (9) for obvious damage and secure installation.
4. Inspect electrical connector (11) and electrical wiring (30) for obvious damage.
4. VALVE ASSEMBLY - REPAIR
MATERIALS REQUIRED
NUMBER NOMENCLATURE
1. Local dings, dents, and bumps not exceeding 0,25 in (6,35 mm) depth and 1,0 in (25,4 mm) diameter may be ignored
or repaired at operator discretion provided there is no interference with operation of valve box assembly.
2. Local dings, dents, or bumps exceeding 0,25 in (6,35 mm) depth and greater than 1,0 in (25,4 mm) diameter shall be
71-61-03
Page 4 Rev. 1
E-AB412-PT6T-2
repaired or replaced. Rework shall restore damaged area to original contour or limits stated in step 1.
3. Damage in flat surfaces that can be cleaned up with a 2,0 in (50,8 mm) diameter hole may be repaired using a doubler
as shown in view A, figure 3. Apply a bead of sealing compound (C-353) or equivalent around edges of doubler.
4. Attachment flanges may be reworked to remove local wrinkles and surface deformities. Cracks in flange where crack
does not originate from a hole may be stop-drilled (0,094 in (2,387 mm) diameter) and an angle reinforcement added
(see view B, figure 3). Where crack extends to spot-welded flange, stop-drill is permitted through flange and box.
Where cracks are through nutplate hole pattern, remove nutplate, clean out flange area, and install nutplate on
reinforcement angle (view B). Cracks through a single hole may be stop-drilled and a reinforcement angle installed.
5. Only one repair per flange is allowed.
6. Damage on one surface which overlaps another shall be classified as being a repair on each of the surfaces. No more
than two repairs per figure 3, view A, are allowed per surface. Repairs on one surface that can be combined and
repaired with same doubler shall be classified as one repair.
7. Repairs to door hinge fittings (other than buffing out minor surface damage) are not allowed. Repairs due to cracks in
door shall consist of stop-drilling (0,094 in (2,387 mm) diameter) all cracks and attaching a doubler made of 0,012 in
(0,305 mm) thick corrosion resistant steel, MIL-S-6721, or equivalent.
8. Cracks in support brackets are not reparable. Cracked support brackets shall be replaced.
9. Seals and gaskets are not reparable.
71-61-03
Rev. 1 Page 5
E-AB412-PT6T-2
G6AB0295A
Figure 3. Air management valve assembly repair
71-61-03
Page 6 Rev. 1
E-AB412-PT6T-2
71-61-04
AIR MANAGEMENT SYSTEM - FORWARD DUCTS
1. FORWARD DUCTS - REMOVAL
NOTE
The removal procedure for right forward duct is given. The removal procedure for
left forward duct is the same.
The left and right forward transition ducts (5 and 6, figure 2) are integral parts of the
engine air inlet cowlings (2, figure 3).
1. Remove the forward and aft pylon fairings (module 71-11-01 paragraph "2-1. Forward and aft transmission pylon
fairing - removal").
2. Remove transmission fairing (module 71-11-02 paragraph "1. Transmission fairing and engine air inlet cowling -
removal").
3. Remove the left-hand or right-hand engine air inlet cowling, as applicable (module 71-11-02
4. Remove the forward transition duct (11) from the engine air inlet cowling (2) as follows:
a. Remove the two bolts (12) and washers (13) that attach the forward transition duct (11) to the engine air inlet
cowling (2).
b. Remove the forward transition duct (11) from the engine air inlet cowlings (2).
5. Remove valve assembly (1, figure 4) (module 71-61-03 paragraph "1. Valve assembly - removal").
6. Remove the air management system forward duct (3, figure 1) from the air management system induction baffle (2)
as follows:
a. Remove screws (4) and thin aluminum washers (5), securing air management system forward duct (3) to air
management system induction baffle (2).
b. Remove air management system forward duct (3).
2. FORWARD DUCTS - INSTALLATION
NOTE
The installation procedure for left forward duct is given. Installation procedure for
right forward duct is the same.
NOTE
71-61-04
Rev. 1 Page 1
E-AB412-PT6T-2
1. Position air management system forward duct (3, figure 1) on induction baffle (2) and install screws (4) and washers
(5).
2. Install valve assembly (1) (module 71-61-03 paragraph "2. Valve assembly - installation").
3. Install the forward transition duct (11, figure 3) into the engine air inlet cowling (2). Make sure the seal is properly
seated in the flange sealing ring.
4. Install the two bolts (12) and washers (13) to secure the forward transition duct (11) to the engine air inlet cowling (2).
5. Install the left-hand or right-hand engine air inlet cowling, as applicable (module 71-11-02 paragraph "2. Transmission
fairing and engine air inlet cowling - installation").
6. Install transmission fairing (module 71-11-02 paragraph "2. Transmission fairing and engine air inlet cowling -
installation").
7. Install the forward and aft pylon fairings (module 71-11-01 paragraph "2-2. Forward and aft transmission pylon fairing
- installation").
3. FORWARD DUCTS - INSPECTION
NOTE
The inspection procedure for right forward duct is given. The inspection procedure
for left forward duct is the same.
1. Inspect air management system duct (3, figure 1) and forward transition duct (11, figure 3) for evidence of distortion,
cracks and holes.
2. Inspect ducts for secure installation of attaching screws.
71-61-04
Page 2 Rev. 1
E-AB412-PT6T-2
1. Air management system valve assembly

2. Air management system induction baffle
3. Air management system forward duct
4. Screw
G6AB0296B
Figure 1. Forward duct
71-61-04
Rev. 1 Page 3
E-AB412-PT6T-2
1. Left ejector or ejector/deflector

assembly
2. Left transition duct
3. Left valve assembly
4. Left froward duct
5. Left forward transition duct
6. Right forward transition duct
7. Right forward duct
8. Right induction baffle
9. Right valve assembly
10. Right transition duct
11. Right ejector or ejector/deflector
assembly
12. Left induction baffle
13. Valve assembly door
14. Right exhaust duct
15. Engine exhaust flange
G6AB0272B
Figure 2. Engine air management system
71-61-04
Page 4 Rev. 1
E-AB412-PT6T-2
3. Fastener
4. Dowel pin
5. Bolt
6. Washer
7. Dowel pin
8. Cowling latch
9. Cowling latch fitting
10. Dowel pin
11. Forward transition duct
12. Bolt
13. Washer
14. Forward duct
G6AB0260B
Figure 3. Transmission fairings and engine air inlet cowling
71-61-04
Rev. 1 Page 5
E-AB412-PT6T-2
1. Engine air management 8. Screw 19. Thin steel washer 30. Electrical wire
system valve assembly 9. Actuator 20. Thin steel washer 31. Cotter pin
(left) 10. Actuator mount lug 21. Shim 32. Nut
2. Transition duct 11. Electrical connector 22. Nut 33. Thin steel washer
3. Middle firewall 12. Washer 23. Cotter pin 34. Thin steel washer
4. Engine air management 13. Screw 24. Shim 35. Thin steel washer
system valve assembly 14. Door 25. Thin steel washer 36. Bolt
(right) 15. Rod end 26. Screw 37. Valve body
5. Washer 16. Jam nut 27. Fitting 38. Valve cover
6. Screw 17. Thin steel washer 28. Thin steel washer
7. Thin steel washer 18. Bolt 29. Actuator mount lug
G6AB0294B
Figure 4. Air management system valve
71-61-04
Page 6 Rev. 1
E-AB412-PT6T-2
71-61-05 AIR MANAGEMENT SYSTEM - INDUCTION BAFFLES
71-61-05
AIR MANAGEMENT SYSTEM - INDUCTION BAFFLES
1. INDUCTION BAFFLES - REMOVAL
NOTE
Induction baffles are normally removed with the middle firewall and centerline
firewall in conjunction with engine change.
2. INDUCTION BAFFLES - INSTALLATION
NOTE
Induction baffles are normally installed with the centerline firewall and middle
firewall in conjunction with engine change.
71-61-05
Page 1
E-AB412-PT6T-2
71-61-05
Page 2
E-AB412-PT6T-2
71-61-06
AIR MANAGEMENT SYSTEM - EXHAUST DUCTS
1. EXHAUST DUCT - REMOVAL
NOTE
The removal procedure for the right exhaust duct (1, figure 1) is given. The removal
procedure for the left exhaust duct is the same.
1. Remove right transition duct (10) (module 71-61-01 paragraph "2-1. Ejectors - removal").
2. Remove nuts (3), bolts (4), and washers (5).
NOTE
Some exhaust ducts have 14 mounting holes. Remove 14 nuts (3), 14 bolts (4), and
28 washers (5).
3. Remove right exhaust duct (1).
2. EXHAUST DUCT - INSTALLATION
NOTE
The installation procedure for the right exhaust duct (1, figure 1) is given. The
installation procedure for left exhaust duct is the same.
1. Position right exhaust duct (1) over engine exhaust flange (6).
2. Install nuts (3), bolts (4), and washers (5).
NOTE
Some exhaust ducts have 14 mounting holes. Install 14 nuts (3), 14 bolts (4), and 28
washers (5).
3. Install right transition duct (2) (module 71-61-02 paragraph "2. Transition ducts - installation").
3. EXHAUST DUCT - INSPECTION
NOTE
The inspection procedure is for the right exhaust duct (1, figure 1). Inspection
procedure for left exhaust duct is the same.
1. Inspect duct (1) for distortion, cracks, and holes.
2. Inspect duct for secure installation of nuts (3) and bolts (4).
71-61-06
Page 1
E-AB412-PT6T-2
3. Inspect duct for secure installation with flange (6).
4. EXHAUST DUCT - REPAIR
CAUTION
ANY REPAIRS REQUIRING WELDING SHALL BE CARRIED OUT BY

COMPETENT CERTIFIED WELDERS USING PROPER EQUIPMENT.
1. If flange (1, figure 2) is cracked, fabricate a doubler (2) from material described in step 4., and install, provided the
following conditions are met:
a. If flange is cracked between bolt holes or from bolt holes to outboard edge of flange, cracks shall be welded and
ground smooth. Use tungsten inert gas (TIG) fusion method of welding with argon shielding.
b. Before installing doubler, check flange to ensure a flat, waveless, and clean surface.
c. After complying with steps a. and b., position doubler on flange and weld in place on three sides (figure 2).
d. No more than four bolt holes are to be reinforced per single repair.
e. A total of two repairs may be made to a flange provided repairs are not closer than 3,0 in. (76,2 mm).
f. The engine exhaust flange (6, figure 1) shall not be modified or redrilled to a larger size to accommodate
additional bolts or larger diameter bolts.
CAUTION
A GAP IN EXCESS OF 0,030 IN. (0,762 MM) BETWEEN EXHAUST DUCT

FLANGE AND ENGINE EXHAUST FLANGE MAY CAUSE NEW REPAIRS TO
CRACK WHEN MOUNTING BOLTS ARE TIGHTENED.
g. After flange of exhaust duct (1) is repaired per steps a. through f., make a careful check to ensure entire flange
is flat and waveless. Ensure flange will fit engine exhaust flange within 0,030 in. (0,762 mm).
h. If a total of 25% or more of flange area requires repair, exhaust duct is not reparable. Replace with a serviceable
exhaust duct.
2. If duct half (3 or 4, figure 2) is cracked or damaged, repair is permitted provided the following conditions are met.
a. Not more than two repairs are permitted per duct half.
b. Use TIG fusion welding process with argon shielding to repair cracks 4,0 in. (101,6 mm) or less in length.
c. Grind and blend welded cracks to normal contour.
d. Fabricate a doubler (5) of material described in step 4., formed to fit and overlap underlying weld area by 1,0 in.
(25,4 mm) in all directions. Place doubler over weld area. Use TIG fusion welding method with argon shielding
to attach doubler on all four sides to duct half.
e. Duct halves shall not be replaced. If exhaust duct is damaged to the extent replacement of duct half is indicated,
exhaust duct is not reparable. Scrap damaged exhaust duct and replace with a serviceable exhaust duct.
f. Exhaust ducts with bulges, dents, or other damage (whether from repairs or abuse) are not airworthy. Scrap
damaged exhaust duct and replace with a serviceable exhaust duct.
71-61-06
Page 2
E-AB412-PT6T-2
G6AB0292A
Figure 1. Exhaust duct
71-61-06
Page 3
E-AB412-PT6T-2
G6AB0293A
Figure 2. Exhaust duct repair
71-61-06
Page 4
E-AB412-PT6T-2
3. It is permissible to modify the 14-bolt-hole flange of exhaust duct to 28-bolt-hole flange by drilling fourteen 0,276 to
0,286 in. (7,01 to 7,26 mm) holes to match hole pattern, provided the following conditions are met.
a. No previous repair to flange and none required at time of modification.
b. Exhaust duct shall be free of cracks and repairs before and after modification. With any exception, exhaust duct
is not airworthy. Scrap exhaust duct if cracked or if repair is required after modification.
4. If bolt holes in flange of exhaust duct are worn, elongated, or distorted, inspect engine exhaust flange (6, figure 1) for
worn, elongated, or distorted bolt holes, cracks, and other damage. Consult Pratt & Whitney Engine Customer Support
Representative for evaluation of engine exhaust section.
5. Make doublers from corrosion resistant steel N-155 per AMS 5532. Hastalloy X material per AMS 5536 is an
acceptable alternate. Material thickness varies from 0,025, 0,032, 0,040, to 0,050 in. Use Hastalloy X filler rod per
AMS 5798.
71-61-06
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E-AB412-PT6T-2
71-61-06
Page 6
E-AB412-PT6T-2
71-81-01
ENGINE ACCESSORIES - GAS PRODUCER TACHOMETER GENERATOR
1. GAS PRODUCER TACHOMETER GENERATOR - DESCRIPTION
A gas producer tachometer generator is mounted on the front of each power section accessory gearbox. The generators are
connected by electrical harness to the respective gas producer (GAS PROD) indicator on the instrument panel.
2. GAS PRODUCER TACHOMETER GENERATOR - REMOVAL
NOTE
Maintenance procedures are the same for both gas producer tachometer generators.
3. Remove nuts (5) and washers (4). Remove generator (3).
4. Remove and discard gasket (2), if unserviceable.
3. GAS PRODUCER TACHOMETER GENERATOR - INSTALLATION
1. Install gasket (2, figure 1) if removed.
2. Install generator on mounting studs with electrical receptacle pointing down. Install washers (4) and nuts (5).
4. Close engine cowling.
71-81-01
Page 1
E-AB412-PT6T-2
G6AB0243A
Figure 1. Gas producer tachometer generator
71-81-01
Page 2
E-AB412-PT6T-2
71-81-02
ENGINE ACCESSORIES - POWER TURBINE TACHOMETER GENERATOR
1. POWER TURBINE TACHOMETER GENERATOR - DESCRIPTION
Two power turbine tachometer generators are mounted on the rear of the engine reduction gearbox. The generators are
connected by electrical harness to the triple tachometer on the instrument panel.
2. POWER TURBINE TACHOMETER GENERATOR - REMOVAL
NOTE
Maintenance procedures are the same for both power turbine tachometer generator,
except brackets (2 and 6, figure 1) are mounted with the left tachometer generator.
3. Remove nuts (8) and washers (7).
4. If removing left generator, remove brackets (2 and 6) from generator mounting studs.
5. Remove generator (5).
6. Remove and discard gasket (4), if unserviceable.
3. POWER TURBINE TACHOMETER GENERATOR - INSTALLATION
1. Install new gasket (4, figure 1), if removed.
2. Install generator (5) on mounting studs with electrical receptacle pointing up. If installing left generator, place brackets
(2 and 6) over mounting studs.
3. Install washers (7) and nuts (8).
71-81-02
Page 1
E-AB412-PT6T-2
G6AB0244A
Figure 1. Power turbine tachometer generator
71-81-02
Page 2
E-AB412-PT6T-2
71-81-03
ENGINE ACCESSORIES - DIFFERENTIAL PRESSURE INDICATOR
1. DIFFERENTIAL PRESSURE INDICATOR - DESCRIPTION
A differential pressure indicator is mounted on the left aft side of the reduction gearbox. The indicator is connected to inlet
and outlet sides of gearbox oil filter. A button located on the side of the indicator will extend at approximately 27 psi (186
kPa) indicating an impending filter bypass condition.
2. DIFFERENTIAL PRESSURE INDICATOR - REMOVAL
1. Open left engine cowling.
2. Disconnect tubes (7 and 8, figure 1).
3. Remove nuts (2), washers (1), and bolts (5).
4. Remove indicator (3).
5. Remove unions (6 and 9) with packings (10) and (11). Discard packings.
3. DIFFERENTIAL PRESSURE INDICATOR - INSTALLATION
1. Install unions (6 and 9, figure 1) with packings (10 and 11) in indicator (3).
2. Position indicator (3) on brackets (4). Install bolts (5), washers (1), and nuts (2).
71-81-03
Page 1
E-AB412-PT6T-2
G6AB0245A
Figure 1. Differential pressure indicator
71-81-03
Page 2
E-AB412-PT6T-2
71-81-04
ENGINE ACCESSORIES - TORQUE PRESSURE TRANSMITTERS
1. TORQUE PRESSURE TRANSMITTER - DESCRIPTION
Two torque transmitters are mounted on rear of firewall support. The transmitters are connected by electrical harness to the
dual torque pressure indicator on instrument panel.
2. TORQUE PRESSURE TRANSMITTER - REMOVAL
1. Open reduction (combining) gearbox access door.
2. Remove pressure hose (1, figure 1) from elbow (2).
3. Remove electrical connector (9) from transmitter (8).
4. Remove vent hose (12) from union (11).
5. Remove nut (5) and washer (6). Remove transmitter from bracket (7). Cap open lines.
6. If replacing transmitter, accomplish the following:
a. Remove nut (3) with elbow (2) and packing (4).
b. Remove union (11) and packing (10). Discard packings (4 and 10).
NOTE
Removal procedures are identical for opposite torque pressure transmitter.
3. TORQUE PRESSURE TRANSMITTER - INSTALLATION
1. If installing new transmitter, accomplish the following:
a. Install union (11) with packing (10) in vent port transmitter (8).
b. Install elbow (2) with nut (3) and packing (4) in pressure port of transmitter.
2. Position transmitter (8) in bracket (7) with pressure elbow directed through hole in bracket.
3. Install washer (6) and nut (5). Tighten nut (5).
4. Install vent hose (12) on union (11).
5. Install electrical connector (9) on transmitter (8).
6. Install pressure hose (1) on elbow (2).
7. Perform operational check for proper calibration.
71-81-04
Page 1
E-AB412-PT6T-2
G6AB0246A
Figure 1. Torque pressure transmitter (sheet 1 of 2)
71-81-04
Page 2
E-AB412-PT6T-2
G6AB0247A
Figure 1. Torque pressure transmitter (sheet 2 of 2)
NOTE
Installation and operational check procedures are identical for opposite torque
pressure transmitter.
8. Close reduction gearbox access door.
71-81-04
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71-81-04
Page 4
E-AB412-PT6T-2
71-81-05
ENGINE ACCESSORIES - POWER SECTION OIL PRESSURE SWITCH
1. POWER SECTION OIL PRESSURE SWITCH - DESCRIPTION
An oil pressure switch for each power section is installed on lower aft side of reduction (combining) gearbox. The pressure
switches are electrically connected to segments (ENG 1 OIL PRESSURE and ENG 2 OIL PRESSURE) in caution panel
located in pedestal. The pressure switch causes segment in caution panel to extinguish when oil pressure reaches 40 psi after
engine start. If oil pressure in either power section decreases below approximately 31 psi, the appropriate segment in the
caution panel illuminates.
2. POWER SECTION OIL PRESSURE SWITCH - REMOVAL
NOTE
Maintenance procedures are the same for each pressure switch.
3. Remove switch (4) with packing (3). Discard packing.
4. Remove cap (8).
5. Remove bolts (6), washers (7), fitting (2), and packing (1). Discard packing.
3. POWER SECTION OIL PRESSURE SWITCH - INSTALLATION
MATERIALS REQUIRED
NUMBRE NOMENCLATURE
C-405 LOCKWIRE
C-508 LOCKWIRE
1. Install fitting (2, figure 1) with packing (1), bolts (6), and washers (7).
2. Install cap (8).
3. Install switch (4) with packing (3).
4. Secure bolts (6) to switch (4) with lockwire (C-405).
5. Connect electrical connector (5) and lockwire (C-508).
6. Check power section oil level, service if required (Chapter 12).
71-81-05
Page 1
E-AB412-PT6T-2
G6AB0248A
Figure 1. Power section oil pressure switch
71-81-05
Page 2
E-AB412-PT6T-2
71-81-06
ENGINE ACCESSORIES - REDUCTION (COMBINING) GEARBOX OIL
PRESSURE SWITCH
1. REDUCTION (COMBINING) GEARBOX OIL PRESSURE SWITCH - DESCRIPTION
The oil pressure switch is installed on aft side of reduction (combining) gearbox, left of oil filter. The pressure switch is
electrically connected to a warning segment (C BOX OIL PRESSURE) in caution panel located in pedestal. The pressure
switch causes the segment to extinguish when oil pressure reaches 40 psi after engine start. If oil pressure in gearbox
decreases below approximately 31 psi, the segment illuminates.
2. REDUCTION (COMBINING) GEARBOX OIL PRESSURE SWITCH - REMOVAL
3. REDUCTION (COMBINING) GEARBOX OIL PRESSURE SWITCH - INSTALLATION
1. Install switch (2, figure 1) with packing (3) in tee (4).
3. Check gearbox oil level, service if required (Chapter 12).
71-81-06
Page 1
E-AB412-PT6T-2
G6AB0249A
Figure 1. Reduction (combining) gearbox oil pressure switch
71-81-06
Page 2
E-AB412-PT6T-2
71-81-07 ENGINE ACCESSORIES - REDUCTION (COMBINING) GEARBOX OIL TEMPERATURE BULB
71-81-07
TEMPERATURE BULB
1. REDUCTION (COMBINING) GEARBOX OIL TEMPERATURE BULB - DESCRIPTION
The temperature bulb is installed on lower side of reduction (combining) gearbox near the oil filter. The bulb is electrically
connected to the C BOX TEMP warning segment in the caution panel.
2. REDUCTION (COMBINING) GEARBOX OIL TEMPERATURE BULB - REMOVAL
3. Remove bulb (2) and packing (1). Discard packing.
3. REDUCTION (COMBINING) GEARBOX OIL TEMPERATURE BULB -

INSTALLATION
MATERIALS REQUIRED
NUMBER NOMENCLATURE
C-405 LOCKWIRE
1. Install bulb (2, figure 1) with packing (1). Torque bulb (2) 20 to 40 in.-lbs. (2,26 to 4,52 Nm) and lockwire (C-405).
3. Check reduction gearbox oil level, service if required (Chapter 12).
71-81-07
Page 1
E-AB412-PT6T-2
G6AB0250A
Figure 1. Reduction (combining) gearbox oil temperature bulb
71-81-07
Page 2
E-AB412-PT6T-2
71-81-08 ENGINE ACCESSORIES - REDUCTION (COMBINING) GEARBOX OIL PRESSURE TRANSMITTER
71-81-08
PRESSURE TRANSMITTER
1. REDUCTION (COMBINING) GEARBOX OIL PRESSURE TRANSMITTER -

DESCRIPTION
The oil pressure transmitter is installed on top of reduction (combining) gearbox. The transmitter is electrically connected
to GEARBOX OIL temperature and pressure indicator mounted on instrument panel.

REMOVAL
3. Remove transmitter (4) and packing (3). Discard packing.
4. Remove restrictor (2).
5. If applicable, remove plug (6) and packing (5). Discard packing.

INSTALLATION
MATERIALS REQUIRED
NUMBER NOMENCLATURE
C-320 SEALANT
1. If applicable, install plug (6, figure 1) with packing (5).
2. Apply sealant (C-320) on outer threads of restrictor (2). Install restrictor until it bottoms out in pressure transmitter (4).
3. Install pressure transmitter (4) with packing (3).
71-81-08
Page 1
E-AB412-PT6T-2
G6AB0251A
Figure 1. Reduction (combining) gearbox oil pressure transmitter
71-81-08
Page 2
E-AB412-PT6T-2
71-81-09
ENGINE ACCESSORIES - POWER SECTION OIL PRESSURE
TRANSMITTER
1. POWER SECTION OIL PRESSURE TRANSMITTER - DESCRIPTION
An oil pressure transmitter is installed on bottom of each power section accessory gearbox below power section oil tank.
The transmitters are electrically connected to ENGINE OIL 1 and 2 temperature and pressure indicators located on
instrument panel.
2. POWER SECTION OIL PRESSURE TRANSMITTER - REMOVAL
NOTE
Maintenance procedures are the same for each pressure transmitter.
3. Remove transmitter (4) and packing (2). Discard packing.
4. Remove restrictor (3).
5. Remove plug (6) and packing (5). Discard packing.
6. For engine 2, right side, remove access panel inside helicopter on right side of transmission pylon.
3. POWER SECTION OIL PRESSURE TRANSMITTER - INSTALLATION
MATERIALS REQUIRED
NUMBER NOMENCLATURE
C-320 SEALANT
1. If applicable, install plug (6, figure 1) with packing (5).
2. Apply sealant (C-320) on outer threads of restrictor (3). Install restrictor (3) until it bottoms out in pressure transmitter
(4).
3. Install transmitter (4) with packing (2).
71-81-09
Page 1
E-AB412-PT6T-2
7. Secure access panel inside helicopter for engine 2, right side on transmission pylon.
71-81-09
Page 2
E-AB412-PT6T-2
G6AB0252A
Figure 1. Engine power section oil pressure transmitter
71-81-09
Page 3
E-AB412-PT6T-2
71-81-09
Page 4
E-AB412-PT6T-2
71-81-10
ENGINE ACCESSORIES - POWER SECTION OIL TEMPERATURE BULB
1. POWER SECTION OIL TEMPERATURE BULB - DESCRIPTION
An oil temperature bulb is installed on bottom of each power section accessory gearbox below power section oil tank. The
temperature bulbs are electrically connected to ENGINE OIL 1 and 2 temperature and pressure indicators on instrument
panel.
2. POWER SECTION OIL TEMPERATURE BULB - REMOVAL
NOTE
Maintenance procedures are the same for each temperature bulb.
3. Remove bulb (2) and packing (1). Discard packing.
3. POWER SECTION OIL TEMPERATURE BULB - INSTALLATION
MATERIALS REQUIRED
NUMBER NOMENCLATURE
C-405 LOCKWIRE
1. Install bulb (2, figure 1) with packing (1). Torque bulb (2) 20 to 40 in.-lbs. (2,26 to 4,52 Nm) and lockwire (C-405).
71-81-10
Page 1
E-AB412-PT6T-2
G6AB0253A
Figure 1. Engine power section oil temperature bulb
71-81-10
Page 2
E-AB412-PT6T-2
71-81-11
ENGINE ACCESSORIES - STARTER-GENERATOR
1. STARTER-GENERATOR - DESCRIPTION
The starter-generator is a 30 Vdc unit mounted on upper forward right of each power section accessory gearbox. The
starter-generator drives compressor input shaft through gearing in accessory gearbox during engine starting cycle and
provides primary 28 Vdc power for the helicopter.
2. STARTER-GENERATOR - REMOVAL
NOTE
Maintenance procedures are the same for each starter generator except where noted.
3. Disconnect duct from air inlet assemblies (12, figure 1).
4. Remove clamp (10) attaching air inlet assembly (12) to starter generator (9). Remove air inlet assembly.
5. Remove fan cover (11) from starter generator (9).
NOTE
Identify location of electrical cables to aid during installation.
6. Disconnect electrical cables from terminal block (8).
7. While supporting starter generator (9), remove clamp (6). Remove starter generator.
8. Remove nuts (4), washers (3) and adapter (2).
9. Remove packing (7) from shaft of starter generator (9) and discard packing.
3. STARTER-GENERATOR - INSTALLATION
MATERIALS REQUIRED
NUMBER NOMENCLATURE
C-201 PRIMER
NOTE
Installation procedures are the same for each starter-generator except as described
below.
71-81-11
Page 1
E-AB412-PT6T-2
1. Clean accessory gearbox (1, figure 1) and start adapter (2) mating surfaces to ensure good electrical bonding.
2. Install starter adapter (2) as follows:
a. If installing left starter-generator, position starter adapter (2) with one dowel pin (5) at 12 o'clock position.
b. If installing right starter-generator, position starter adapter (2) with one dowel pin (5) at 9 o'clock position.
c. Coat washers (3) with primer (C-201). Install washers (3) and nuts (4).
3. Install starter-generator (9) as follows:
a. Lubricate packing (7) with engine oil (Chapter 12) and install on shaft of starter generator (9).
b. Place clamp (6) over starter adapter (2).
c. If installing left starter-generator, position terminal block (8) at 12 o'clock position, place starter-generator on
starter adapter (2) and tighten clamp (6).
d. If installing right starter-generator, position terminal block (8) at 11 o'clock position, place starter-generator on
starter adapter (2) and tighten clamp (6).
e. On left starter-generator, position fan cover (11) and air inlet assembly (12) at 12 o'clock and tighten clamp (10).
f. On right starter-generator position air inlet (12) at 1 o'clock and tighten clamp (10).
4. Ensure electrical terminals on starter-generator and ends of electrical cables are clean.
5. Connect electrical cables to starter-generator, positioning as shown on figure 2.
NOTE
Torque nuts to the following values:
3/8 inches 220-235 (pound-inches)
#10-32 20-25 (pound-inches)
6. Place nipples over ends of electrical cables, and secure cables using plate and straps.
7. Ensure no interference exists between electrical cables and engine cowling.
8. Attach duct to air inlet screen (12, figure 1).
71-81-11
Page 2
E-AB412-PT6T-2
G6AB0254A
Figure 1. Starter-generator
71-81-11
Page 3
E-AB412-PT6T-2
4. STARTER-GENERATOR - INSPECTION
1. Inspect exterior for condition and damage.
2. Inspect the air inlet assembly (12, figure 1) for security of attachment, cracks, and dents which might interfere with
fan operation.
NOTE
To carry out the following steps removal of the starter-generator will be required.
3. Inspect brushes, brush holders, commutator and bearings.
a. Remove the brush inspection cover.
NOTE
Prior to removing brushes, identify their location in the unit. Brushes must be
reinstalled in their original location.
b. Remove screw securing brush leads to the brush holders.
c. Carefully lift the brush springs and remove the brushes.
NOTE
Brushes must be replaced as a set. If one brush is defective or has reached the wear
limit replace the entire set of brushes.
d. Inspect brushes for cracks, chips, frayed leads, loose rivets and loose shunt connections.
e. Inspect brushes as per figure 3, detail A. It is recommended that brushes be replaced at or near the time the brush
wear indicates 1/4 life remaining.
f. Inspect brush holders for security and condition of springs.
g. Inspect the commutator for a burnished appearance with light filming. A defective commutator will be black,
burned or pitted.
h. Inspect the mica undercut, it must be 0,02 inch (0,51 mm) minimum.
NOTE
Interpreting the feel of bearings requires experience. Some bearings use a high
temperature lubricant that will cause a good bearing to feel rough when turned.
i. Inspect the bearings for roughness by turning the armature in the normal direction of rotation slowly by hand
using your fingers to obtain the “feel” of the bearings. Bearing rotation should be relatively smooth, and the
bearings should not sound dry.
CAUTION
RAPID RELEASE OF THE BRUSH SPRINGS CAN DAMAGE THE BRUSHES.
j. Carefully insert the brushes in their original location on the brush holder assembly. Referring to figure 3, ensure
the shorter side of the brush will be the first to contact the commutator when the armature is rotated in the normal
direction.
71-81-11
Page 4
E-AB412-PT6T-2
G6AB0255A
Figure 2. Starter-generator electrical cable
k. Gently lower the brush springs onto the top of the brush clips.
l. Position the brush leads over the brush spring clips.
m. Install the brush inspection cover.
4. Visually inspect the drive shaft spline for excessive wear or damage.
5. STARTER-GENERATOR - CLEANING
MATERIALS REQUIRED
NUMBER NOMENCLATURE
1. Internal cleaning.
a. Remove the brush inspection cover.
WARNING
WHEN USING COMPRESSED AIR, REGULATE PRESSURE TO 40 PSI OR

LESS. WEAR GOGGLES OR FACE SHIELD TO PROTECT EYES. USE A
DUST FILTER RESPIRATOR. DO NOT AIM THE AIR JET AT EXPOSED
SKIN.
71-81-11
Page 5
E-AB412-PT6T-2
CAUTION
TO PREVENT DAMAGE TO THE BERING SEALS AND TO AVOID FORCING

CONTAMINANTS INTO BEARINGS, DO NOT DIRECT THE AIR JET AT THE
BEARINGS.
b. Remove carbon copper dust from the armature and stator windings using compressed air. Start at the drive and
of the unit and work towards the brushes and commutator area.
c. Inspect the interior of the unit for oil and other contaminants. Remove contaminants by wiping with a cloth
moistened with aliphatic naphtha (C-305).
d. Inspect the air intake and exhaust screens for foreign material. Carefully remove foreign material and check for
possible internal damage to the unit.
2. External cleaning.
a. Thoroughly clean the exterior of the unit using a soft cloth moistened with aliphatic naphtha (C-305). Wipe dry
with a clean lint free cloth.
71-81-11
Page 6
E-AB412-PT6T-2
G6AB0256A
Figure 3. Starter-generator brush installation
71-81-11
Page 7
E-AB412-PT6T-2
71-81-11
Page 8
E-AB412-PT6T-2
CHAPTER 76 - ENGINE CONTROLS

Module Page
Number Title Number
76-00-00 ENGINE CONTROLS
1. Engine controls - general ........................................................................................................................ 1

2. Engine controls - torque matching .......................................................................................................... 1
76-10-01 ENGINE (N1) POWER CONTROLS
1. Engine power controls - description ....................................................................................................... 1
76-10-02 ENGINE (N1) POWER CONTROLS - POWER LEVER (N1) CONTROL RIGGING
1. Power lever (N1) control rigging - description ....................................................................................... 1
76-10-03 ENGINE (N1) POWER CONTROLS - ENGINE TEMPERATURE COMPENSATOR

VERIFICATIONS (ITT VALUES)
1. Engine temperature compensator verifications (ITT trim values) - description ..................................... 1
76-10-04 ENGINE (N1) POWER CONTROLS - ENGINE TORQUE TRANSMITTER ADJUSTMENT

AND FUNCTIONAL CHECK
1. Engine torque transmitter adjustment and functional check - helicopters codes [A] [B] [C] ................ 1
2. Engine torque transmitter adjustment and functional check - helicopters code [D] ............................... 8
76-10-05 ENGINE (N1) POWER CONTROLS - MAXIMUM TORQUE CHECK AND CONTROL LIMIT
SETTING
1. Maximum torque check and control limit setting - description .............................................................. 1

2. Maximum torque check and control limit setting - torque limit adjustment .......................................... 1
3. Maximum torque check and control limit setting - torque limit adjustment, alternate method ........... 13
4. Maximum torque check and control limit setting - torque limit adjustment [A] [B] [C] ..................... 14
76-10-06 ENGINE (N1) POWER CONTROLS - AUTOMATIC FUEL CONTROL IDLE SPEED CHECK
1. Automatic fuel control idle speed check - description ........................................................................... 1
76-10-07 ENGINE (N1) POWER CONTROLS - POWER SECTION ACCELERATION AND

DECELERATION CHECK
1. Power section acceleration and deceleration check - description ........................................................... 1
76-Index
Page 1
E-AB412-PT6T-2

Module Page
Number Title Number
76-10-08 ENGINE (N1) POWER CONTROLS - AUTOMATIC MODE MAXIMUM GAS PRODUCER
SPEED CHECK AND AFCU MAXIMUM N1 STOP ADJUSTMENT
1. Automatic mode maximum gas producer speed check and AFCU maximum N1 stop
adjustment - PT6T-3B/BE engine ...........................................................................................................1
2. Automatic mode maximum gas producer speed check and AFCU maximum n1
stop adjustment - PT6T-3B/BE engine AFCU maximum
N1 stop adjustment, alternate procedure ..................................................................................................3
3. Automatic mode maximum gas producer speed check and AFCU maximum N1 stop
adjustment - PT6T-3D/DE/DF engine .....................................................................................................4
76-10-09 ENGINE (N1) POWER CONTROLS - ENGINE IDLE SPEED ADJUSTMENT
1. Engine idle speed adjustment - description .............................................................................................1
76-10-10 ENGINE (N1) POWER CONTROLS - MANUAL CHANGE-OVER CHECK AND MANUAL/
AUTOMATIC INTERCONNECT LINKAGE ADJUSTMENT
1. Manual change-over check and manual/automatic interconnect linkage adjustment - description ........1
76-11-01 DROOP COMPENSATOR (N2) CONTROLS
1. Droop compensator - description ............................................................................................................1
76-11-02 DROOP COMPENSATOR (N2) CONTROLS - LINEAR ACTUATOR
1. Linear actuator - removal ........................................................................................................................1

2. Linear actuator - installation and rigging ................................................................................................1
3. Linear actuator - inspection .....................................................................................................................2
76-11-03 DROOP COMPENSATOR (N2) CONTROLS - ITT ACTUATOR (ENG 2 ACTUATOR)
1. ITT actuator (ENG 2 actuator) - removal ................................................................................................1

2. ITT actuator (ENG 2 actuator) - installation and rigging ........................................................................1
3. ITT actuator (ENG 2 actuator) - inspection ............................................................................................2
76-11-04 DROOP COMPENSATOR (N2) CONTROLS - DROOP COMPENSATOR CAMBOX [A] [B]
1. Droop compensator cambox [A] [B] - removal ......................................................................................1

2. Droop compensator cambox [A] [B] - installation ..................................................................................1
3. Droop compensator cambox [A] [B] - inspection ...................................................................................1
76-11-05 DROOP COMPENSATOR (N2) CONTROLS - N2 CONTROL RIGGING [A] [B]
1. N2 control rigging [A] [B] - description .................................................................................................1
76-12-01 DROOP COMPENSATOR (N2) CONTROLS - DROOP COMPENSATOR AND CABLE [C] [D]
1. Droop compensator and cable [C] [D] - removal ....................................................................................1

2. Droop compensator and cable [C] [D] - installation ...............................................................................1
3. Droop compensator and cable [C] [D] - inspection .................................................................................4
76-Index
Page 2
E-AB412-PT6T-2

Module Page
Number Title Number
76-12-02 DROOP COMPENSATOR (N2) CONTROLS - N2 CONTROL RIGGING [C]
1. N2 control rigging [C] - description ....................................................................................................... 1
76-12-03 DROOP COMPENSATOR (N2) CONTROLS - N2 CONTROL RIGGING [D]
1. N2 control rigging [D] - description ....................................................................................................... 1
76-Index
Page 3
E-AB412-PT6T-2
FIGURES
Figure Page
Number Title Number
76-00-00 ENGINE CONTROLS
Figure 1. Engine power lever controls............................................................................................................................2

Figure 2. Droop compensator linkage ............................................................................................................................3
Figure 1. Engine power lever controls............................................................................................................................2
Figure 1. Power lever (N1) controls rigging (sheet 1 of 3) ............................................................................................3

Figure 2. Manual and automatic fuel control adjustment...............................................................................................7
Figure 3. Engine idle adjustment....................................................................................................................................8
76-10-04 ENGINE (N1) POWER CONTROLS - ENGINE TORQUE TRANSMITTER ADJUSTMENT

AND FUNCTIONAL CHECK
Figure 1. Torque transmitter calibration (412-075-008-101 torque indicators) (helicopters codes [A] [B]).................3
Figure 2. Torque transmitter calibration (412-075-008-111/-113 torque indicators) (helicopters codes [A] [B] [C]) ..4
Figure 3. Torque transmitter (typical) (sheet 1 of 2) ......................................................................................................5
Figure 4. Calibration tool - hand pressure tester ............................................................................................................7
Figure 5. Torque transmitter setting (typical) (helicopters code [D]) ..........................................................................10
SETTING
Figure 1. Torque Control Unit (TCU) adjustment..........................................................................................................6

Figure 2. Calibration tool - hand pressure tester ............................................................................................................7
Figure 3. Torque Control Unit (TCU) torque limit adjustment......................................................................................8
Figure 4. Universal Torque Control Unit (TCU) torque limit adjustment .....................................................................9
Figure 5. Torque transmitter setting (typical) (helicopters code [D]) ..........................................................................10
Figure 1. Power lever (N1) controls rigging (sheet 1 of 3) ............................................................................................2

Figure 2. Manual and automatic fuel control adjustment provisions .............................................................................5
76-10-07 ENGINE (N1) POWER CONTROLS - POWER SECTION ACCELERATION AND

DECELERATION CHECK
76-10-08 ENGINE (N1) POWER CONTROLS - AUTOMATIC MODE MAXIMUM GAS PRODUCER
SPEED CHECK AND AFCU MAXIMUM N1 STOP ADJUSTMENT
Figure 1. Engine idle adjustment....................................................................................................................................2
76-Index
Page 4
E-AB412-PT6T-2
FIGURES (CONT)
Figure Page
Number Title Number
76-10-10 ENGINE (N1) POWER CONTROLS - MANUAL CHANGE-OVER CHECK AND MANUAL/
AUTOMATIC INTERCONNECT LINKAGE ADJUSTMENT
Figure 1. Manual and automatic fuel control adjustment provisions............................................................................. 2
76-11-01 DROOP COMPENSATOR (N2) CONTROLS
Figure 1. Droop compensator linkage (helicopters codes [A] [B])................................................................................ 2

Figure 2. Droop compensator linkage (helicopters codes [C] [D])................................................................................ 3
Figure 3. Pilot collective switchbox (helicopters code [D]) .......................................................................................... 4
76-11-02 DROOP COMPENSATOR (N2) CONTROLS - LINEAR ACTUATOR
Figure 1. Linear actuator ................................................................................................................................................ 3
76-11-03 DROOP COMPENSATOR (N2) CONTROLS - ITT ACTUATOR (ENG 2 ACTUATOR)
Figure 1. ITT actuator installation ................................................................................................................................. 3
76-11-04 DROOP COMPENSATOR (N2) CONTROLS - DROOP COMPENSATOR CAMBOX [A] [B]
Figure 1. Droop compensator cambox (helicopters codes [A] [B])............................................................................... 2
76-11-05 DROOP COMPENSATOR (N2) CONTROLS - N2 CONTROL RIGGING [A] [B]
Figure 1. N2 controls rigging (helicopters codes [A] [B])............................................................................................. 5

Figure 2. Idle solenoid stops .......................................................................................................................................... 6
Figure 1. Droop compensator cambox control cable (helicopters codes [C] [D]) ......................................................... 3
Figure 1. N2 controls rigging (helicopters code [C])..................................................................................................... 5

Figure 1. N2 controls rigging (helicopters code [D])..................................................................................................... 5

76-Index
Page 5
E-AB412-PT6T-2
TABLES
Table Page
Number Title Number
SETTING
Table 1. Model 412 Pratt and whitney PT6T-3B torque meter pressure at torque limit [A] [B]
with 412-075-008-101 indicators....................................................................................................................3
Table 2. Model 412 Pratt and Whitney PT6T-3B torque meter pressure at torque limit [A] [B] [C]
with 412-075-008-111/113 indicators.............................................................................................................4
Table 3. Model 412 HP Pratt and Whitney PT6T-3BE /-3D torquemeter pressure at torque limit [D] ......................5
Table 4. Coarse adjustment dome range .....................................................................................................................12
76-Index
Page 6
E-AB412-PT6T-2
76-0 -0 ENGINE CONTROLS
76-00-00
ENGINE CONTROLS
1. ENGINE CONTROLS - GENERAL
Major components of the system are the Automatic Fuel Control Units (AFCU), Manual Fuel Control Units (MFCU), power
turbine (N2) governors, Torque Control Unit (TCU), droop compensator control linkage and power lever control linkage
(figure 1 and figure 2).
The engine control system permits the pilot to obtain maximum engine performance with minimum attention. Under normal
flight conditions, the power turbine (N2) speed is controlled by Automatic Fuel Control Units (2 and 7, figure 1), power
turbine governors (3 and 7, figure 2), and droop compensator (45).
The Automatic Fuel Control Units (2 and 7, figure 1) safeguard engine power sections, against overloading. On acceleration
and deceleration, the Automatic Fuel Control Units avoid engine damage and/or flameout due to sudden power changes.
The Manual fuel Control Units (3 and 8) can be operated in either automatic or manual mode. The pilot can select AUTO
or MAN operation by means of engine GOV switches. When operating in MANUAL mode, the pilot positions lever (4 and/
or 9) on manual fuel controls by means of twist grip throttles (29 and/or 30),
Refer to Pratt & Whitney Aircraft of Canada Ltd. PT6T-3 Series Maintenance Manual for detailed description of engine
mounted components.
2. ENGINE CONTROLS - TORQUE MATCHING
NOTE
Code [D] helicopters have an ITT trim actuator (2, figure 2) installed in place of tube
(1) which can be extended or retracted to provide torque or ITT matching. Refer to
module 76-10-05 paragraph "4. Maximum torque check and control limit setting -
torque limit adjustment [A] [B] [C]" for ITT trim actuator.
1. Prior to making any adjustments, ensure the pointers on the torque pressure transmitters are indexed in accordance with
the reduction (combining) gearbox data plate.
NOTE
Notwithstanding the favoring of torque matching over RPM INCR/DECR switch
matching, the engine controls rigging must allow steady state, single power section
flight at 97% or higher power turbine N.2 speed with either engine power section.
2. If the torque split exceeds 4%, during steady state operations, match engine 1 (left power section) torque to engine 2
(right power selection) torque by adjusting the length of tube (9).
a. If engine 1 (left power section) torque is too high throughout collective range, lengthen tube (9).
b. If engine 1 (left power section) torque is too low throughout collective range, shorten tube (9).
3. After adjusting control tube (9), check clearance between stop arms adjacent to governors (3 and 7) and minimum/
maximum stop crews.
76-00-00
Page 1
E-AB412-PT6T-2
G6AB0226A
Figure 1. Engine power lever controls
76-00-00
Page 2
E-AB412-PT6T-2
HELICOPTERS CODE D
G6AB0227A
Figure 2. Droop compensator linkage
76-00-00
Page 3
E-AB412-PT6T-2
76-00-00
Page 4
E-AB412-PT6T-2
76-10-01
ENGINE (N1) POWER CONTROLS
1. ENGINE POWER CONTROLS - DESCRIPTION
The (N1) power lever control system consists of two parallel mechanical linkage subsystems, connecting dual throttle
control twist grip (29 and 30, figure 1) to Manual Fuel Control Units (3 and 8), on engine power sections. From the collective
jackshaft, the power lever control linkage extends aft under the cabin floor between the main beams, then up inside the pylon,
and through the cabin roof into the inlet faring forward of the engine accessory gearboxes.
The power lever control linkage are actuated by throttle twist grips (29 and 30). A friction control is provided on pilots
throttle only. The upper twist grip (30) marked ENG 1, controls engine 1 gas producer (GAS PROD) rpm for left (No. 1)
power section. The lower twist grip (29), marked ENG 2, controls engine 2 gas producer (GAS PROD) rpm for right (No.
2) power section. Both twist grips are marked with arrows showing direction of movement to increase (INCR) rpm. When
twist grip is turned right, rpm will be reduced until linkage contacts idle stop at approximately 61% GAS PROD rpm.
Idle stop solenoids (1 and 15), are operated by IDLE STOP ENG 1 and ENG 2 release switch on pilot collective switch box.
When either idle stop release switch is activated, the corresponding idle stop solenoid plunger will retract allowing MFCU
to be placed in cut-off position. The idle stop plunger will not retract if excessive pressure is applied by the twist grip toward
the closed position.
76-10-01
Page 1
E-AB412-PT6T-2
G6AB0226A
Figure 1. Engine power lever controls
76-10-01
Page 2
E-AB412-PT6T-2
76-10-02
ENGINE (N1) POWER CONTROLS - POWER LEVER (N1) CONTROL
RIGGING
1. POWER LEVER (N1) CONTROL RIGGING - DESCRIPTION
MATERIALS REQUIRED
NUMBER NOMENCLATURE
NOTE
If dual controls kit (212-706-005-101) is installed, refer to module 76-11-05
"DROOP COMPENSATOR (N2) CONTROLS - N2 CONTROL RIGGING [A]
[B]" for instructions to rig droop compensator controls.
1. Comply with the following general procedures when rigging power lever controls.
a. When a rigging procedure requires a specific position to accomplish steps, manually hold controls in position or
secure controls in position with pilot friction adjustment.
b. Tolerance for rigging dimensions is ±0,030 in. (0,76 mm) unless stated otherwise.
c. All adjustable control tubes shall have a maximum of 1,00 in. (25,4 mm) of exposed threads after adjustment. If
control tubes have inspection holes, threads shall engage sufficiently to cover holes.
d. Apply corrosion preventive compound (C-101) to exposed threads of all adjustable rod bearings and clevises
after adjustment.\
e. Torque control tube jamnuts 80 to 100 in-lbs (9,0 to 11,3 Nm) after adjustment unless otherwise specified.
f. Control tubes must be free to rotate several degrees about longitudinal axis. If necessary, loosen jamnuts, adjust
end fittings, and re-torque jamnuts.
2. If not previously accomplished, rig collective control system (Chapter 67).
3. Verify proper throttle flex shaft to gear sector engagement as follows:
a. Disconnect tubes (25 and 11, figure 1).
b. Disconnect control tube (16) from rod end bearing (17).
c. Disconnect control tube (21) rod end bearing (22).
d. Inspect marked tooth (41) on pilot engine 1 flex shaft (40) to ensure engagement of tenth tooth space on pilot
engine 1 gear sector.
e. Inspect marked tooth on pilot engine 2 flex shaft (39) to ensure engagement of tenth tooth space on pilot engine
2 gear sector (42).
f. Inspect two gear sectors and flex shafts at base of copilot collective stick in same manner outlined in steps d. and e.
76-10-02
Page 1
E-AB412-PT6T-2
NOTE
If dual controls are installed accomplish step g., do not accomplish step h. If dual
controls are not installed accomplish step h., do not accomplish step g.
g. If dual controls are installed, position pilot ENG 1 and ENG 2 (20) throttles to full open position against stops.
Position copilot ENG 1 and ENG 2 throttles to full open. Hold twist grips in position against stops. Do not
accomplish step h. Proceed to step i.
h. If dual controls are not installed, position pilot ENG 1 (19) and ENG 2 (20) throttles to full open position against
stops. Hold twist grips in position against stops. Position copilot engine 1 and engine 2 gear sectors (44 and 45)
as shown in View D. Hold gear sectors in position while accomplishing steps i. and j.
NOTE
Controls must be positioned as described in steps g. or h. as applicable, prior to
accomplishing steps i. and j.
i. Adjust control tube (21) to fit double rod end bearing (22). Torque jamnut on control tube (21) clevis. Install
control tube (21) on double rod end bearing (22).
j. Adjust control tube (16) to fit double rod end bearing (17). Torque jamnut on control tube (16) clevis. Install
control tube (16) on double rod end bearing (17).
k. Move pilot throttle controls through the full range and verify for binding and/or obstruction of control
movement.
l. Check pilot engine 2 gear sector (42) at base of pilot collective and pilot engine 2 flex shaft (39) when engine 2
throttle (20) is moved through full range to ensure gear sector (42) is a minimum of one tooth of rolling off flex
shaft (39) pinion.
m. Check pilot engine 1 flex shaft (40) pinion and mating gear sector at base of pilot collective is same manner
described in preceding step.
n. Check gear sectors (44 and 45) at the base of copilot collective in the same manner described in steps k. and l.
4. Comply with the following rigging procedure for engine 2 (ENG 2).
a. For ENG 2, inspect lever (3, figure 1) for correct position in relation to stop arm (32, view A). If lever is not
aligned within 15 degrees of center line, loosen nut (33), position lever (3) on shaft of MFCU (2) within 15
degrees of center line, and tighten nut (33). Ensure serrations on lever are properly engaged with serrations on
shaft. Install cotter pin to secure nut (33).
b. Disconnect tubes (28), (27), and (11).
c. Loosen clamps holding boot (47) on tube (28) and allow boot to float on tube.
d. Adjust tube (28) to a nominal dimension of 28,63 in. (727,20 mm). The measurement is from center of the
bearing bolt hole to the center of the other bearing bolt hole.
e. Adjust tube (11) to a nominal dimension to 26,94 in. (684,28 mm). The measurement is from center of the
NOTE
Refer to applicable Pratt & Whitney Aircraft of Canada Ltd. PT6T-3 Series
Maintenance Manual for MFCU clearance adjustment procedure.
76-10-02
Page 2
E-AB412-PT6T-2
G6AB0851A
Figure 1. Power lever (N1) controls rigging (sheet 1 of 3)
76-10-02
Page 3
E-AB412-PT6T-2
G6AB0852A
76-10-02
Page 4
E-AB412-PT6T-2
G6AB0853A
76-10-02
Page 5
E-AB412-PT6T-2
f. With part power trim stop (12, figure 2) in stowed position rotate lever (3, figure 1) until Automatic Fuel Control
Unit (AFCU) (1) max stop is contacted. Check for 0,015 to 0,020 in. (0,38 to 0,51 mm) clearance between
Manual Fuel Control Unit (MFCU) stop (8, figure 2) and maximum stop screw (9). If required, adjust AFCU/
MFCU interconnect linkage as per applicable Pratt & Whitney Aircraft of Canada Ltd. PT6T-3 Series
Maintenance Manual to obtain required clearance.
NOTE
During following steps a small wooden block can be used as a work aid to hold idle
stop solenoid plunger in the retracted position.
g. Connect tube (28, figure 1) to lever (3). With idle stop solenoid (30) plunger retracted, check for power lever
travel form FULL OFF to MAX POWER. Ensure maximum stop screw (9, figure 2) and minimum stop screw
(6) contact stop (8).
h. Connect tube (27, figure 1) in the center hole of jackshaft (10) arm lever and extend plunger of idle stop solenoid
(30) (remove wooden block).
i. Rotate jasckshaft (10) to contact idle solenoid stop. Ensure MFCU (2) pointer is aligned at approximately 37
degrees. If not, adjust tube (28) for proper alignment. Check for smooth rotation.
j. Connect tube (11) and hold idle stop solenoid (30) plunger in retracted position (install wooden block).
k. Rotate ENG 2 throttle twist grip (20) to full open and check overtravel (cushion). Twist grip should rotate an
additional 4 to 6 degrees after maximum stop screw (9, figure 2) contacts stop (8). Rotate throttle twist grip (20,
figure 1) to full closed. The twist grip should rotate an additional 4 to 6 degrees after minimum stop screw (6,
figure 2) contacts stop (8).
l. If overtravel is not equal between full open and full closed positions, adjust tube (11, figure 1). Ensure rod end
of tube (11) is visible in witness hole. If twist grip (20) does not have sufficient travel, move tube (27) to next
hole towards end of arm on jackshaft (10) (refer to figure 1).
m. Rotate ENG 2 throttle twist grip (20) to full open and hold with friction. Secure boot (47) on tube (28) with
clamps.
n. Extend idle stop solenoid (30) plunger (remove wooden block). With idle stop lever (29) against plunger, verify
that MFCU (2) pointer is aligned to approximately 37 degrees. If not adjust idle stop adjustment screw
(1, figure 3). If available adjustment of idle stop adjustment screw (1) is not adequate (insufficient threads),
replace four NAS43DD3 spacers (5) under the idle stop solenoid (3) with longer or shorter lenghts as required.
NOTE
Idle stop solenoid (30, figure 1) is operated by IDLE STOP release switch (18) on
pilot collective stick. When IDLE STOP release switch is activated, the
corresponding idle stop solenoid plunger is retracted for 5 seconds.
o. Move IDLE STOP release switch (18) to ENG 2 position and check clearance between plunger (4, figure 3) and
idle stop lever (2). Acceptable clearance is 0,003 to 0,015 in. (0,08 to 0,38 mm). If clearance is not within
tolerance, adjust position of idle stop solenoid (3) on serrated bracket assembly (10) and base (11) to obtain
acceptable clearance.
p. Inspect all linkage shown on figure 1 for proper installation of bolts, nuts, and cotter pins.
76-10-02
Page 6
E-AB412-PT6T-2
G6AB0854A
Figure 2. Manual and automatic fuel control adjustment
76-10-02
Page 7
E-AB412-PT6T-2
G6AB0855A
Figure 3. Engine idle adjustment
76-10-02
Page 8
E-AB412-PT6T-2
5. Comply with the following rigging procedure for engine 1 (ENG 1).
a. For ENG 1, inspect lever (6, figure 1) for correct position in relation to stop arm (36, view B). If lever is not
aligned within 15 degrees of centerline, loosen nut (37), position lever (6) on shaft of MFCU (5) within 15
degrees of centerline, and tighten nut (37). Ensure serrations on lever are properly engaged with serrations on
shaft. Install cotter pin to secure nut (37).
b. Disconnect tubes (7,26 and 25) and link (49).
c. Loosen clamps holding boot (48) on tube (7) and allow boot to float on tube.
d. Adjust tube (7) to a nominal dimension of 25,03 in. (635,76 mm). The measurement is from center of the bearing
bolt hole to the center of the other bearing bolt hole.
e. Adjust tube (25) to a nominal dimension of 25,68 in. (654,27 mm). The measurement is from center of the
NOTE
Refer to applicable Pratt & Whitney Aircraft of Canada Ltd, PT6T-3 Series
Maintenance Manual for MFCU clearance adjustment procedure.
f. With part power trim stop (12, figure 2) until AFCU (4) max stop is contacted. Check for 0,015 to 0,020 in. (0,38
to 0,51 mm) clearance between MFCU stop (8, figure 2) and maximum stop screw (9). If required, adjust AFCU/
MFCU interconnect linkage as per applicable Pratt & Whitney Aircraft of Canada Ltd. PT6T-3 Series
Maintenance Manual to obtain required clearance.
NOTE
During following steps a small wooden block can be used as a work aid to hold idle
stop solenoid plunger in the retracted position.
g. Connect tube (7, figure 1) to jackshaft (50) and link (49) to lever (6). With idle stop solenoid (9) plunger
retracted, check for power lever travel from FULL OFF to MAX POWER without fouling between jackshaft
(50) and tube (7). Ensure maximum stop screw (9, figure 2) and minimum stop screw (6) contact stop (8). In
case of fouling between jackshaft (50, figure 1) and tube (7), offset lever (6) by one serration (±15 degrees) and
repeat step.
h. Connect tube (26, figure 1) in the center hole of jackshaft (10) arm lever and extend plunger of idle stop solenoid
(9) (remove wooden block).
i. Rotate the jackshaft (10) to contact idle solenoid stop. Ensure MFCU (5) pointer is aligned at approximately 37
degrees. If not, adjust tube (7) for proper alignment. Check for smooth rotation.
j. Connect tube (25) and hold idle stop solenoid (9) plunger in retracted position (install wooden block).
k. Rotate ENG 1 throttle twist grip (19) to full open and check overtravel (cushion). Twist grip should rotate an
additional 4 to 6 degrees after maximum stop screw (9, figure 2) contacts stop (8). Rotate throttle twist grip (19,
figure 1) to full closed. The twist grip should rotate an additional 4 to 6 degrees after minimum stop screw (6,
figure 2) contacts stop (8).
l. If overtravel is not equal between full open and full closed positions, adjust tube (25, figure 1). Ensure rod end
of tube (25) is visible in witness hole. If twist grip (19) does not have sufficient travel, move tube (26) to next
hole towards end of arm on jackshaft (10). If twist grip (19) has too much travel, move tube (26) to the next hole
in arm nearer jackshaft (10) (refer to figure 1).
m. Rotate ENG 1 Throttle twist grip (19) to full open and hold with friction. Secure boot (48) on tube (7) with
clamps.
76-10-02
Page 9
E-AB412-PT6T-2
n. Extend idle stop solenoid (9) plunger (remove wooden block). With idle stop lever (8) against plunger, verify
that MFCU (5) pointer is aligned to approximately 37 degrees. If not, adjust idle stop adjustment screw
(9, figure 3). If available adjustment of idle stop adjustment screw (9) is not adequate (insufficient threads),
replace four NAS43DD3 spacers (5) under the idle stop solenoid (7) with longer or shorter lenghts as required.
NOTE
Idle stop solenoid (9, figure 1) is operated by IDLE STOP release switch (18) on
pilot collective stick. When IDLE STOP release switch is activated, the
corresponding idle stop solenoid plunger is retracted for 5 seconds.
o. Move IDLE STOP release switch (18) to ENG 1 position and check clearance between plunger (6, figure 3) and
idle stop lever (8). Acceptable clearance is 0,003 to 0,015 in. (0,08 to 0,38 mm). If clearance is not within
tolerance, adjust position of the idle stop solenoid (7) on serrated bracket assembly (10) and base (11) to obtain
acceptable clearance.
p. Inspect all linkages shown on figure 1 for proper installation of bolts, nuts, and cotter pins.
76-10-02
Page 10
E-AB412-PT6T-2
76-10-03 ENGINE (N1) POWER CONTROLS - ENGINE TEMPERATURE COMPENSATOR VERIFICATIONS (ITT VALUES)
76-10-03
ENGINE (N1) POWER CONTROLS - ENGINE TEMPERATURE
COMPENSATOR VERIFICATIONS (ITT VALUES)
1. ENGINE TEMPERATURE COMPENSATOR VERIFICATIONS (ITT TRIM VALUES) -

DESCRIPTION
NOTE
Reference in the Pratt & Whitney Aircraft of Canada Ltd, PT6T-3 Series
Maintenance Manual to indicate temperature (T5) refers to ITT indicators on
helicopters instrument panel.
1. Start engines and operate for 5 minutes to stabilize operating temperatures.
2. Remove top power connection from trim compensator and note indicated ITT rise by amount equal to trim value on
power section data plate.
3. If not, remove lockwire and protective cap. Adjust trim compensator adjustment screw as necessary.
4. Connect top power connection to trim compensator. Indicated temperature (ITT) should drop by an amount equal to
the trim value.
76-10-03
Page 1
E-AB412-PT6T-2
76-10-03
Page 2
E-AB412-PT6T-2
76-10-04 ENGINE (N1) POWER CONTROLS - ENGINE TORQUE TRANSMITTER ADJUSTMENT AND FUNCTIONAL CHECK
76-10-04
ENGINE (N1) POWER CONTROLS - ENGINE TORQUE TRANSMITTER
ADJUSTMENT AND FUNCTIONAL CHECK
1. ENGINE TORQUE TRANSMITTER ADJUSTMENT AND FUNCTIONAL CHECK -

HELICOPTERS CODES [A] [B] [C]
NUMBER NOMENCLATURE
T93 DEADWEIGHT TESTER OR EQUIVALENT
T120 PRESSURE GAUGE
NOTE
The following procedure is applicable to the 412-075-205-101 torque transmitter
with 412-075-008-101, 412-075-008-111, or 412-075-008-113 torque indicators.
Refer to figure 1 for calibration of 412-075-008-101 indicators and figure 2 for
412-075-008-111/-113 indicators.
The following torque adjustment procedure is required when engine (Twin-Pac) or

reduction gearbox is changed and/or when either torque transmitter is changed.
For additional information on engine torque indicating systems, refer to Chapters 95

or 96.
Torque transmitter adjustment procedures for left power section are given.
Adjustment procedures for right power section are similar.
1. Locate data plate (1, figure 3) on engine reduction gearbox and record torque transmitter settings for left power section
(figure 3, view B). The settings for left torque transmitter on sample data plate are:
LH valves ABD
LH  87,7
2. Remove cover from left torque transmitter (5). Refer to detail A for view of valves A, B, C, and D, with cover removed.
Set valves to On or OFF positions recorded at step 1. Note valves A, B, and D, are ON and valve C is OFF on sample
shown.
3. Locate ° value 8 (recorded at step 1.) on figure 1 for 412-075-008-101 torque indicators and figure 2 for
412-075-008-111/-113 torque indicators. Record corresponding torque indicating reading.
4. Remove hose (2, figure 3) and elbow from torque transmitter (5).
5. If torque transmitter (5) does not contain oil, fill transmitter with engine lubricating oil at port where hose (2) was
removed.
76-10-04
Page 1
E-AB412-PT6T-2
CAUTION
ENSURE PRESSURE TESTER IS SERVICED WITH SAME OIL AS USED IN

COMBINING GEARBOX.
PRESSURE TESTER AND GAUGE SHALL BE AT THE SAME HEIGHT AS

REDUCTION GEARBOX TORQUE METER (APPROXIMATE LEVEL OF OIL
COOLER BLOWER CENTERLINE).
6. Attach a deadweight tester (or equivalent liquid pressure source) (figure 4) to torque transmitter (5, figure 3) port where
hose (2) was removed. Apply 35,4 ± 0,25 psig to transmitter with tester. Verify no air present in line.
7. Position BATTERY BUS 1 and 2 switches ON. Position INV 1 AND INV 2 switches to ON. Record pilot (and copilot,
if installed) ENG 1 TORQUE indication. Compare indication with value recorded at step 3. If pilot TORQUE
indicators are not the same as value recorded at step 3., adjust zero adjust screw on transmitter (5, figure 3).
Counterclockwise rotation of screw increases indicated value. Vibrate transmitter (5) during calibration to ensure
indication remains the same. After zero screw is set, apply torque lacquer dot to screw.
8. Position INV 1 e 2 and BATTERY BUS 1 and 2 switches to OFF.
9. Disconnect and remove tester.
10. Install elbow and hose (2) on transmitter (5).
11. Install cover on transmitter (5) valves (detail A).
12. Start left power section and observe ENG 1 TORQUE indicator. If indicator needle fluctuates, bleed air form hose (2)
at transmitter (5).
76-10-04
Page 2
E-AB412-PT6T-2
G6AB0230A
Figure 1. Torque transmitter calibration (412-075-008-101 torque indicators) (helicopters codes [A] [B])
76-10-04
Page 3
E-AB412-PT6T-2
G6AB0231A
Figure 2. Torque transmitter calibration (412-075-008-111/-113 torque indicators) (helicopters codes [A] [B] [C])
76-10-04
Page 4
E-AB412-PT6T-2
G6AB0232A
Figure 3. Torque transmitter (typical) (sheet 1 of 2)
76-10-04
Page 5
E-AB412-PT6T-2
G6AB0233A
Figure 3. Torque transmitter (typical) (sheet 2 of 2)
76-10-04
Page 6
E-AB412-PT6T-2
G6AB0234A
Figure 4. Calibration tool - hand pressure tester
76-10-04
Page 7
E-AB412-PT6T-2
2. ENGINE TORQUE TRANSMITTER ADJUSTMENT AND FUNCTIONAL CHECK -

HELICOPTERS CODE [D]
NUMBER NOMENCLATURE
T120 PRESSURE GAUGE
MATERIALS REQUIRED
NUMBER NOMENCLATURE
C-405 LOCKWIRE
NOTE
The following procedure is applicable to the 412-375-006-101 torque transmitter.
Perform the following torque adjustment procedure when engine (Twin-Pac) or
reduction gearbox is charged and/or when either torque transmitter is changed.
For additional information on engine torque indicating systems refer to Chapters 95

and 96.
Torque transmitter adjustment procedures for left power section are given.
Adjustment procedures for right power section are similar.
1. Locate data plate on engine reduction gearbox and record torque transducer settings for left power section (figure 5,
detail B). The torque transducer settings for left torque transmitter on sample data plate are:
LH valves ABD
LH ° 87,7
2. Remove slope adjustment cover from left torque transmitter (detail C). Using table (detail A), verify rotary switch is
set to position associated with code letter on data plate. Install cover.
CAUTION

COMBINING GEARBOX.
PRESSURE TESTER AND GAUGE SHALL BE AT THE SAME HEIGHT AS

COOLER BLOWER CENTERLINE).
3. Disconnect hose at torque transmitter pressure port and attach a deadweight pressure tester or equivalent pressure
source to torque transmitter pressure port where hose was removed. Apply a reference pressure of 35,4 ± 0,25 psig to
pressure port of torque transmitter. Verify no air is present in line.
4. Energize essential busses by turning on either BATTERY BUS 1 or 2 switch. Record pilot ENG 1 TORQUE indication.
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E-AB412-PT6T-2
5. Calculate percentage torque corresponding to referenced test pressure (35,4 psig) according to the following equation:
% Engine torque = ° ÷ 2, ° previously recorded in step 1.
EXAMPLE CALCULATION:
% Eng 1 torque = 87,7 ÷ 2 = 43,85% which rounds off to 43,8%
6. The pilot ENG 1 TORQUE pointer reading should match engine torque percentage calculated in step 5. If not, remove
zero adjustment cover (detail C) on pressure transducer and rotate zero adjustment screw until pilot engine 1 pointer
displays calculated torque value. The copilot indicator (if installed) should read within 1,0% of pilot indicator. ENG 2
TORQUE pointer on both indicators should indicate zero torque.
7. Turn BATTERY BUS 1 nd 2 switches OFF.
8. Disconnect and remove tester installed at step 3.
9. Connect hose on pressure port of torque transmitter.
10. Install the two covers and lockwire (C-405) together.
11. Start left power section and observe ENG 1 TORQUE indicator. If indicator needle fluctuates, bleed air from hose at
pressure port of torque transmitter.
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E-AB412-PT6T-2
G6AB0235A
Figure 5. Torque transmitter setting (typical) (helicopters code [D])
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76-10-05 ENGINE (N1) POWER CONTROLS - MAXIMUM TORQUE CHECK AND CONTROL LIMIT SETTING
76-10-05
ENGINE (N1) POWER CONTROLS - MAXIMUM TORQUE CHECK AND
CONTROL LIMIT SETTING
1. MAXIMUM TORQUE CHECK AND CONTROL LIMIT SETTING - DESCRIPTION
NUMBER NOMENCLATURE
T120 PRESSURE GAUGE
CAUTION
PERFORM TORQUE LIMITER CHECK AND ADJUSTMENT PROCEDURE

AFTER EACH CHANGE OF REDUCTION GEARBOX AND/OR TORQUE
CONTROL UNIT (TCU).
NOTE
Procedures outline in paragraph "2. Maximum torque check and control limit setting
- torque limit adjustment" or paragraph "3. Maximum torque check and control limit
setting - torque limit adjustment, alternate method" are applicable to all 412/412EP
helicopters.
There are two preferred methods to adjust and check the Torque Control Unit (TCU) maximum torque limit setting. The
primary method (paragraph "2. Maximum torque check and control limit setting - torque limit adjustment") requires
operation of the engines. The alternate method (paragraph "3. Maximum torque check and control limit setting - torque limit
adjustment, alternate method") is performed without operating the engines. Both of these procedures are performed on the
ground. Refer to paragraph "4. Maximum torque check and control limit setting - torque limit adjustment [A] [B] [C]" for
an additional method applicable to 412 helicopters codes [A] [B] [C] only.
2. MAXIMUM TORQUE CHECK AND CONTROL LIMIT SETTING - TORQUE LIMIT

ADJUSTMENT
1. For aircraft equipped with Torque Control Unit (TCU) per figure 1 proceed as follows:
a. Remove lockwire and disconnect tube assemblies (6 and 7) from fitting (5 and 8).
b. Plug open ends of tubes (6 and 7).
c. Using test equipment (figure 2 or equivalent) with a tee fitting and two lines. Connect one line of the pressure
tester to fitting (5, figure 1) and one line to fitting (8).
2. For aircraft equipped with Torque Control Unit (TCU) as shown on figure 3 or Universal Torque Control Unit (TCU)
as shown on figure 4 proceed as follows:
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E-AB412-PT6T-2
a. Remove lockwire and disconnect tube assemblies (1 and 2, figure 3 or figure 4) from tee fittings (3 and 4).
b. Plug open ends of the tube assemblies (1 and 2) and cap port “D” on tee fitting (4).
c. Using test equipment hoses, connect pressure tester to port “A” on tee fitting (3). Connect test hose between port
“B” and “C”.
CAUTION

COMBINING GEARBOX.
PRESSURE TESTER AND GAUGE SHALL BE AT SAME HEIGHT AS

COOLER BLOWER CENTER LINE).
3. Fill and bleed pressure tester, fitting and hoses.
4. Calculate torque limiter setting as follows:
NOTE
In the following steps table 3 is used as an example. Use the following chart to
determine the correct table for a particular helicopter configuration.
codes [A] [B] with 412-075-008-101 indicators table 1
codes [A] [B] [C] with 412-075-008-111/113 indicators table 2
code [D] table 3
a. Locate data plate on reduction (combining) gearbox and record “SPAN” and “ZERO” setting for left and right
power section. See figure 5 detail B for sample date plate. The “span” and “zero” setting for left and right power
sections on the sample data plate are:
- LH ZERO NEG 5,1 RH ZERO NEG 4,0
- LH SPAN POS 9,2 RH SPAN POS 4,5
b. For left and right sides combining gearbox determine torque pressure equivalent to limiting torque as follows:
NOTE
If “SPAN” number falls between two ranges (e.g., is 5,0 or 8,0 etc.), use row at next
higher range (e.g., if “SPAN” number is 5,0, follow row corresponding to 5 to 6
range).
c. Enter in table 3 on left side row corresponding to range in which “SPAN” number falls.
NOTE
If “ZERO” number falls between two ranges (e.g., is 7 or 9 etc.), use row at the next
lower (less negative) range (e.g. if “ZERO” number is -7,0, use column
corresponding to -6 to -7,0 range).
76-10-05
Page 2
Table 1. Model 412 Pratt and whitney PT6T-3B torque meter pressure at torque limit [A] [B] with 412-075-008-101 indicators
Zero Inc. –12 –11 –10 -9 –8 –7 –6 –5 –4 –3 –2 –1 0 1
Span Ratio
22
42,29 41,93 41,57 41,22 40,86 40,50 40,14 39,78 39,42 39,06 38,70 38,34 37,98 37,62
21
42,51 42,15 41,79 41,43 41,07 40,70 40,34 39,98 39,62 39,26 38,90 38,54 38,18 37,82
20
42,73 42,37 42,00 41,64 41,28 40,91 40,55 40,19 39,82 39,46 39,10 38,74 38,37 38,01
19
42,95 42,58 42,22 42,85 41,49 41,13 40,76 40,40 40,03 39,67 39,30 38,94 38,57 38,21
18
43,17 42,81 42,44 42,07 41,71 41,34 40,97 40,61 40,24 39,87 39,51 39,14 38,77 38,41
17
43,40 43,03 42,66 42,29 41,92 41,55 41,19 40,82 40,45 40,08 39,71 39,34 38,97 38,61
16
43,63 43,25 42,88 42,51 42,14 41,77 41,40 41,03 40,66 40,29 39,92 39,55 39,18 38,81
15
43,86 43,48 43,11 42,74 42,37 41,99 41,62 41,25 40,88 40,50 40,13 39,76 39,39 39,01
14
44,09 43,71 43,34 42,96 42,59 42,22 41,84 41,47 41,09 40,72 40,34 39,97 39,59 39,22
13
44,32 43,95 43,57 43,19 42,82 42,44 42,06 41,69 41,31 40,94 40,56 40,18 39,81 39,43
12
44,56 44,18 43,80 43,34 43,05 42,67 42,29 41,91 41,53 41,15 40,78 40,40 40,02 39,64
11
44,80 44,42 44,04 43,66 43,28 42,90 42,52 42,14 41,76 41,38 41,00 40,62 40,24 39,85
10
45,04 44,66 44,28 43,90 43,51 43,13 42,75 42,37 41,98 41,60 41,22 40,84 40,45 40,07
9
45,29 44,90 44,52 44,14 43,75 43,37 42,98 42,60 42,21 41,83 41,44 41,06 40,67 40,29
8
45,54 45,15 44,76 44,38 43,99 43,60 43,22 42,83 42,44 42,06 41,67 41,28 40,90 40,51
7
45,79 45,40 45,01 44,62 44,23 43,84 43,46 43,07 42,68 42,29 41,90 41,51 41,12 40,73
6
46,04 45,65 45,26 44,87 44,48 44,09 43,70 43,30 42,91 42,52 42,13 41,74 41,35 40,96
5
46,30 45,91 45,51 45,12 44,73 44,33 43,94 43,55 43,15 42,76 42,37 41,97 41,58 41,19
4
46,56 46,16 45,77 45,37 44,98 44,58 44,19 43,79 43,39 43,00 42,60 42,21 41,81 41,42
3
46,82 46,42 46,02 45,63 45,23 44,83 44,43 44,04 43,64 43,24 42,84 42,45 42,05 41,65
2
47,09 46,69 46,29 45,89 45,49 45,09 44,69 44,29 43,89 43,49 43,09 42,69 42,29 41,89
1
47,35 46,95 46,55 46,15 45,75 45,34 44,94 44,54 44,14 43,73 43,33 42,93 42,53 42,13
0
47,63 47,22 46,82 46,41 46,01 45,60 45,20 44,79 44,39 43,98 43,58 43,18 42,77 42,37
–1
47,90 47,49 47,09 46,68 46,27 45,87 45,46 45,05 44,65 44,24 43,83 43,42 43,02 42,61
–2
48,18 47,77 47,36 46,95 46,54 46,13 45,72 45,31 44,90 44,49 44,09 43,68 43,27 42,86
–3
48,46 48,05 47,64 47,22 46,81 46,40 45,99 45,58 45,17 44,75 44,34 43,93 43,52 43,11
–4
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E-AB412-PT6T-2
Table 2. Model 412 Pratt and Whitney PT6T-3B torque meter pressure at torque limit [A] [B] [C] with 412-075-008-111/113
indicators
Page 4
76-10-05
Zero Inc. –12 –11 –10 -9 –8 –7 –6 –5 –4 –3 –2 –1 0 1 2
Span Ratio
22 E-AB412-PT6T-2
43,71 43,35 43,00 42,64 42,28 41,92 41,56 41,20 40,84 40,48 40,12 39,76 39,40 39,04
21
43,94 43,58 43,22 42,85 42,49 42,13 41,77 41,41 41,05 40,69 40,33 39,97 39,61 39,24
20
44,16 43,80 43,44 43,07 42,71 42,35 41,99 41,62 41,26 40,90 40,53 40,17 39,81 39,45
19
44,39 44,03 43,66 43,30 42,93 42,57 42,20 41,84 41,47 41,11 40,74 40,38 40,01 39,65
18
44,62 44,26 43,89 43,52 43,16 42,79 42,42 42,06 41,69 41,32 40,96 40,59 40,22 39,86
17
44,86 44,49 44,12 43,75 43,38 43,01 42,64 42,28 41,91 41,54 41,17 40,80 40,43 40,06
16
45,09 44,72 44,35 43,98 43,61 43,24 42,87 42,50 42,13 41,76 41,39 41,02 40,64 40,27
15
45,33 44,96 44,58 44,21 43,84 43,47 43,09 42,72 42,35 41,98 41,60 41,23 40,86 40,49
14
45,57 45,19 44,82 44,45 44,07 43,70 43,32 42,95 42,57 42,20 41,82 41,45 41,08 40,70
13
45,81 45,44 45,06 44,68 44,31 43,93 43,55 43,18 42,80 42,42 42,05 41,67 41,29 40,92
12
46,06 45,68 45,30 44,92 44,54 44,17 43,79 43,41 43,03 42,65 42,27 41,89 41,52 41,14
11
46,31 45,93 45,54 45,16 44,78 44,40 44,02 43,64 43,26 42,88 42,50 42,12 41,74 41,36
10
46,56 46,17 45,79 45,41 45,03 44,64 44,26 43,88 43,50 43,11 42,73 42,35 41,97 41,48
9
46,81 46,43 46,04 45,66 45,27 44,89 44,50 44,12 43,73 43,35 42,96 42,58 42,20 41,81
8
47,07 46,68 46,29 45,91 45,52 45,13 44,75 44,36 43,97 43,59 43,20 42,81 42,43 42,04
7
47,33 46,94 46,55 46,16 45,77 45,38 44,99 44,60 44,22 43,83 43,44 43,05 42,66 42,27
6
47,59 47,20 46,81 46,42 46,02 45,63 45,24 44,85 44,46 44,07 43,68 43,29 42,90 42,51
5
47,85 47,46 47,07 46,67 46,28 45,89 45,49 45,10 44,71 44,31 43,92 43,53 43,14 42,74
4
48,12 47,73 47,33 46,94 46,54 46,14 45,75 45,35 44,96 44,56 44,17 43,77 43,38 42,98
3
48,39 48,00 47,60 47,20 46,80 46,40 46,01 45,61 45,21 44,81 44,42 44,02 43,62 43,22
2
48,67 48,27 47,87 47,47 47,07 46,67 46,27 45,87 45,47 45,07 44,67 44,27 43,87 43,47
1
48,94 48,54 48,14 47,74 47,34 46,93 46,53 46,13 45,73 45,32 44,92 44,52 44,12 43,72
0
49,22 48,82 48,42 48,01 47,61 47,20 46,80 46,39 45,99 45,58 45,18 44,78 44,37 43,97
–1
49,51 49,10 48,70 48,29 47,88 47,47 47,07 46,66 46,25 45,85 45,44 45,03 44,63 44,22
–2
49,80 49,39 48,98 48,57 48,16 47,75 47,34 46,93 46,52 46,11 45,70 45,29 44,89 44,48
–3
50,09 49,67 49,26 48,85 48,44 48,03 47,62 47,21 46,79 46,38 45,97 45,56 45,15 44,74
–4
Table 3. Model 412 HP Pratt and Whitney PT6T-3BE /-3D torquemeter pressure at torque limit [D]
Zero Inc. –12 –11 –10 -9 –8 –7 –6 –5 –4 –3 –2 –1 0 1 2
Span Ratio
22
49,63 49,00 48,65 48,29 47,93 47,57 47,21 46,85 46,49 46,13 45,77 45,41 45,05 44,69
21
49,62 49,26 48,89 48,53 48,17 47,81 47,45 47,09 46,73 46,37 46,01 45,65 45,28 44,92
20
49,87 49,51 49,15 48,78 48,42 48,06 47,69 47,33 46,97 46,61 46,24 45,88 45,52 45,15
19
50,13 49,76 49,40 49,03 48,67 48,31 47,94 47,58 47,21 46,85 46,48 46,12 45,75 45,39
18
50,39 50,02 49,66 49,29 48,92 48,56 48,19 47,82 47,46 47,09 46,72 46,36 45,99 45,62
17
50,65 50,28 49,92 49,55 49,18 48,81 48,44 48,07 47,70 47,34 46,97 46,60 46,23 45,86
16
50,92 50,55 50,18 49,81 49,44 49,07 48,70 48,33 47,95 47,58 47,21 46,84 46,47 46,10
15
51,19 50,81 50,44 50,07 49,70 49,33 48,95 48,58 48,21 47,84 47,46 47,09 46,72 46,35
14
51,46 51,08 50,71 50,34 49,96 49,59 49,21 48,84 48,46 48,09 47,71 47,34 46,97 46,59
13
51,73 51,36 50,98 50,60 50,23 49,85 49,47 49,10 48,72 48,35 47,97 47,59 47,22 46,84
12
52,01 51,63 51,25 50,88 50,50 50,12 49,74 49,36 48,98 48,60 48,23 47,85 47,47 47,09
11
52,29 51,91 51,53 51,15 50,77 50,39 50,01 49,63 49,25 48,87 48,49 48,11 47,73 47,34
10
52,57 52,19 51,81 51,43 51,04 50,66 50,28 49,90 49,51 59,13 48,75 48,37 47,98 47,60
9
52,86 52,48 52,09 51,71 51,32 50,94 50,55 50,17 49,78 49,40 49,01 48,63 48,25 47,86
8
53,15 52,76 52,38 51,99 51,60 51,22 50,83 50,44 50,06 49,67 49,28 48,90 48,51 48,12
7
53,44 53,05 52,67 52,28 51,89 51,50 51,11 50,72 50,33 49,94 49,55 49,17 48,78 48,39
6
53,74 53,35 52,96 52,57 52,18 51,78 51,39 51,00 50,61 50,22 49,83 49,44 49,05 48,66
5
54,04 53,65 53,25 52,86 52,47 52,07 51,68 51,29 50,89 50,50 50,11 49,71 49,32 48,93
4
54,34 53,95 53,55 53,16 52,76 52,36 51,97 51,57 51,18 50,78 50,39 49,99 49,60 49,20
3
54,65 54,25 53,85 53,45 53,06 52,66 52,26 51,86 51,47 51,07 50,67 50,27 49,88 49,48
2
54,96 54,56 54,16 53,76 53,36 52,96 52,56 52,16 51,76 51,36 50,96 50,56 50,16 49,76
1
55,27 54,87 54,47 54,06 53,66 53,26 52,86 52,46 52,05 51,65 51,25 50,85 50,44 50,04
0
55,59 55,18 54,78 54,37 53,97 53,56 53,16 52,76 52,35 51,95 51,54 51,14 50,73 50,33
–1
55,91 55,50 55,09 54,69 54,28 53,87 53,47 53,06 52,65 52,25 51,84 51,43 51,03 50,62
–2
56,23 55,82 55,41 55,00 54,60 54,19 53,78 53,37 52,96 52,55 52,14 51,73 51,32 50,91
–3
56,56 56,15 55,74 55,33 54,91 54,50 54,09 53,68 53,27 52,86 52,44 52,03 51,62 51,21
–4
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E-AB412-PT6T-2
E-AB412-PT6T-2
G6AB0236A
Figure 1. Torque Control Unit (TCU) adjustment
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E-AB412-PT6T-2
G6AB0234A
Figure 2. Calibration tool - hand pressure tester
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E-AB412-PT6T-2
G6AB0237A
Figure 3. Torque Control Unit (TCU) torque limit adjustment
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E-AB412-PT6T-2
G6AB0238A
Figure 4. Universal Torque Control Unit (TCU) torque limit adjustment
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E-AB412-PT6T-2
G6AB0235A
Figure 5. Torque transmitter setting (typical) (helicopters code [D])
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E-AB412-PT6T-2
d. Follow row from left to right until under column corresponding to range in which “ZERO” number falls. Record
number at this location.
e. The pressure at which torque limiting should occur is the average left and right pressures found in steps c. and
d. Calculate this as follows:
Average pressure = (LH press + RH press)

2
EXAMPLE:
- LH ZERO = NEG 5,1 RH ZERO = NEG 4,0
- LH SPAN = POS 9,2 RH SPAN = POS 4,5
For left hand pressure, enter left side of table 3 at row corresponding to range 9 to 10. Follow this row until under column
corresponding to range -5 to -6. The pressure at this location is 50,28 psig.
For RH pressure, enter left side of table 3 at row corresponding to range 4 to 5. Follow this row until under column
corresponding to range -3 to -4. The pressure at this location is 50,89 psig.
Average pressure for LH and RH sides:
50,28 + 50,89 = 50,585 psig rounded off to 50,6 psig.

2
5. Aircraft equipped with TCU (11, figure 4) adjust as follows prior to ground run.
CAUTION
ON A NEW TCU, THREE LOCKWIRE/SEALS ARE INSTALLED FOR

QUALITY CONTROL. THE SEAL BETWEEN THE COARSE ADJUSTMENT
DOME AND THE COARSE ADJUSTMENT LOCKNUT MUST NOT BE
REMOVED OR WARRANTY WILL BE VOIDED.
NOTE
Seals between the coarse adjustment dome and TCU and between the fine
adjustment locknut can be removed and lockwire as require for maintenance.
a. Remove the lockwire/seal between the coarse adjustment dome (7) and TCU (11) body.
b. Remove the lockwire/seal between the fine adjustment screw (5) and fine adjustment locknut (06).
NOTE
On fine adjustment screw, internal stops allow nearly half a turn in each direction.
Full travel (stop to stop) is equivalent to one coarse adjustment position change. The
fine adjustment screw should be returned to the nominal (center) position prior to
any coarse adjustment change (marks or inner and outer screw aligned).
c. Verify the fine adjustment screw (5) is in the nominal position (center); if necessary reset the fine adjustment
screw before adjusting the coarse adjustment dome (7).
d. Set the coarse adjustment dome to the position (1 to 9) matching coarse adjustment range as per table 4. The
coarse adjustment range corresponds to the addition of LH and RH pressure as determined from table 3. From
the example, 50,28 to 50,89 = 101,17. This corresponds to dial position 4 from table 4.
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E-AB412-PT6T-2
Table 4. Coarse adjustment dome range
DIAL POSITION COARSE ADJUSTMENT RANGE
1 56,6 TO 68,4
2 68,5 TO 80,3
3 80,4 TO 92,2
4 92,3 TO 104,1
5 104,2 TO 116,0
6 116,1 TO 127,9
7 128,0 TO 140,8
8 140,9 TO 152,7
9 152,8 TO 164,6
6. Check torque limiter adjustment as follows:
a. Start both power sections and stabilize at idle for 5 minutes. Verify if ENG 1 and ENG 2 switches are in AUTO
position.
b. Increase twin-engine power to achieve 100% ROTOR (Nr) rpm, while maintaining flat pitch.
CAUTION
TO AVOID DAMAGE TO TCU, DO NOT EXCEED 57 PSIG FROM PRESSURE

TESTER.
c. Increase pressure (57 psig maximum) from hand pressure calibrator and record what pressure rotor (Nr) rpm
begins to droop.
NOTE
A 1/8 of a turn of screw (2, figure 1) or (7, figure 3) or (5, figure 4) will change
pressure at which droop occurs by approximately 3,0 psig.
d. If droop does not occur at calculated pressure ±0,35 psig (as read on tester), decrease applied pressure and adjust
TCU adjustment screw clockwise to increase pressure or counterclockwise to decrease pressure.
e. Repeat steps c. and d. until limiter setting is adjusted within ±0,35 psig of pressure calculated.
f. Shut down engine power sections.
7. Remove pressure test equipment.
a. Remove plugs from end of tubes (6 and 7).
b. Connect tubes assemblies (6 and 7) to fittings (5 and 8) and lockwire.
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E-AB412-PT6T-2
9. For aircraft equipped with Torque Control Unit (TCU) per figure 3 and figure 4 proceed as follows:
a. Remove test hose between ports “B” and “C”.
b. Remove plugs from tube assemblies (1 and 2) and from port “D” on tee fitting (4).
c. Connect tubes (1 and 2) to tee fittings (3 and 4) and lockwire.

ADJUSTMENT, ALTERNATE METHOD
NUMBER NOMENCLATURE
COMMERCIAL FILTERED, REGULATED AIR PRESSURE SOURCE
NOTE
This alternate procedure can be used when it is desirable to adjust the torque limiter
without operating the engines.
1. Install equipment and calculate the torque limiter setting as per paragraph "2. Maximum torque check and control limit
setting - torque limit adjustment", steps 1. through 5.
2. Connect filtered air with in-line regulator to one or both Pg air ports (E and F, figure 1, figure 3 or figure 4) on right
and/or left side of TCU.
3. Adjust air pressure (Pg) to approximately 15 psig.
CAUTION
TO AVOID DAMAGE TO TCU, DO NOT EXCEED 57 PSIG FROM PRESSURE

TESTER.
4. Increase pressure from pressure tester and record at what oil pressure the air pressure begins to drop.
NOTE
A 1/8 of a turn of screw (2, figure 1) or (7, figure 3) or (5, figure 4) will change
pressure at which droop occurs by approximately 3,0 psig.
5. If air pressure drop does not occur at calculated pressure ±0,35 psig (as read on tester), decrease applied pressure and
adjust TCU adjustment screw clockwise to increase pressure or counterclockwise to decrease pressure.
6. Repeat steps 4. and 5. until limiter setting is adjusted within ±0,35 psig of pressure calculated.
7. Remove test equipment.
a. Remove plugs from end of tubes (6 and7).
b. Connect tube assemblies (6 and 7) to fittings (5 and 8) and lockwire.
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E-AB412-PT6T-2
9. For aircraft equipped with Torque Control Unit (TCU) per figure 3 and figure 4 proceed as follows:
a. Remove test hose between post “B” and “C”.
b. Remove plugs from tube assemblies (1 and 2) and from port “D” on tee fitting (4).
c. Connect tubes (1 and 2) to tee fittings (3 and 4) and lockwire.

ADJUSTMENT [A] [B] [C]
CAUTION
PERFORM TORQUE LIMITER CHECK AND ADJUSTMENT PROCEDURE

AFTER EACH CHANGE OF REDUCTION GEARBOX AND/OR TORQUE
CONTROL UNIT (TCU).
WHEN PERFORMING THE FOLLOWING STEPS, DO NOT EXCEED

OPERATING LIMITATIONS.
NOTE
This procedure is applicable to helicopters codes [A] [B] [C] only. It should only be
used if test equipment listed in paragraph "2. Maximum torque check and control
limit setting - torque limit adjustment" is not available.
1. Start both power sections and let idle for 5 minutes.
NOTE
On a hot day or at high altitude conditions, it may not be possible to reach torque
limit required by the following test.
2. Perform a maximum power climb and record point at which torque limiting begins. This is indicated by ROTOR speed
decaying with further power application and GAS PROD RPM appearing to be too low to have reached engine
topping. Torque limiting should occur between 101 and 103% for 412-075-008-101 indicators and between 98 and
100% for 412-075-008-111/113 indicators.
CAUTION
IF ITT IS REACHED BEFORE ATTAINING DESIRED INITIAL TORQUE, DO

NOT MAKE ANY ADJUSTMENT TO TORQUE CONTROL UNIT.
3. If torque limit does not occur before reaching either the maximum initial value (100 or 103% as applicable), turn
adjustment screw (2, figure 1) or (7, figure 3) counterclockwise in 1/8 turn increments and repeat step 2. after each
adjustment until torque limiting occurs within desired initial range.
4. Insert a wrench in adjustment screw (2, figure 1 or 7, figure 3) and mark the starting location with a soft lead pencil or
other removable marker. Rotate adjustment screw 3/8 turn clockwise to establish new limiting setting.
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76-10-06
ENGINE (N1) POWER CONTROLS - AUTOMATIC FUEL CONTROL IDLE
SPEED CHECK
1. AUTOMATIC FUEL CONTROL IDLE SPEED CHECK - DESCRIPTION
NOTE
Refer to Pratt & Whitney Aircraft of Canada Ltd. PT6T-3 Series maintenance
Manual for greater detail on adjustment procedure.
1. Start both engines and let idle for 5 minutes.
2. Activate ENG 1 IDLE STOP release switch (18, figure 1). Rotate ENG 1 throttle twist grip (19) below the idle stop so
the Manual Fuel Control Unit (MCFU) (5, figure 2) pointer (15) is positioned between 30 and 35 degrees on the
quadrant (16).
3. Aircraft with PT6T-3B/BE engine verify that gas producer speed (N1) is between 51 and 52,5%. Aircraft with
PT6T-3D/DE/DF verify that N1 speed is between 53,8 and 55%. If necessary, adjust the Automatic Fuel Control Unit
(AFCU) (4) idle to bring N1 within required range.
NOTE
The difference between N1 IDLE speeds of both engines must not exceed 1%.
4. Repeat steps 2. and 3. above with ENG 2.
5. Torque idle stop locknut and lockwire (refer to Pratt & Whitney Maintenance Manual).
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G6AB0851A
76-10-06
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G6AB0852A
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G6AB0853A
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G6AB0239A
Figure 2. Manual and automatic fuel control adjustment provisions
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76-10-07 ENGINE (N1) POWER CONTROLS - POWER SECTION ACCELERATION AND DECELERATION CHECK
76-10-07
ENGINE (N1) POWER CONTROLS - POWER SECTION ACCELERATION
AND DECELERATION CHECK
1. POWER SECTION ACCELERATION AND DECELERATION CHECK - DESCRIPTION
NOTE
Refer to Pratt & Whitney Aircraft of Canada Ltd. PT6T-3 Series Maintenance
Manual for greater detail on adjustment procedures.
1. Perform automatic fuel control idle speed check per module 76-10-06 paragraph "1. Automatic fuel control idle speed
check - description" prior to accomplishing acceleration and deceleration check.
3. With collective at flat pitch and both engines at IDLE, increase N2 to maximum beep. Set N1 IDLE speed to 61% on
each power section, using throttles.
4. Check acceleration time from 61 to 90% N1 for ENG 1 as follows:
CAUTION
MONITOR ENGINE TORQUE AND ITT DURING THIS PROCEDURE.
NOTE
Measurement of acceleration time begins when ENG throttle is snapped to FULL
OPEN and stops when N1 reaches 90%.
a. Set ENG 2 throttle to IDLE and apply friction to hold it in position.
b. Snap open ENG 1 throttle to FULL OPEN. Start timing.
c. When 90% N1 is reached, snap ENG 1 throttle back to IDLE. Stop timing.
NOTE
Acceleration time from 61 to 90% N1 should be 4 seconds maximum. Acceleration
times less than 3 seconds are acceptable if outside air temperature is below 32°F
(0°C), provided there is no compressor surge.
Match both power sections acceleration times as close as possible. The maximum
acceptable difference in acceleration time is 0,5 second.
d. If acceleration time is too slow or too fast (compressor surge), adjust acceleration dome (3, figure 1) (refer to
Pratt & Whitney Maintenance Manual).
5. Repeat step 4. with ENG 2.
6. Check deceleration time from 90 to 61% N1 for ENG 1 as follows:
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NOTE
Measurement of deceleration time begins when ENG throttle is snapped to IDLE
and stops when N1 reaches 61%.
a. Set ENG 2 throttle to IDLE and apply friction to hold it in position.
b. Gradually open ENG 1 throttle to FULL OPEN,
c. Increase power to 90% N1 and stabilize, then snap ENG 1 throttle back to IDLE.
d. Confirm deceleration time from 90 to 61% N1of 5 seconds maximum below 6000ft. pressure altitude, and
smooth deceleration to a stabilized IDLE of 61% N1.
7. Repeat step 6. with ENG 2.
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76-10-08 ENGINE (N1) POWER CONTROLS - AUTOMATIC MODE MAXIMUM GAS PRODUCER SPEED CHECK AND AFCU MAXIMUM N1 STOP ADJUSTMENT
76-10-08
ENGINE (N1) POWER CONTROLS - AUTOMATIC MODE MAXIMUM GAS
PRODUCER SPEED CHECK AND AFCU MAXIMUM N1 STOP ADJUSTMENT
1. AUTOMATIC MODE MAXIMUM GAS PRODUCER SPEED CHECK AND AFCU

MAXIMUM N1 STOP ADJUSTMENT - PT6T-3B/BE ENGINE
NOTE
Refer to Pratt & Whitney Aircraft of Canada Ltd, PT6T-3 Series Maintenance
Manual No. 3017042 for detailed procedure.
This single power section check to be performed with helicopter heavily loaded and
light on skids. However, pilot must be prepared for the possibility helicopter may
become airborne.
1. Rotate in place and secure part power trim stop (12, figure 1).
3. With collective at flat pitch and both engines at IDLE, increase ENG 1 throttle to FULL OPEN. Using INCR/DECR
switch increase ROTOR rpm (NR) to full INCR.
NOTE
Maximum gas producer (N1) speed (topping) is achieved when N1 ceases to
increase and N2/NR droops as collective is further applied. Do not droop below 90%
N2. The observed reading at this point should be 99,8 to 100,8% N1. A minimum
value of 99,8% N1 is required to assure in flight topping at 103,4% N1.
4. Gradually increase collective until N1 topping is achieved and note N1 value.
NOTE
If maximum stop screw is adjusted, readjust the interconnect linkage for proper
AUTO/MANUAL gap and throttle cushions per module 76-10-02 paragraph "1.
Power lever (N1) control rigging - description" and Pratt & Whitney Aircraft of
Canada Ltd. PT6T-3 Series Maintenance Manual. This is accomplished once
maximum gas producer (N1) speed is attained and part power trim stop is retracted.
5. If required, adjust the topping adjustment screw and repeat step 4.
6. Repeat steps 3 through 5. with ENG 2.
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MAXIMUM N1 STOP ADJUSTMENT - PT6T-3B/BE ENGINE AFCU MAXIMUM N1
STOP ADJUSTMENT, ALTERNATE PROCEDURE
CAUTION
DO NOT EXCEED TORQUE LIMIT OF 73,2% (76,0 FOR AIRCRAFT CODES

[A] [B] WHICH HAVE NOT HAD SB 412-17 INCORPORATED) OR ITT LIMIT
OF 850 DEGREES C.
MAXIMUM N1 TOPPING CHECKS SHOULD ONLY BE PERFORMED AFTER

ENGINE CONTROL RIGGING IS ADJUSTED OR WHEN ANY OF THE
FOLLOWING COMPONENTS ARE REPLACED: (TWO POWER SECTIONS
AND REDUCTION GEARBOX), POWER SECTION, AFCU, MFCU AND FUEL
PUMP.
NOTE
Field experience particularly in warm climates, has revealed it is not possible to
operate both power sections at 102,4% N1 rpm with indicator 212-075-037-101 or
103,4% N1 rpm with indicator 212-075-037-113 at any altitude without exceeding
maximum ITT limit of 850°C. This condition does not prevent engine from
achieving required performance, but does not present a functional test problem.
This single power section check to be performed in flight or with helicopter heavily
loaded and light on skids. However, pilot must be prepared for the possibility
helicopter may become airborne.
2. Increase both throttles to FULL OPEN one at a time and adjust ENG N2 rpm to INCR with RPM INCR/DECR switch.
3. Decrease throttle of one engine to flight IDLE leaving the other at FULL OPEN with ENG N2 rpm to full INCR.
4. Increase power by raising the collective, drooping ENG rpm to approximately 97% to obtain 103,4% N1 rpm.
NOTE
Power lever (N1) control rigging - description" and Pratt and Whitney Aircraft of
Canada Ltd. PT6T-3 Series Maintenance Manual. This is accomplished once
maximum gas producer (N1) speed is attained and part power trim stop is retracted.
a. If ENG rpm droops below 97% prior to obtaining 103,4% N1 rpm, increase topping. Turn stop screw (14, figure
1) counterclockwise to increase.
b. If 103,4% N1 rpm is reached without ENG rpm droop, apply power to a maximum of 103,4% and 103,6% N1
rpm, decrease topping. Turn stop screw (14) clockwise to decrease.
5. If stop screw (14) was adjusted, tighten jamnuts and lockwire.
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MAXIMUM N1 STOP ADJUSTMENT - PT6T-3D/DE/DF ENGINE
NOTE
Refer to Pratt & Whitney Aircraft of Canada Ltd. PT6T-3 Series Maintenance
Manual No. 3040592 for detailed procedure.
This single power section check to be performed with helicopter heavily loaded and
light on skids. However, pilot must be prepared for the possibility helicopter may
become airborne.
1. Rotate in place and secure part power trim stop (12, figure 1).
3. With collective at flat pitch and both engines at IDLE, increase ENG 1 throttle to FULL OPEN. Using INCR/DECR
switch increase rotor rpm (NR) to full INCR.
NOTE
Maximum gas producer (N1) speed (topping) is achieved when N1 ceases to
increase and N2/NR droops as collective is further applied. Do not droop below 90%
N2. The observed reading at this point should be 92,0 to 92,6% N1. A minimum
value of 92,0% N1 is required to assure in flight topping at 109,2% N1.
4. Gradually increase collective until N1 topping is achieved and note N1 value.
NOTE
Power lever (N1) control rigging - description" and Pratt & Whitney Aircraft of
Canada LTD. PT6T-3 Series Maintenance Manual. This is accomplished once
maximum gas generator (N1) speed is attained and part power trim stop is retracted.
5. If required, adjust the topping adjustment screw and repeat step 4.
6. Repeat steps 3, 4 and 5 with ENG 2.
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76-10-09
ENGINE (N1) POWER CONTROLS - ENGINE IDLE SPEED ADJUSTMENT
1. ENGINE IDLE SPEED ADJUSTMENT - DESCRIPTION
2. With collective at flat pitch and both engines at IDLE, set ENG 1 N1 at 61% using throttle.
3. Gradually increase ENG 1 throttle to FULL OPEN, then retard throttle to IDLE.
4. Verify ENG 1 idle speed is 61 ± 1% N1. If required, adjust idle stop adjustment screw (9, figure 1). If available
adjustment of idle stop adjustment screw (9) is not adequate (insufficient threads), replace four NAS43DD3 spacers
(5) under the idle stop solenoid (7) with longer or shorter lengths as required (refer to module 76-10-02 paragraph "1.
Power lever (N1) control rigging - description").
5. Repeat steps 3. and 4. above with ENG 2.
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Figure 1. Engine idle adjustment
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76-10-10 ENGINE (N1) POWER CONTROLS - MANUAL CHANGE-OVER CHECK AND MANUAL/AUTOMATIC INTERCONNECT LINKAGE ADJUSTMENT
76-10-10
ENGINE (N1) POWER CONTROLS - MANUAL CHANGE-OVER CHECK AND
MANUAL/AUTOMATIC INTERCONNECT LINKAGE ADJUSTMENT
1. MANUAL CHANGE-OVER CHECK AND MANUAL/AUTOMATIC INTERCONNECT

LINKAGE ADJUSTMENT - DESCRIPTION
1. Check interconnect linkage (1, figure 1) as follows:
a. Inspect trim stop (12) on left power section. The trim stop should be in stowed position as shown on view A.
b. Inspect stop screws (6 and 9) for presence of metal seals. If metal seals are present, it indicates that manual fuel
control has been preset to 0 to 95 degrees travel and that dimension between stop screw (9) and stop (8) should
be a minimum of 0.4 mm (0.012 in) when accomplishing step 3. If metal seals are not present, the dimension
between stop screw (9) and stop (8) should be 0.635 to 0.889 mm (0.025 to 0.035 in) when accomplishing step 3.
c. Gradually rotate engine 1 throttle grip to full open until stop screw (14) contacts trim stop (12). Measure
clearance between stop (8) and stop screw (9). Refer to step b. above for acceptable dimension. If dimension is
not within limits, adjust interconnect linkage (1) to obtain dimension within limits. Refer to pratt & Whitney
Aircraft of Canada, Ltd., PT6T-3B Twinned Turboshaft Engine Maintenance Manual Part No. 3017042, for
procedure to adjust interconnect linkage.
d. Inspect, and if required, adjust, trim stop on right power section in same manner outlined in steps a. through c.
2. Check MANUAL/AUTOMATIC changeover N1 (N2) speed as follows:
NOTE
If the operator flies below 5.000 feet refer to Pratt & Whitney Aircraft of Canada Ltd
CT6T-3 Series Maind Manual for procedures. If the operators flies higher than 5.000
feet accomplish check at 6.000 feet altitude.
a. Fly helicopter to 6.000 feet altitude.
b. Rotate engine 1 throttle to IDLE STOP. N2 RPM should be 61±5%. Record RPM indication.
c. Position engine 1 GOV switch to MANUAL. N2 RPM should be 61±5%. Record RPM indication.
d. Position engine 1 GOV switch to AUTO. Record RPM indication.
e. Repeat steps b. and c. for right power section (engine 2).
f. If either power section is out of acceptable limit (61±5%), adjust interconnect linkage (1). Refer to Pratt and
Whitney Aircraft of Canada, Ltd., PT6T-3B Twinned Engine Maintenance Manual for procedure.
g. If interconnect linkage is adjusted in accordance with step f., and the manual fuel control does not have metal
seals on stop screws (6 and 9), adjust stop screw (9) to 0.635 to 0.889 mm (0.025 to 0.035 in) dimension while
stop screw (14) is in contact with stop (12).
h. After all adjustments are complete, check for 4 to 6 degrees cushion overtravel of both engine throttle grips after
contact with fuel control stops (12) and (8).
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76-1 -01 DROOP COMPENSATOR (N2) CONTROLS
76-11-01
DROOP COMPENSATOR (N2) CONTROLS
1. DROOP COMPENSATOR - DESCRIPTION
The droop compensator linkage extends through droop compensator (12, figure 1 or 11, figure 2) and linear actuator (10,
figure 1 or 9, figure 2) to N2 power turbine governors (3 and 7, figure 1, figure 2). The linear actuator (10, figure 1 or 9,
figure 2) can be retracted or extended by use or the RPM INCR/DECR (beep) switch on pilot or co-pilot collective switchbox
to set engine power turbine ENG (N2) rpm range.
Helicopters code [D] have a +2/-2 switch included in RPM INCR/DECR switch located on pilot collective switchbox (figure
3). The +2/-2 switch controls the ITT actuator (2, figure 1 and figure 2), connected to ENG 2 power turbine governor (3,
figure 1 and figure 2) can be extended or retracted to provide torque or ITT matching.
When pilot/copilot collective controls are moved, droop compensator linkage control tubes (and control cable) are also
moved. This repositions cam in droop compensator (12, figure 1 or 11, figure 2) and positions power turbine governors (3
and 7, figure 1 and figure 2) to accommodate the need for increased or reduced power as main rotor blades change pitch.
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HELICOPTERS CODE D
G6AB0227A
Figure 1. Droop compensator linkage (helicopters codes [A] [B])
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G6AB0228A
Figure 2. Droop compensator linkage (helicopters codes [C] [D])
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G6AB0929A
Figure 3. Pilot collective switchbox (helicopters code [D])
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76-1 -02 DROOP COMPENSATOR (N2) CONTROLS - LINEAR ACTUATOR
76-11-02
DROOP COMPENSATOR (N2) CONTROLS - LINEAR ACTUATOR
1. LINEAR ACTUATOR - REMOVAL
1. Remove cotter pin (2, figure 1), nut (3), washer (4), and bolt (21).
2. Loosen jamnut (19). Remove rod end bearing (20).
3. Remove spring (9).
4. Remove cotter pin (15), nut (14), washers (13, 16, 8, and 10), and bolt (11).
5. Index three on terminal block (17) for reinstallation in same location. Disconnect wires from terminal block.
6. Move actuator (7) aft out of the split bushing (5) and remove from helicopter.
7. Install jamnut (19) and rod end bearing (20) in actuator (7) tube.
2. LINEAR ACTUATOR - INSTALLATION AND RIGGING
MATERIALS REQUIRED
NUMBER NOMENCLATURE
1. Remove rod end bearing (20, figure 1) and jamnut (19) from actuator (7).
2. Position actuator (7) tube through split bushing (5). Install jamnut (19) and rod end bearing (20).
NOTE
Ensure electrical wires are connected to correct terminals.
3. Connect three wires to terminal block (17) (Chapter 98).
4. Position aft end of actuator (7) in jackshaft lever (12). Install bolt (11), washer (10, 8, 16, and 13), nut (14), and cotter
pin (15).
5. If not previously accomplished, adjust total stroke (from full retract to full extend) of actuator (7) as follows:
a. While measuring actuator (7) stroke, position power turbine governor lever against maximum power stop by
holding lever (12) full down (forward).
b. Position RPM switch on collective switch box to DECR. Hold until actuator (7) reaches full extend position.
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NOTE
In the following steps a. locally fabricated metal block or similar device may be used
as a work aid to assist measuring the actuator stroke.
c. Place a metal block on service deck in contact with forward end of actuator (7).
d. Place RPM INCR/DECR switch to INCR. Hold until actuator (7) reaches full retract position.
e. Measure and record distance between block positioned in step c., and forward end of actuator (7) rod. If distance
is 0,62 in. (15,7 mm). Proceed to step g. If distance is not 0,62 (15,7 mm) or accomplish steps f. and g.
CAUTION
SET ACTUATOR (7) TO MIDPOINT TRAVEL WITH RPM SWITCH PRIOR TO

MAKING ADJUSTMENT ON SCREW (23) OR DAMAGE TO ACTUATOR (7)
MAY RESULT.
f. Set actuator (7) to midpoint of travel. Loosen jamnut (22) and rotate screw (23) slightly in INCR direction or
DECR direction in accordance with arrows on decal. Repeat making small adjustment until total stroke is set to
the proper dimension. Tighten jamnut.
g. Remove metal block (installed in step c.) from service deck.
6. Coat threads of rod end bearing (20) with corrosion preventive compound (C-101). Install rod end bearing (20) and
jamnut (19) on actuator (7). Dimension from center of rod end bearing (20) bolt hole to edge of jamnut (19) to be 1,88
in. (47,8 mm).
7. Install bolt (21), nut (3), washer (4), and cotter pin (2).
8. Install spring (9).
3. LINEAR ACTUATOR - INSPECTION
1. Inspect actuator (7, figure 1) for secure installation and damage.
2. Inspect electrical terminal block (17) and associated electrical wiring for damage.
3. Inspect split bushing (5) for damage.
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G6AB0242A
Figure 1. Linear actuator
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76-1 -03 DROOP COMPENSATOR (N2) CONTROLS - ITT ACTUATOR (ENG 2 ACTUATOR)
76-11-03
DROOP COMPENSATOR (N2) CONTROLS - ITT ACTUATOR (ENG 2
ACTUATOR)
1. ITT ACTUATOR (ENG 2 ACTUATOR) - REMOVAL
1. Remove electrical cover (8, figure 1) to gain access to the three wires.
2. Index three wires on terminal block (9) for reinstallation in same location. Disconnect wires from terminal block.
3. Remove cotter pin (2), nut (3), washers (4 and 5), and bolt (6) from lever (7).
4. Remove cotter pin (10), nut (11), washers (12 and 13), and bolt (14) from jackshaft (15).
5. Remove actuator (1) from helicopter.
2. ITT ACTUATOR (ENG 2 ACTUATOR) - INSTALLATION AND RIGGING
MATERIALS REQUIRED
NUMBER NOMENCLATURE
NOTE
ITT actuator (1, figure 1) is installed with fixed end connected to jackshaft (15),
terminal block (9) facing down, and adjustable rod end (17) connected to lever (7).
1. Position fixed end of actuator (1) on jackshaft (15).
2. Install bolt (14), washer (12 and 13), nut (11), and cotter pin (10).
NOTE
Ensure wires are connected to correct terminals.
3. Connect three wires to terminal block (9) (Chapter 98).
4. Install actuator electrical cover (8).
5. If not previous accomplished, adjust total stroke on actuator (1) to 0,150 in. (3,81 mm) as follows:
a. Gain access to adjustment screws on actuator (1) by remove dust cap screws (18 and 19).
b. Turn both adjustment screws in direction of arrows till the screws bottom out.
c. Using RPM (INCR/DECREASE +2/-2) switch on pilot collective stick box, activate the +2 so that the actuator
is fully retracted. Using a fine marker, draw a line on the shaft at the entrance of the actuator body.
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d. Using RPM (INCR/DECREASE +2/-2) switch on pilot collective stick box, activate the -2 so that the actuator
is fully extended. Measure the distance from marker line on the shaft to the entrance of the actuator body and
record.
e. The recorded value is the total stroke dimension of the actuator. Divide the total stroke by 2 and record.
f. The recorded value is the mid stroke of the actuator. Using mid stroke dimension, measure from the marker line
on shaft performed in step c. towards the actuator body. Using a fine marker, draw a line on the shaft; this will
be the mid stroke of the actuator.
g. Remove marker line on shaft that was installed in step c.
h. Using RPM (INCR/DECREASE +2/-2) switch on pilot collective stick box, activate the -2 so that the actuator
retracts to the mid stoke mark on the shaft.
i. From the mid position using RPM (INCR/DECREASE +2/-2) switch on pilot collective stick box, activate the
-2 so that the actuator extends to 0,075 in. (1,90 mm).
j. Turn the EXT (extend) screw in the opposite direction of the arrow (figure 1) until the EXT (extend) electrical
stop switch is engaged. This will be observed by a clicking sound and the adjustment screw will no longer turn.
k. From the extend position using RPM (INCR/DECREASE +2/-2) switch on pilot collective stick box; activate
the +2 so that the actuator retracts to 0,150 in. (3,81 mm).
l. Turn the RET (retract) screw in the opposite direction of the arrow (figure 1) until the RET (retract) electrical
stop switch in engaged. This will be observed by a clicking sound and the adjustment screw will no longer turn.
m. Verify actuator total stroke is 0,150 in. (3,81 mm).
n. Install dust cap screws (18 and 19).
6. With actuator (1) fully extended, loosen jamnut (16) and turn rod end bearing (17) to adjust the total length of the
actuator to 9,415 in. (239,140 mm) or 9,455 in. (240,157 mm). Tighten jamnut (16). The measurement is taken between
attachment points (center of rod end bearing (17) to the center of the actuator attachment hole).
7. Install actuator rod end bearing (17) into governor lever (7).
8. Install bolt (6), washers (5 and 4), nut (3) and cotter pin (2).
3. ITT ACTUATOR (ENG 2 ACTUATOR) - INSPECTION
1. Inspect actuator (1, figure 1) for secure installation and damage.
2. Inspect terminal block (9) and associated electrical wiring for damage.
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G6AB0857A
Figure 1. ITT actuator installation
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76-1 -04 DROOP COMPENSATOR (N2) CONTROLS - DROOP COMPENSATOR CAMBOX [A] [B]
76-11-04
DROOP COMPENSATOR (N2) CONTROLS - DROOP COMPENSATOR
CAMBOX [A] [B]
1. DROOP COMPENSATOR CAMBOX [A] [B] - REMOVAL
1. Remove cotter pin (7, figure 1), nut (8), washer (9), and bolt (11).
2. Remove cotter pin (2), nut (3), washer (4), and bolt (14).
4. Remove cambox (13) from service deck (15).
2. DROOP COMPENSATOR CAMBOX [A] [B] - INSTALLATION
1. Position cambox (13, figure 1) on service deck (15).
3. Position tube (10) on slider (12). Install bolt (11) washer (9), nut (8), and cotter pin (7).
4. Position tube (1) on forward end of cambox (13). Install bolt (14), washer (4), nut (3), and cotter pin (2).
5. Move collective controls through full range and inspect for binding and interference in droop compensator control
installation.
6. Rig droop compensator controls per module 76-11-05 "DROOP COMPENSATOR (N2) CONTROLS - N2
CONTROL RIGGING [A] [B]".
3. DROOP COMPENSATOR CAMBOX [A] [B] - INSPECTION
1. Inspect cambox (13, figure 1) for secure installation.
2. Inspect cambox for binding when collective controls are moved through full range.
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G6AB0240A
Figure 1. Droop compensator cambox (helicopters codes [A] [B])
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76-1 -05 DROOP COMPENSATOR (N2) CONTROLS - N2 CONTROL RIGGING [A] [B]
76-11-05
DROOP COMPENSATOR (N2) CONTROLS - N2 CONTROL RIGGING [A] [B]
1. N2 CONTROL RIGGING [A] [B] - DESCRIPTION
MATERIALS REQUIRED
NUMBER NOMENCLATURE
NOTE
Refer to module 76-10-02 paragraph "1. Power lever (N1) control rigging -
description" for instructions to rig power lever control.
1. Comply with the following general procedures when rigging droop compensator controls.
b. Tolerance for rigging dimensions is ±0.7 mm (0.03 in) unless stated otherwise.
c. All adjustable control tubes must have a maximum of 25.4 mm (1.00 in) of exposed threads after adjustment. If
control tubes have inspection holes, the threads must be engaged sufficiently to cover holes.
adjustment.
e. Torque control jam nuts 92 to 115 kgcm (80 to 100 in-lb) after adjustment unless other torque is specified.
and torque jam nuts if necessary.
2. Ensure that collective pitch control system rigging has been accomplished (Chapter 67).
3. Check that levers (2 and 6, figure 1) are properly installed on control shafts of power turbine governors (1 and 5).
Centerline of levers (2 and 6) must be 30o C clockwise from centerline of governor stop arm (21), viewed from left.
See detail A.
4. Check that adjustable tube (7) is approximately same length as nonadjustable tube (3). Begin with tube (7) attached at
middle hole of arm on jackshaft (4). See detail C.
5. Disconnect actuator (8) from lower arm of jackshaft (4).
6. Disconnect tube (18) from cambox (10).
7. Check that long arm of cambox bellcrank (26) is attached approximately in middle of adjustment slot of cam (23). See
detail B.
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E-AB412-PT6T-2
NOTE
The dimensions given in steps 7. and 8., are approximate for initial rigging. Minor
adjustment may be necessary during ground and flight tests.
8. Use RPM (beep) switch on collective stick switchbox to operate actuator. Check that actuator (8) is adjusted for total
stroke of approximately 16 mm (0.62 in) from full extend DECR to full retract INCR position.
NOTE
Adjustment to stroke must be made with the actuator (8) in mid position.
9. Adjust rod end on actuator (8) to approximately 48 mm (1.88 in) from center of bearing bolt hole to face of jam nut as
shown on detail D.
10. Manually rotate jackshaft (4) and check that no interference exists. Reconnect actuator (8) to lower arm of jackshaft
(4).
11. Disconnect tube (12) and rotate idler (11) to ensure that no interference exists. Reconnect tube (12) to idler (11).
12. With hydraulic boost on, place and hold collective stick full down.
13. Rotate cambox bellcrank (26) to ensure no interference exists. Connect tube (18) to cambox bellcrank (26). If
necessary, adjust tube (18) to hold cam (23) so that lower end of cam slot is 0.3 mm (0.010 in) minimum below slider
housing (24) as shown on detail B.
14. With hydraulic boost on, place collective stick full down. Hold RPM (beep) switch to DECR until actuator (8) is fully
extended. Check stop arms adjacent to governors (1 and 5) for clearance between stop arms (21) and minimum power
stop screws (20) on both governors. There must be a small amount of clearance at both stop screws (20).
15. Place collective stick full up. Adjust tube (18) so that upper end of cam (23) slot is 0.3 mm (0.010 in) minimum above
slider housing (24) as shown on detail B.
16. Place collective stick full up. Hold RPM (beep) switch to INCR until actuator (8) is fully retracted. Check stop arms
adjacent to governors(1 and 5) for 0.3 mm (0.010 in) clearance between stop arms (21) and maximum power stop
screws (22) on both governors as shown on detail A.
NOTE
Accomplish following steps in conjunction with ground run and flight tests.
17. Start both power sections and idle for 5 minutes.
18. Rotate engine 1 (left power section) throttle grip to full INCR, then retard throttle (without pressing IDLE STOP ENG
1 switch) until stop contacts solenoid plunger. Adjust stop on torque tube (5, figure 2) to obtain 61±1% N2 RPM when
stop is in contact with plunger of solenoid (6).
NOTE
If is not possible to adjust the N2 speed to 61±1% using the stop on the torque tube
(5), the four spacers which support the solenoid (6) on the engine deck may be
replaced. Longer spacers will increase the flight N2 speed.
19. Perform check similar to step 18. for engine 2 (right section). Make adjustment to stop on torque tube (11) against
solenoid (12).
20. Actuate RPM (beep) switch to full DECR.
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E-AB412-PT6T-2
21. Place collective stick full down. Rotate engine 2 (right power section) throttle grip to full INCR. Record rotor RPM.
Slowly actuate RPM (beep) switch to full INCR, but do not exceed 100%. Record rotor RPM. The rotor RPM should
be 95%. The INCR rotor RPM should be 99%. If range and/or spread is not within limits, adjust as follows:
a. If range is not within limits, adjust actuator (8, figure 1) rod end. Lengthen or shorten so range is 95 to 99%.
NOTE
If it is not possible to obtain the required range with the adjustment of the actuator,
rotate levers (2 and 6) one tooth (corresponding to 15°) CCW.
b. If spread is not within limits, adjust stroke of actuator (8). Position actuator (8) to mid travel position prior to
adjusting actuator. Repeat adjustment of actuator (8) if required to obtain stroke within limits.
22. Place collective stick full down. Rotate engine 1 (left power section) throttle grip to full INCR. Record rotor RPM.
Slowly actuate RPM (beep) switch to full INCR, but do not exceed 100 percent. Record rotor RPM. The rotor RPM
recorded should be 95%. The full INCR rotor RPM should be 99%. If RPM is out of limits, adjust length of tube (7).
If adjustment of tube (7) length does not result in correct RPM, move tube (7) rod end to a different hole in arm of
jackshaft (4) as shown on detail C.
NOTE
It is necessary that the single power section rotor RPM ranges be correct at this time;
however, later adjustments to achieve proper twin power section RPM range, and
adjustments to avoid torque needle split, shall supersede these initial adjustments.
23. Actuate RPM (beep) switch to full INCR. Place collective stick full down. Rotate both engine throttle grips to full
INCR. Record rotor RPM.
24. Actuate RPM (beep) switch to full DECR. Record rotor RPM. Adjust length of actuator (8) rod end as required to
obtain 97 to 101.5% RPM range. Shorten to raise or lengthen to lower range.
NOTE
When performing checks in step 25., the helicopter will become airborne.
25. Place collective stick full down. Rotate both engine throttle grips to full INCR. Use RPM (beep) switch to obtain 100%
rotor RPM indication. Increase collective pitch slowly in a series of equal steps from flat pitch to full power (either
engine temperature limit or transmission torque limit). Rotor RPM should remain at 100±1% throughout the power
sweep. Also check that engine torque readings are matched within 4% during steady state operation.
NOTE
Ensure the pointers on the reduction gearbox torque pressure transmitters are
indexed to the number stamped on the reduction gearbox data plate for the torque
meter for that side of the gearbox. If, after this check, the engine torque readings do
not match with 4%, refer to module 76-00-00 paragraph "2. Engine controls - torque
matching". If torque matching requirement conflicts with the beep range or the
relationship of N2, ITT (T5), or fuel flow between the power sections, comply with
torque matching requirements.
26. If rotor RPM droops (decays below tolerance) or overspeed (increases above 100%) during power applications, make
a cam rate adjustment. For increased cam compensation to correct droop, adjust cam (23) counterclockwise relative to
bellcrank (26) as shown on detail B. For reduced cam compensation to correct overspeed, adjust cam (23) clockwise
relative to bellcrank (26). After each cam adjustment, ad adjustment of tube (18) may be required to ensure that the
slot in cam (23) does not bottom out during full down collective.
27. Check system to ensure no interference exists and for security of all parts.
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E-AB412-PT6T-2
28. With collective stick full up and actuator (8) fully retracted by RPM (beep) switch at INCR, adjust maximum power
stop screw (22) for both governors (1 and 5) to 0.3 mm (0.010 in) of stop arm (21).
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E-AB412-PT6T-2
G6AB0858A
Figure 1. N2 controls rigging (helicopters codes [A] [B])
76-11-05
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E-AB412-PT6T-2
G6AB0859A
Figure 2. Idle solenoid stops
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E-AB412-PT6T-2
76-12-01
DROOP COMPENSATOR (N2) CONTROLS - DROOP COMPENSATOR AND
CABLE [C] [D]
1. DROOP COMPENSATOR AND CABLE [C] [D] - REMOVAL
1. Remove upper aft center fuel cell (Chapter 28).
2. Remove nut (17, figure 1), washer (19), and bolt (1), (view A-A), from cambox bellcrank (2).
3. Remove nut (27), washer (19), and bolt (15) (view B-B) from cambox bellcrank (16).
4. Remove rod ends (3), washer (4), and nuts (5) from both ends of cable (13).
5. Loosen jamnuts (7). Hold cable with wrench while loosening jamnuts.
6. Remove bearing (8) from lower support (14).
7. Remove clamps (12) securing cable. To gain access to upper most clamp, remove panel on aft wall of fuel cell cavity.
8. Remove screws (11) retaining guide (10)
9. Remove bearing (8) from upper support (9).
10. 1Remove both upper and lower bearings (w8) from cable (13).
11. Remove jamnuts (7) from cable.
CAUTION
TO PREVENT DAMAGE TO CABLE DO NOT COIL IN A TIGHT LOOP.
12. Remove cable (13) through large access opening in bottom of helicopter.
13. Remove nut (20), washer, (21), and bolt (22).
15. Remove cambox (25) from service deck.
2. DROOP COMPENSATOR AND CABLE [C] [D] - INSTALLATION
1. Position cambox (25, figure 1) on service deck.
2. Install four screws (23) and washers (24).
3. Position actuator rod end bearing (26) on cambox (25) slider and install bolt (22), washer (21) and nut (20).
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E-AB412-PT6T-2
CAUTION
TO PREVENT DAMAGE TO CABLE DO NOT COIL IN A TIGHT LOOP.
4. Upon removal from packing, lay cable (13) straight on a flat surface. Ensure cable is no twisted.
5. After ensuring cable is free of twist, rod end should be stroked by hand to ensure cable is not binding or has excessively
high operating loads and motions smooth. Erratic or increasing load as cable is stroked is reason to replace cable.
6. Stroke cable by hand to check for operation. No increase in load indicates cable has not been twisted and positioning
is satisfactory.
7. Install guide (10) with screws (11).
8. Install jamnuts (7) on cable at both ends.
9. Install bearing (8) and jamnut (7) on upper portion of cable. Do not tighten at this time.
10. Install bearing (8) on upper support (9).
11. Install bearing (8) and jamnut (7) on lower portion of cable. Do not tighten at this time.
12. Install bearing (8) onto lower support (14).
13. Center bearings on both cable ends using jamnuts. Adjust jamnuts to prevent cable inner member from bottoming out
in cable outer casing when collective is full down.
14. Do not apply torque to cable housing as this will introduce twist against cable housing while holding cable housing.
Stroke cable by hand to check for freedom of operation.
15. Install nuts (5), washer 84), and rod ends (3) on both ends of cable. Install rod end at full thread engagement then back
off six turns.
16. Connect rod end (3) by installing bolts (1), washer (18), and nut (17) on cambox bellcrank(2).
17. Connect rod end (3) by installing bolts (1), washer (19), and nut (17) on bellcrank (16).
18. Ensure both upper and lower rod ends of cable engage without inducing any cable twisting. Operate system and check
for freedom of operation.
19. If proceeding check shows no appreciable increase in load or affect on smoothness of operation, control cable has been
properly installed. Install clamps (12). Do not force cable to take an unusual configuration ensure clamps do not pinch
or axially restrain conduit.
20. Install upper aft cell (Chapter 28).
21. Rig droop compensator controls per module 76-12-02 paragraph "1. N2 control rigging [C] - description" or
module 76-12-03 paragraph "1. N2 control rigging [D] - description", depending on aircraft configuration.
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E-AB412-PT6T-2
G6AB0241A
Figure 1. Droop compensator cambox control cable (helicopters codes [C] [D])
76-12-01
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E-AB412-PT6T-2
3. DROOP COMPENSATOR AND CABLE [C] [D] - INSPECTION
1. Inspect cambox (25, figure 1) for secure installation.
2. Inspect cambox for binding when collective controls are moved through full range.
3. Inspect cable (13) for damage and corrosion. Inspect cable rod end bearing for damage.
4. Inspect cable to ensuring cable is free of twists, rod end should be stroked by hand to ensure cable is not binding or
has excessively high operating loads and motion is smooth. Erratic or increasing load as cable is stroked is reason to
replace cable.
5. Inspect bearing (8) for wear and damage.
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E-AB412-PT6T-2
76-12-02
DROOP COMPENSATOR (N2) CONTROLS - N2 CONTROL RIGGING [C]
1. N2 CONTROL RIGGING [C] - DESCRIPTION
MATERIALS REQUIRED
NUMBER NOMENCLATURE
NOTE
b. Tolerance for rigging dimensions is plus or minus 0.03 inch (0.7 millimeter) unless otherwise stated.
c. All adjustable control tubes must have a maximum of 25,4 mm (1,00 in) of exposed threads after adjustment. If
control tubes have inspection holes, the threads must be engaged sufficiently to cover holes. Ensure shear rivet
(17, figure 4-27) is in serviceable condition prior to rigging.
CAUTION
DO NOT PERMIT ANY LUBRICANT OR COMPOUND TO CONTACT

CONTROL CABLES.
adjustment.
e. Torque control jamnuts 92 to 115 kgcm (80 to 100 in.lb.) after adjustment unless other torque is specified.
f. Control tubes must be free to rotate several degrees about longitudinal axis. Loosen jamnuts, adjust end fittings,
and torque jamnuts if necessary.
2. Ensure that collective pitch control system rigging has been accomplished (Chapter 67).
3. Check that levers (2 and 6, figure 1) are properly installed on control shafts of power turbine governors (1 and 5).
Centerline of levers (2 and 6) must be 30o clockwise from centerline of governor stop arm (21), viewed from left. See
detail A.
4. Check that adjustable tube (7) is approximately same length as nonadjustable tube (3). Begin with tube (7) attached at
middle hole of arm on jackshaft (4). See detail C.
5. Disconnect actuator (8) from lower arm of jackshaft (4).
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E-AB412-PT6T-2
6. Disconnect control cable (13) from cambox (10).
7. Check that long arm of cambox bellcrank (28) is attached approximately in middle of adjustment slot of cam (25). See
detail B.
NOTE
The dimensions given in steps 7. and 8., are approximate for initial rigging. Minor
adjustment may be necessary during ground and flight tests.
8. Use RPM (beep) switch on collective stick switchbox to operate actuator. Check that actuator (8) is adjusted for total
stroke of approximately 16 mm (0,62 in) from full extend DECR, to full INCR positions.
NOTE
Adjustment to stroke must be made with the actuator (8) in mid position.
9. Adjust rod end on actuator (8) to approximately 48 mm (1,88 in) from center of bearing bolt hole to face of jamnut as
shown on detail D.
10. Manually rotate jackshaft (4) and check that no interference exists. Reconnect actuator (8) to lower arm of jackshaft
(4).
11. Disconnect tube (20) and rotate idler (19) to ensure that no interference exists. Reconnect tube (20) to idler (19).
12. With hydraulic boost on, place and hold collective stick full down.
13. Check slider follower bearing as follows:
a. Rotate cambox bellcrank (28) to ensure no interference exists. Connect and adjust length and/or position of
control cable (13) so the slider follower bearing does not touch bottom of cam slot, record dimension.
b. Move collective stick to full up position.
c. Ensure slider follower bearing does not touch top of cam slot. Record dimension.
d. Adjust length and/or position of control cable (13) so the recorded dimensions are equal within 1,52 mm (0,060
in).
e. Move collective stick through full range of travel (up, down, and up) to ensure clearance between slider and cam.
NOTE
Cable adjustments can be made at support (11) or at support (15). Install rod end on
control cable (13) at full thread engagement then back off 6 turns and position outer
race of bearing 90o to wrench flat on control cable at this position. Torque jamnut.
f. Add lockwire and cotter pins to both ends of control cable (13), at support (11), and at rod ends.
14. With hydraulic boost on, place collective stick down. Hold RPM (beep) switch to DECR until actuator (8) is fully
extended. Check stop arms adjacent to governors (1 and 5) for clearance between stop arms (23) and minimum power
stop screws (22) on both governors. There must be a small amount of clearance at both stop screws (22).
15. Place collective stick full up. Adjust controls cable (13) so that upper end of cam (25) slot is 0,3 mm (0,010 inch)
minimum above slider housing (27) as shown on detail B.
16. Place collective stick full up. Hold RPM (beep) switch to INCR until actuator (8) is fully retracted. Check stop arms
adjacent to governors (1 and 5) for 0,3 mm (0,010 inch) clearance between stop arms (23) and maximum power stop
screws (24) on both governors as shown on detail A.
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E-AB412-PT6T-2
NOTE
Accomplish following steps in conjunction with ground run and flight tests.
17. Start both power sections and idle for 5 minutes.
18. Rotate engine 1 (left power section) throttle grip full open, then retard throttle to idle stop without using IDLE ENG 1
on collective switchbox, until stop contacts solenoid plunger. Adjust stop on torque tube (11, figure 2) to obtain 61±1
percent N1 (N2) RPM when stop is in contact with plunger of solenoid (6).
NOTE
If it is not possible to adjust the N1 (N2) speed to 61±1 percent using the stop on the
torque tube(5), the four spacers which support the solenoid (6) on the engine deck
may be replaced. Longer spacers will increase the flight idle N1 (N2) speed.
19. Perform check similar to step 18. for engine 2 (right power section). Make adjustment to stop on torque tube (11)
against solenoid (12).
20. Actuate RPM (beep) switch to full DECR.
21. Place collective stick full down. Rotate engine 2 (right power section) throttle grip to full INCR. Record rotor RPM.
Slowly actuate RPM (beep) switch to full INCR, but do not exceed 100%. Record rotor RPM. The full DECR rotor
RPM should be 95%. The full INCR rotor RPM should be 99%. If range and/or spread is not within limits, adjust as
follows:
a. If range is not within limits, adjust actuator (8, figure 1) rod end. Lengthen or shorten so range in 95 to 99%.
NOTE
If it is not possible to obtain the required range with the adjustment of the actuator,
rotate levers (2 and 6) one tooth (corresponding to 15°) CCW.
b. If spread is not within limits, adjust stroke of actuator (8). Position actuator (8) to midtravel position prior to
22. Place collective stick full down. Rotate engine 1 (left power section) throttle grip to full INCR. Record rotor RPM.
Slowly actuate RPM (beep) switch to full INCR, but do not exceed 100%. Record rotor RPM. The full DECR rotor
RPM recorded should be 95%. The full INCR rotor RPM should be 99%. If RPM is out of limits, adjust length of tube
(7). If adjustment of tube (7) length does not result in correct RPM, move tube (7) rod end to a different hole in arm
of jackshaft (4) as shown on detail C.
NOTE
It is necessary that the single power section rotor RPM ranges be correct at this time;
however, later adjustments to achieve proper twin power section RPM range, and
adjustments to avoid torque needle split, shall supersede these initial adjustments.
23. Actuate RPM (beep) switch to full INCR. Place collective stick full down. Rotate both engine throttle grips to full
INCR. Record rotor RPM.
24. Actuate RPM (beep) switch to full DECR. Record rotor RPM. Adjust length of actuator (8) rod end as required to
obtain 97 to 101.5% RPM range. Shorten to raise or lengthen to lower range.
NOTE
When performing checks in step 24., the helicopter will become airborne.
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E-AB412-PT6T-2
25. Place collective stick full down. Rotate both engine throttle grips to full INCR. Use RPM (beep) switch to obtain 100%
rotor RPM indication. Increase collective pitch slowly in a series of equal steps from flat pitch to full power (either
engine temperature limit or transmission torque limit). Rotor RPM should remain at 100±1% throughout the power
sweep. Also check that engine torque readings are matched within 4% during steady state operation.
NOTE
Ensure the pointers on the reduction (combining) gearbox torque pressure
transmitters are indexed to the number stamped on the reduction gearbox data plate
for the torque meter for that side of the gearbox. If, after this check, the engine
torque readings do not match within 4%, refer to module 76-00-00 paragraph "2.
Engine controls - torque matching". If torque matching requirements conflict with
the beep range or the relationship of N1 (N2), ITT (T5), or fuel flow between the
power sections, comply with torque matching requirements.
26. If rotor RPM droops (decays below tolerance) or overspeeds (increases above 100%) during power applications, make
a cam rate adjustment. For increased cam compensation to correct droop, adjust cam (25, figure 4-27)
counterclockwise relative to bellcrank (28) as shown on detail B. For reduced cam compensation to correct overspeed,
adjust cam (25) clockwise relative to bellcrank (28). After each cam adjustment, an adjustment of control cable (13)
may be required to ensure that the slot in cam (25) does not bottom out during full down collective.
27. Check system to ensure no interference exists and for security of all parts.
28. With collective stick full up and actuator (8) fully retracted by RPM (beep) switch at INCR, adjust maximum power
stop screw (24) for both governors (1 and 5) to 0.3 mm (0.010 in) of stop arm (23).
76-12-02
Page 4
E-AB412-PT6T-2
G6AB0860A
Figure 1. N2 controls rigging (helicopters code [C])
76-12-02
Page 5
E-AB412-PT6T-2
G6AB0859A
76-12-02
Page 6
E-AB412-PT6T-2
76-12-03
DROOP COMPENSATOR (N2) CONTROLS - N2 CONTROL RIGGING [D]
1. N2 CONTROL RIGGING [D] - DESCRIPTION
MATERIALS REQUIRED
NUMBER NOMENCLATURE
C-405 LOCKWIRE
NOTE
b. Tolerance for rigging dimensions is 0.7 mm (± 0.03 in), unless otherwise stated.
c. All adjustable control tubes shall have a maximum of 25.4 mm (1.00 in) of exposed threads after adjustment. If
control tubes have inspection holes, threads shall be engaged sufficiently to cover holes. Ensure shear rivet (17,
figure 1) is in serviceable condition prior to rigging.
CAUTION
DO NOT PERMIT ANY LUBRICANT OR COMPOUND TO CONTACT

CONTROL CABLE(S).
adjustment.
e. Torque control jamnuts 9.0 to 11.3 Nm (80 to 100 in.lbs) after adjustment unless other torque is specified.
f. Control tubes must be free to rotate several degrees about longitudinal axis. Loosen jamnuts, adjust end fittings,
and torque jamnuts if necessary.
2. Ensure collective pitch control system rigging has been accomplished (Chapter 67).
3. Verify levers (2 and 6) are properly installed on control shafts of power turbine governors (1 and 5). Centerline of
levers (2 and 6) shall be 30 degrees clockwise from centerline of governor stop arm (23), viewed from left (detail A).
4. Verify tube (7) is approximately 237.24 mm (9.34 in) in length. Begin with tube (7) attached at middle hole of arm on
jackshaft (4) (detail C).
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E-AB412-PT6T-2
5. Adjust ITT trim actuator (3) stroke to 3.81 mm (0.15 in) by using actuator adjustment screw (see instructions on
actuator). With actuator at full extension, adjust actuator length to match length of tube (7) plus 1.90 mm (0.075 in).
Retract ITT trim actuator (3) by moving RPM (beep) switch in increase (INCR) direction until actuator length is
approximately equal to length of tube (7). This is mid stroke length of actuator. Ensure extend and retract strokes each
are 1.9 mm (0.075 in) with respect to actuator mid stroke length. Adjust as necessary using actuator adjustment screw.
6. Disconnect linear actuator (8) from lower arm of jackshaft (4).
7. Disconnect control cable (13) from cambox (10).
8. Check long arm of cambox bellcrank (28) is attached approximately in middle of adjustment slot of cam (25) (detail
B).
NOTE
The dimensions given in steps 8. and 9. are approximate for initial rigging. Minor
adjustment may be necessary during ground and flight test.
9. Use RPM (INCR/DECR +2/-2) switch on collective switchbox to operate linear actuator. Verify actuator (8) is adjusted
for total stroke of approximately 16 mm (0.62 in) from full extend (DECR), to full retract (INCR) positions.
NOTE
Adjustment to stroke shall be made with actuator (8) in midposition.
10. Adjust rod end on actuator (8) to approximately 48 mm (1.88 in) from center of bearing bolt hole to face of jamnut
(detail D).
11. Manually rotate jackshaft (4) and verify no interference exists. Reconnect actuator (8) to lower arm of jackshaft (4).
12. Disconnect tube (20) and rotate idler (19) to ensure no interference exists. Reconnect tube (20) to idler (19).
13. With hydraulic boost on (HYDR SYS NO.1 and HYDR SYS NO. 2), place and hold collective stick full down.
14. Check slider follower bearing as follows:
a. Rotate cambox bellcrank (28) to ensure no interference exists. Connect and adjust length and/or position control
cable (13) so slider follower bearing does not touch bottom of cam slot. Record dimension.
b. Move collective stick to full up position. Ensure slider follower bearing does not touch top of cam slot. Record
dimension.
c. Adjust length and/or position of control cable (13) so recorded dimensions are equal within 1.52 mm (0.060 in).
d. Move collective stick through full range of travel (up, down, and up) to ensure clearance between slider and cam.
NOTE
Cable adjustments can be made at support (11) or at support (15). Install rod end on
control cable (13) at full thread engagement then back off 6 turns and position outer
race of bearing 90° to wrench flat on control cable at this position. Torque jamnut.
e. Add lockwire (C-405) and cotter pins to both ends of control cable (13), at support (11), and at rod ends.
15. With hydraulic boost on, place collective stick full down. Hold RPM switch to DECR until linear actuator (8) is fully
extended. Hold RPM switch in -2 position until ITT trim actuator (3) is fully extended. Check stop arms adjacent to
governors (1 and 5) for clearance between stop arms (23) and minimum power stop screws (22) on both governors.
There shall be a small amount of clearance at both stop screws (22).
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E-AB412-PT6T-2
16. Place collective stick full up. Adjust controls cable (13) so upper end of cam (25) slot is 0.3 mm (0.010 in) minimum
above slider housing (27) (detail B).
17. Place collective stick full up. Hold RPM switch to INCR until linear actuator (8) is fully retracted. Hold RPM switch
in +2 position until ITT trim actuator (3) is fully retracted. Check stop arms adjacent to governors (1 and 5) for 0.3 mm
(0.010 in) clearance between stop arms (23) and maximum power stop screws (24) on both governors (detail A).
NOTE
Accomplish following steps in conjunction with ground run (tie down) and flight
test.
18. Start both power sections (E-AB412-PT6T-1) and idle for 5 minutes.
19. Rotate ENG 1 throttle to full INCR, then retard to idle stop (without pressing IDLE STOP ENG 1 switch) until stop
contacts solenoid plunger. Adjust stop on torque tube (5, figure 2) to obtain 61 ± 1% GAS PROD RPM when stop is
in contact with plunger of solenoid (6).
NOTE
If it is not possible to adjust GAS PROD RPM to 61 ± 1% using stop on torque tube
(5), the four spacers which support solenoid (6) on engine deck may be replaced.
Longer spacers will increase idle RPM.
20. Perform check similar to step s. for engine 2. Make adjustment to stop on torque tube (11) against solenoid (12).
21. Ensure linear actuator (8, figure 1) is fully extended by holding RPM switch in DECR direction and ensure ITT trim
actuator (3) is in mid stroke position, approximately 237.24 mm (9.34 in), before proceeding to the next steps.
22. Place collective stick full down. Rotate ENG 2 throttle to full INCR. Record ROTOR RPM. Slowly actuate RPM
switch to full INCR (do not exceed 100%). Record ROTOR RPM. The full DECR rotor RPM should be 95%. The full
INCR rotor RPM should be 99%. If range and/or spread is not within limits, adjust as follows:
a. If range is not within limits, adjust linear actuator (8) rod end. Lengthen or shorten so range is 95% to 99%.
b. If spread is not within limits, adjust stroke of actuator (8). Position actuator (8) to mid stroke position prior to
23. Place collective stick full down. With ENG 2 throttle to full INCR and RPM switch in full DECR (95% rotor RPM),
actuate ITT trim actuator RPM switch to full +2. Record ROTOR RPM. Actuate ITT trim actuator RPM switch to full
-2. Record ROTOR RPM. Rotor RPM should be 94% to 96%. If spread is not within limits, make appropriate
adjustment procedures on actuator.
24. Return ITT trim actuator back to mid travel position (95% rotor RPM).
25. With ENG 2 throttle at idle, and collective stick full down, rotate ENG 1 throttle to full INCR. Record ROTOR RPM.
Slowly actuate RPM switch to full INCR (do not exceed 100%). Record ROTOR RPM. The full DECR rotor RPM
recorded should be 95%. The full INCR rotor RPM should be 99%. If RPM is out of limits, adjust length of tube (7).
If adjustment of tube (7) length does not result in correct RPM, move tube (7) rod to a different hole in arm of jackshaft
(4) (detail C).
NOTE
It is necessary that single power section rotor RPM ranges be correct at this time;
however, later adjustments to achieve proper twin power range section RPM range,
and adjustments to obtain torque matching will supersede these initial adjustments.
26. Actuate RPM switch to full INCR. Place collective stick full down. Rotate both engine throttles to full INCR. Record
ROTOR RPM.
76-12-03
Page 3
E-AB412-PT6T-2
27. Actuate RPM switch to full DECR. Record ROTOR RPM. Adjust length of actuator (8) rod end as required to obtain
97% to 101.5% RPM range. Shorten to raise range or lengthen to lower range.
28. With rotor at flat pitch, increase both throttles to full open position and adjust rotor RPM to 100%.
29. Increase power to approximately 62% MAST TORQUE and match ENG 1 TORQUE to ENG 2 TORQUE by adjusting
control tube (7). Shorten to increase No. 1 engine torque. Lengthen to decrease No. 1 engine torque.
30. Ensure ITT trim actuator (3) is in mid stroke position, approximately 237.24 mm (9.34 in).
31. With rotor at flat pitch, rotate ENG 1 and ENG 2 throttles to full open. Adjust RPM switch until 100% ROTOR RPM
is indicated. Increase collective pitch slowly in a series of successive equal steps from flat pitch to full power (either
engine ITT limit or MAST TORQUE limit). ROTOR RPM should ideally remain at 100 ± 1% throughout power
sweep. If rotor RPM droops (decays to a value less than is allowed upon power application) or overspeeds (increases
above 100% upon power application) make a cam rate adjustment. For increased cam compensation (use if rotor
droops) adjust cam counterclockwise with respect to bellcrank (28). For decreased cam compensation (use if rotor
overspeeds), adjust cam clockwise with respect to bellcrank (28). After every cam adjustment, step M. and N. should
be accomplished to ensure slot in cam (25) does not bottom out during full down collective.
NOTE
If rotor overspeed cannot be corrected by adjusting droop cam, verify autorotation
RPM is correct. A very low main rotor blade angle can cause an excessive
overspeed.
32. Verify no interference exists and for security of all parts.
33. With collective pitch full up and RPM switches for linear actuator (8) and ITT trim actuator (3) in the full +2 position
(actuator retracted), adjust governor stop screw (24) for both governors (1 and 5) to a minimum of 2.54 mm (0.10 in)
o governor stop arm (23). Secure stops with lockwire (C-405).
34. Additional actuator adjustment may be required during initial ground run and/or flight to achieve optimum ITT
matching due to manufacturing and installation tolerances. Maintain 3.81 mm (0.15 in) stroke on ITT trim actuator (3).
76-12-03
Page 4
E-AB412-PT6T-2
G6AB0860A
Figure 1. N2 controls rigging (helicopters code [D])
76-12-03
Page 5
E-AB412-PT6T-2
G6AB0859A
76-12-03
Page 6
E-AB412-PT6T-2
CHAPTER 79 - ENGINE OIL SYSTEM

Module Page
Number Title Number
79-00-00 OIL
1. Oil - general ............................................................................................................................................ 1

2. Oil - troubleshooting ............................................................................................................................... 1
79-21-01 ENGINE OIL COOLING SYSTEM
1. Engine oil cooling system - description .................................................................................................. 1

2. Engine oil cooling system - reduction (combining) gearbox oil temperature switch ............................. 1
2-1. Reduction (combining) gearbox oil temperature switch - removal ............................................... 1
2-2. Reduction (combining) gearbox oil temperature switch - installation .......................................... 1
3. Engine oil cooling system - check valves................................................................................................ 4
3-1. Check valves - description ............................................................................................................. 4
3-2. Check valves - removal ................................................................................................................. 4
3-3. Check valves - installation ............................................................................................................. 4
4. Engine oil cooling system - drain valves ................................................................................................ 4
4-1. Drain valves - description .............................................................................................................. 4
4-2. Drain valves - removal.................................................................................................................... 6
4-3. Drain valves - installation .............................................................................................................. 6
5. Engine oil cooling system - combining gearbox and transmission oil cooler ........................................ 6
5-1. Combining gearbox and transmission oil cooler - removal ........................................................... 6
5-2. Combining gearbox and transmission oil cooler - installation ...................................................... 7
5-3. Combining gearbox and transmission oil cooler - inspection ....................................................... 7
6. Engine oil cooling system - engine power section oil cooler ............................................................... 10
6-1. Engine power section oil cooler - removal .................................................................................. 10
6-2. Engine power section oil cooler - installation ............................................................................. 11
6-3. Engine power section oil cooler - inspection ............................................................................... 11
79-22-01 ENGINE AND TRANSMISSION OIL COOLER BLOWER
1. Engine and transmission oil cooler blower - description ........................................................................ 1

2. Engine and transmission oil cooler blower - removal ............................................................................ 1
3. Engine and transmission oil cooler blower - installation ........................................................................ 1
4. Engine and transmission oil cooler blower - inspection ......................................................................... 1
79-Index
Rev. 2 Page 1
E-AB412-PT6T-2
FIGURES
Figure Page
Number Title Number
79-00-00 OIL
Figure 1. Engine oil system schematic ...........................................................................................................................2
Figure 1. Engine oil cooling system ...............................................................................................................................2

Figure 2. Reduction (combining) gearbox oil temperature switch.................................................................................3
Figure 3. Engine oil cooling system check valve ...........................................................................................................5
Figure 4. Engine oil cooling system drain valve ............................................................................................................8
Figure 5. Combining gearbox and transmission oil cooler (sheet 1 of 2) ......................................................................9
Figure 6. Engine power section oil cooler....................................................................................................................12
79-22-01 ENGINE AND TRANSMISSION OIL COOLER BLOWER
Figure 1. Engine and transmission oil cooler blower .....................................................................................................2
79-Index
Page 2 Rev. 2
E-AB412-PT6T-2
TABLES
Table Page
Number Title Number
79-00-00 OIL
Table 1. Troubleshooting - engine oil system .............................................................................................................. 3
79-Index
Rev. 2 Page 3
E-AB412-PT6T-2
79-Index
Page 4 Rev. 2
E-AB412-PT6T-2
79-0 -0 OIL
79-00-00
OIL
1. OIL - GENERAL
NOTE
Terminology reduction gearbox and combining gearbox as used in this manual are
one in the same. AgustaWestland uses combining gearbox as evident on annunciator
light panel.
This chapter contains maintenance data for both engine (power sections) oil systems and reduction (combining) gearbox oil
system.
The oil systems of power sections and reduction (combining) gearbox are separate systems and are connected by external
hoses to three radiator-type coolers located aft of engine. The upper cooler is a dual unit, serving both the reduction
(combining) gearbox and transmission oil system. The coolers are installed in a structural support, and are connected by air
ducts to two blowers mounted on (and shaft-driven by) the reduction (combining) gearbox. Drain lines with manual valves
are provided for all engine-to-cooler lines (figure 1).
The oil supply for each power section is located in a tank in the accessory gearbox. The reduction (combining) gearbox has
an internal oil supply. A temperature bulb and pressure transmitter in each system are connected to oil temperature and
pressure gages on the instrument panel. Pressure switches, temperature switches, and chip detectors in each system are
connected to segments on the caution panel.
2. OIL - TROUBLESHOOTING
NOTE
If metallic pickup is found in external lines of engine, reduction (combining)
gearbox, or transmission oil system, and if engine or reduction (combining) gearbox,
or transmission are being replaced, and if metal particles are suspected of being
present in oil cooler, replace oil cooler.
When troubleshooting engine oil system refer to table 1.
79-00-00
Rev. 2 Page 1
E-AB412-PT6T-2
G6AB0306A
Figure 1. Engine oil system schematic
79-00-00
Page 2 Rev. 2
E-AB412-PT6T-2
Table 1. Troubleshooting - engine oil system
ENG CHIP ENG 1, ENG 2, or C Box Normal wear Remove all chip detectors and oil fil-
segment(s) illuminates ters. Verify metallic pickup consists of
nothing larger than fuzz or fine slivers.
Change oil (Chapter 12) and clean chip

detectors and oil
filters. Run affected power section for
10 minutes at conveniently high power
level.
Pull chip detectors and oil filters again.

If no significant pickup is found,
engine is acceptable. If significant
metallic pickup is found on combining
gearbox third oil system chip detector,
or filter, replace gearbox. If significant
pickup is found on accessory gearbox
chip detector, replace power section
and combining gearbox (Chapter 71).
Excessive wear. 1. Remove all chip detectors and fil-

ters. If metallic pickup consists of
flakes or other particles not in the cate-
gory of fuzz or fine slivers, excessive
wear is indicated.
2. If excessive pickup occurs on either

of combining gearbox input section
chip detectors or input power section
oil filters, replace gearbox. Flush
power section oil system.
If excessive pickup is found on com-

bining gearbox third oil system chip
detectors, replace gearbox. If excessive
pickup is found on accessory gearbox
chip detector, replace power section
and combining gearbox.
3. Rotate power turbine of affected

power section by hand and check for
roughness or other abnormalities.
Refer to Pratt and Whitney of Canada,
Ltd. PT6T-3 Series engine mainte-
nance manual for further procedures.
79-00-00
Rev. 2 Page 3
E-AB412-PT6T-2
(Cont.d)
4. If excessive pickup is found on com-

bining gearbox third oil system chip
detectors, replace combining gearbox.
If excessive pickup is found on acces-
sory gearbox chip detector, replace
power section and reduction gearbox.
Chips in oil cooler. Check external lines of cooling system

for evidence of metal chips.
a. If metallic pickup is found in exter-

nal lines of engine oil system or if par-
ticles are suspected of being present in
oil cooler, replace oil cooler with new
cooler (module 79-21-01 paragraph "6.
Engine oil cooling system - engine
power section oil cooler").
b. If it is necessary to replace engine

because of metallic chip damage, oil
cooler shall be replaced with new
cooler (module 79-21-01 paragraph "6.
Engine oil cooling system - engine
power section oil cooler").
OIL PRESSURE ENG 1 or ENG 2 low Fault in pressure gage or caution panel Replace faulty electrical
circuits. components or repair circuit. A direct
reading gage can be connected at
points shown on figure 1 to check
accuracy of indicating system.
No oil supply. Check oil level.
Faulty oil pump or pressure Refer to Pratt and Whitney of Canada

relief valve. Ltd. PT6T-3 Series engine mainte-
nance manual.
Reduction gearbox impending bypass Impending filter bypass. 1. Reset the indicator button and verify
indicator extended. that it does not extend a second time by
running the aircraft.
2. If indicator extends a second time

remove the filter and inspect for block-
age.
a. If filter is found serviceable, replace
the impending bypass indicator (Ref.
Chapter 71)
79-00-00
Page 4 Rev. 2
E-AB412-PT6T-2
(Cont.d)
b. If the filter is found obstructed or

contaminated, refer to Pratt & Whitney
maintenance manual for corrective
action.
79-00-00
Rev. 2 Page 5
E-AB412-PT6T-2
79-00-00
Page 6 Rev. 2
E-AB412-PT6T-2
79-21-01
ENGINE OIL COOLING SYSTEM
1. ENGINE OIL COOLING SYSTEM - DESCRIPTION
The engine oil cooling system (figure 1) consists of engine power section and reduction (combining) gearbox oil coolers and
lines, valves, and switch between engine and coolers.
2. ENGINE OIL COOLING SYSTEM - REDUCTION (COMBINING) GEARBOX OIL

TEMPERATURE SWITCH
2-1. REDUCTION (COMBINING) GEARBOX OIL TEMPERATURE SWITCH - REMOVAL
1. Open left engine oil cooler support cowling.
2. Drain oil from combining gearbox oil cooler until oil level is below switch (4, figure 2).
3. Disconnect connector (5).
5. Remove bushing (2) with packing (1).
2-2. REDUCTION (COMBINING) GEARBOX OIL TEMPERATURE SWITCH - INSTALLATION
1. Install bushing (2, figure 2) with new packing (1).
2. Install switch (4) with packing (3). Torque switch 25 in.-lbs. (2,82 Nm) maximum.
3. Connect connector (5).
4. Check gearbox oil level, service if required (Chapter 12).
5. Ground run helicopter. Ensure C BOX TEMP caution panel segment is extinguished.
6. Check for oil leaks.
7. Check combining gearbox oil level and service as required (Chapter 12).
8. Close and secure cowling.
79-21-01
Page 1
E-AB412-PT6T-2
G6AB0307A
Figure 1. Engine oil cooling system
79-21-01
Page 2
E-AB412-PT6T-2
G6AB0308A
Figure 2. Reduction (combining) gearbox oil temperature switch
79-21-01
Page 3
E-AB412-PT6T-2
3. ENGINE OIL COOLING SYSTEM - CHECK VALVES
3-1. CHECK VALVES - DESCRIPTION
Four check valves are installed in engine oil cooling system. One check valve is used in each power section oil inlet line and
one check valve is used in inlet and outlet oil lines of combining gearbox.
NOTE
Removal and installation of all check valves is similar. The following procedures are
typical for any valve. Clamping arrangement however, may be different.
3-2. CHECK VALVES - REMOVAL
1. Open engine side cowling.
2. Drain oil from appropriate power section or from combining gearbox.
3. Disconnect tube (5, figure 3) and hose (10).
4. Remove screw (9), washer (8), spacer (6), clamp (7), and check valve.
3-3. CHECK VALVES - INSTALLATION
CAUTION
ENSURE CHECK VALVE IS INSTALLED WITH ETCHED ARROW IN

DIRECTION OF FLOW.
1. Position clamp (7, figure 3) on check valve. Secure clamp with screw (9), washer (8), and spacer (6).
2. Connect tube (5) and hose (10).
3. Check oil level in appropriate power section or combining gearbox. Service as required (Chapter 12).
4. Ground run helicopter and check for oil leaks.
5. Check oil level in appropriate power section or combining gearbox. Service as required (Chapter 12).
6. Close and secure cowling.
4. ENGINE OIL COOLING SYSTEM - DRAIN VALVES
4-1. DRAIN VALVES - DESCRIPTION
Four drain valves are installed in engine oil system. Two drain valves are installed in combining gearbox oil system and one
drain valve is installed in each power section oil system. The drain valves are mounted on engine aft center service deck.
Maintenance procedures for all drain valves are the same except for location.
79-21-01
Page 4
E-AB412-PT6T-2
G6AB0309A
Figure 3. Engine oil cooling system check valve
79-21-01
Page 5
E-AB412-PT6T-2
4-2. DRAIN VALVES - REMOVAL
1. Open engine side cowling where drain valve is located.
2. Remove access panel below side cowling.
3. Drain oil from appropriate power section or from combining gearbox.
4. Disconnect hose (5, figure 4) and tube (12).
5. Loosen nut (8) and remove elbow (10) and union (11) as an assembly. Discard packing.
6. Remove nuts (8 and 7) and drain valve (4).
4-3. DRAIN VALVES - INSTALLATION
1. Position valve (3, figure 4) and washer (6) on service deck and install nut (7).
2. Install nut (8), new packing (9), elbow (10), and union (11). Align elbow (10) with tube (12). Tighten nut (8) against
elbow (10).
3. Connect hose (5) and tube (12).
4. Check oil level in appropriate power section or combining gearbox. Service if needed (Chapter 12).
6. Check oil level in appropriate power section or combining gearbox, service if needed (Chapter 12).
7. Install access panel. Close and secure cowling.
5. ENGINE OIL COOLING SYSTEM - COMBINING GEARBOX AND TRANSMISSION

OIL COOLER
5-1. COMBINING GEARBOX AND TRANSMISSION OIL COOLER - REMOVAL
1. Remove oil cooler support fairing.
NOTE
If oil hoses attached to cooler have enough slack, cooler can be removed by
removing bolts (8, figure 5) and washer (7) then moving cooler aft prior to
disconnecting hoses. If this is possible, skip steps 3. through 5.
2. Remove combining gearbox cowling.
3. Remove ejectors (Chapter 71).
4. Remove oil cooler duct.
5. Remove access panel located below aft end of ejector.
6. Drain cooler.
7. Use suitable container to catch spilled oil. Disconnect hoses (1, 22, 19, and 11).
79-21-01
Page 6
E-AB412-PT6T-2
8. Remove bolts (8) and remove cooler (6).
9. Remove nuts (2), washers (3), connector (4), and gasket (5). Discard gasket.
10. Remove nuts (23), washers (24), flange (25), elbow (26), and gasket (27). Discard gasket.
11. Remove nuts (18), washers (17), flange (16), elbow (15), and gasket (14). Discard gasket.
5-2. COMBINING GEARBOX AND TRANSMISSION OIL COOLER - INSTALLATION
1. Install gasket (5, figure 5), connector (4), washers (3), and nuts (2).
2. Install gasket (27), elbow (26), flange (25), washers (24), and nuts (23).
3. Install gasket (14), elbow (15), flange (16), washers (17), and nuts (18).
4. Install gasket (9), connector (10), washers (13), and nuts (12).
5. If oil cooler was removed without removing ejectors and oil cooler duct, connect hoses to cooler prior to positioning
cooler to support.
6. Position cooler (6) in opening of support (20).
9. Install access panel located below aft end of ejector.
10. Install oil cooler duct.
11. Install ejectors (Chapter 71).
12. Check combining gearbox and transmission oil level, service if required (Chapter 12).
13. Install cowling.
14. Install oil cooler support fairing.
16. Check combining gearbox and transmission oil level. Service if required (Chapter 12).
5-3. COMBINING GEARBOX AND TRANSMISSION OIL COOLER - INSPECTION
1. Inspect fitting, lines, and mountings for damage and general conditions.
2. Inspect air passages of oil cooler core for restrictions, bent core or cooling fins, and leaks.
79-21-01
Page 7
E-AB412-PT6T-2
G6AB0310A
Figure 4. Engine oil cooling system drain valve
79-21-01
Page 8
E-AB412-PT6T-2
G6AB0311A
Figure 5. Combining gearbox and transmission oil cooler (sheet 1 of 2)
79-21-01
Page 9
E-AB412-PT6T-2
G6AB0312A
Figure 5. Combining gearbox and transmission oil cooler (sheet 2 of 2)
6. ENGINE OIL COOLING SYSTEM - ENGINE POWER SECTION OIL COOLER
6-1. ENGINE POWER SECTION OIL COOLER - REMOVAL
1. Remove combining gearbox and transmission oil cooler (paragraph "5-1. Combining gearbox and transmission oil
cooler - removal").
NOTE
Either oil cooler can be removed individually or both coolers can be removed as a
unit.
2. Drain oil from appropriate cooler.
3. If removing oil cooler (3, figure 6), disconnect hose (23), tube (22), and remove bolts (2).
4. If removing oil cooler (8), disconnect tube (16), hose (17), and remove bolts (9).
NOTE
If removing oil coolers as a unit, bolts (7 and 18) can remain in place until coolers
are removed.
5. Remove bolt (7).
6. Remove two bolts (18).
7. Remove cooler from oil cooler support.
NOTE
Removal procedures are the same for connectors on both coolers.
79-21-01
Page 10
E-AB412-PT6T-2
6-2. ENGINE POWER SECTION OIL COOLER - INSTALLATION
NOTE
Installation procedures are the same for connectors on both coolers.
1. Install gasket (12, figure 6), connector (13), washers (14), and nuts (15).
NOTE
If oil coolers are being installed as a unit, install bolts (7 and 18) with washers and
nuts prior to installing coolers.
2. Position cooler (3 or 8) in oil cooler support.
3. If installing cooler (3), install bolt (2) with washer (1). Connect tube (22) and hose (23).
4. If installing cooler (8), install bolt (9) with washer (10). Connect hose (17) and tube (16).
5. Install bolt (7), washers (6 and 5), and nut (4).
6. Install bolts (18), washers (19 and 20), and nuts (21).
7. Install combining gearbox and transmission oil cooler (paragraph "5-2. Combining gearbox and transmission oil cooler
- installation").
8. Check combining gearbox, transmission, and engine power sections oil levels. Service if required (Chapter 12).
10. Check combining gearbox, transmission, and engine power sections oil levels. Service if required (Chapter 12).
6-3. ENGINE POWER SECTION OIL COOLER - INSPECTION
NOTE
If metallic pickup is found in external lines of engine, reduction (combining)
gearbox, or transmission oil system, and if engine, reduction (combining) gearbox,
or transmission are being replaced, and if metal particles are suspected of being
present in oil cooler, replace oil cooler.
1. Inspect fittings, lines, and mountings for damage and general condition.
2. Inspect air passages of oil cooler core for restriction, bent core or cooling fins, and leaks.
79-21-01
Page 11
E-AB412-PT6T-2
G6AB0313A
Figure 6. Engine power section oil cooler
79-21-01
Page 12
E-AB412-PT6T-2
79-2 -01 ENGINE AND TRANSMISSION OIL COOLER BLOWER
79-22-01
ENGINE AND TRANSMISSION OIL COOLER BLOWER
1. ENGINE AND TRANSMISSION OIL COOLER BLOWER - DESCRIPTION
Two shaft driven blowers are mounted on upper aft pads of the combining gearbox. The blowers provide air through
connecting ducts to ensure adequate air flow through the four oil coolers (figure 1).
2. ENGINE AND TRANSMISSION OIL COOLER BLOWER - REMOVAL
1. Open engine top and upper cowl.
2. Open oil cooler air scoop.
3. Remove combining gearbox top cowl.
4. Remove ejector (Chapter 71).
5. Loosen or remove screw (4, figure 1) and remove boot (2) from blower (1).
6. Remove nuts (7) and blower (1).
7. Remove opposite blower in the same manner.
3. ENGINE AND TRANSMISSION OIL COOLER BLOWER - INSTALLATION
1. Place packing (9, figure 1) on shaft of blower (1).
2. Position blower (1) on combining gearbox pad. Install nuts (7).
3. Position boot (2) on blower (1). Install screw (4), two washers (5), and nut (6).
4. Install ejector (Chapter 71).
5. Install combining gearbox top cowl.
6. Close and secure open cowling.
7. Install opposite blower in the same manner.
4. ENGINE AND TRANSMISSION OIL COOLER BLOWER - INSPECTION
1. Inspect boot (2, figure 1) for holes and deterioration.
2. Inspect blades of impeller and guide vanes for cracks and nicks.
3. Rotate impeller and check bearing for roughness.
79-22-01
Page 1
E-AB412-PT6T-2
G6AB0314A
Figure 1. Engine and transmission oil cooler blower
79-22-01
Page 2
E-AB412-PT6T-2
CHAPTER 95 - INSTRUMENT SYSTEM

Module Page
Number Title Number
95-29-30 PROPULSION AND HYDRAULIC INSTRUMENTS
1. Propulsion and hydraulic instruments - description ............................................................................... 1

2. Propulsion and hydraulic instruments - dual torque pressure indicator [A] [B] [C] .............................. 1
3. Propulsion and hydraulic instruments - triple torque pressure indicator [D] ......................................... 1
4. Propulsion and hydraulic instruments - engine oil pressure and temperature indicators ....................... 1
5. Propulsion and hydraulic instruments - fuel pressure indicators ............................................................ 1
6. Propulsion and hydraulic instruments - fuel quantity indicators ............................................................ 1
7. Propulsion and hydraulic instruments - gas producer tachometer indicators .......................................... 2
8. Propulsion and hydraulic instruments - gearbox oil pressure and temperature indicator ....................... 2
9. Propulsion and hydraulic instruments - hydraulic pressure and temperature indicator .......................... 2
10. Propulsion and hydraulic instruments - transmission oil pressure and temperature indicator ............... 2
11. Propulsion and hydraulic instruments - triple tachometer indicator ....................................................... 2
12. Propulsion and hydraulic instruments - interturbine temperature (ITT) indicators ................................ 2
95-31-10 INSTRUMENT SYSTEM
1. Instrument system - description .............................................................................................................. 1

2. Instrument system - panel mounted instruments .................................................................................... 1
2-1. Panel mounted instruments - description ....................................................................................... 1
2-2. Panel mounted instruments - removal ........................................................................................... 1
2-3. Panel mounted instruments - installation ....................................................................................... 2
2-4. Panel mounted instruments - inspection ........................................................................................ 2
2-5. Panel mounted instruments - cleaning ........................................................................................... 2
2-6. Panel mounted instruments - repair or replacement ...................................................................... 2
3. Instrument system - instrument panel ..................................................................................................... 3
3-1. Instrument panel - description ....................................................................................................... 3
3-2. Instrument panel - removal ............................................................................................................ 3
3-3. Instrument panel - installation ....................................................................................................... 3
3-4. Instrument panel - adjustment ....................................................................................................... 3
4. Instrument panel - non-panel mounted instruments ................................................................................ 4
4-1. Non-panel mounted instruments - description ............................................................................... 4
95-31-20 MISCELLANEOUS INSTRUMENTS
1. Miscellaneous instruments - description ................................................................................................. 1

2. Miscellaneous instruments - clock .......................................................................................................... 1
2-1. Clock - description ......................................................................................................................... 1
2-2. Clock - troubleshooting ................................................................................................................. 1
2-3. Clock - maintenance ...................................................................................................................... 1
3. Miscellaneous instruments - dual AC and DC voltmeters....................................................................... 2
3-1. Dual AC and DC voltmeters - description ..................................................................................... 2
3-2. Dual AC and DC voltmeters - troubleshooting ............................................................................. 2
3-3. Dual AC and DC voltmeters - maintenance .................................................................................. 2
4. Miscellaneous instruments - dual DC ammeter ...................................................................................... 2
4-1. Dual DC ammeter - description ..................................................................................................... 2
4-2. Dual DC ammeter - troubleshooting .............................................................................................. 2
4-3. Dual DC ammeter - maintenance .................................................................................................. 2
95-Index
Rev. 2 Page 1
E-AB412-PT6T-2

Module Page
Number Title Number
5. Miscellaneous instruments - free air temperature indicator ....................................................................2

5-1. Free air temperature indicator - description ...................................................................................2
5-2. Free air temperature indicator - removal........................................................................................2
5-3. Free air temperature indicator - installation ...................................................................................3
5-4. Free air temperature indicator - inspection ....................................................................................3
5-5. Free air temperature indicator - cleaning .......................................................................................3
5-6. Free air temperature indicator - repair or replacement...................................................................3
5-7. Free air temperature indicator - troubleshooting............................................................................3
6. Miscellaneous instruments - engine hourmeter system [A] [B]...............................................................4
6-1. Engine hourmeter system [A] [B] - description ..............................................................................4
6-2. Engine hourmeter system [A] [B] - operational check ...................................................................4
6-3. Engine hourmeter system [A] [B] - troubleshooting.......................................................................4
6-4. Engine hourmeter system [A] [B] - maintenance............................................................................5
7. Miscellaneous instruments - engine hourmeter system [C] [D]...............................................................5
7-1. Engine hourmeter system [C] [D] - description ..............................................................................5
7-2. Engine hourmeter system [C] [D] - operational check ...................................................................5
7-3. Engine hourmeter system [C] [D] - troubleshooting.......................................................................6
7-4. Engine hourmeter system [C] [D] - maintenance............................................................................6
95-34-10 FLIGHT INSTRUMENTS - PITOT-STATIC SYSTEM
1. Pitot-static system - pilot .........................................................................................................................1

2. Pitot-static system - copilot (when installed) ..........................................................................................1
3. Pitot-static system - leak check ...............................................................................................................1
3-1. Leak check - pitot system ...............................................................................................................3
3-2. Leak check - static system ..............................................................................................................3
4. Pitot-static system - operational check ....................................................................................................4
5. Pitot-static system - inspection ................................................................................................................5
6. Pitot-static system - hardware .................................................................................................................9
6-1. Hardware - repair or replacement ...................................................................................................9
7. Pitot-static system - pitot and static lines ................................................................................................9
7-1. Pitot and static lines - draining instructions ...................................................................................9
95-34-11 FLIGHT INSTRUMENTS - PITOT TUBE
1. Pitot tube - removal .................................................................................................................................1

2. Pitot tube - installation ............................................................................................................................1
3. Pitot tube - cleaning .................................................................................................................................2
95-34-12 FLIGHT INSTRUMENTS - PITOT TUBE AND STATIC PORT HEATERS
1. Pitot tube and static port heaters - description ........................................................................................1

2. Pitot tube and static port heaters - static port heater elements ................................................................1
2-1. Static port heater elements - removal .............................................................................................1
2-2. Static port heater elements - installation .........................................................................................2
3. Pitot tube and static port heaters - static port heater system ...................................................................2
3-1. Static port heater system - inspection .............................................................................................2
3-2. Static port heater system - cleaning ................................................................................................3
3-3. Static port heater system - repair or replacement ...........................................................................3
3-4. Static port heater system - leakage test ..........................................................................................3
4. Pitot tube and static port heaters - operational check ..............................................................................3
5. Pitot tube and static port heaters - troubleshooting ..................................................................................4
95-Index
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E-AB412-PT6T-2

Module Page
Number Title Number
95-34-13 FLIGHT INSTRUMENTS - PITOT-STATIC INSTRUMENTS
1. Pitot - static instruments - description .................................................................................................... 1

2. Pitot-static instruments - airspeed indicator ............................................................................................ 1
2-1. Airspeed indicator - description ..................................................................................................... 1
2-2. Airspeed indicator - troubleshooting ............................................................................................. 1
3. Pilot-static instruments - altimeter ........................................................................................................... 2
3-1. Altimeter - description ................................................................................................................... 2
3-2. Altimeter - troubleshooting ............................................................................................................ 2
4. Pitot-static instruments - vertical speed indicator.................................................................................... 3
4-1. Vertical speed indicator - description ............................................................................................ 3
4-2. Vertical speed indicator - troubleshooting ..................................................................................... 3
95-34-14 FLIGHT INSTRUMENTS - STAND-BY ATTITUDE INDICATOR (WHEN INSTALLED)
1. Stand-by attitude indicator (when installed) - description....................................................................... 1
95-Index
Rev. 2 Page 3
E-AB412-PT6T-2
FIGURES
Figure Page
Number Title Number
Figure 1. Instrument panel (helicopters codes [A] [B]) (sheet 1 of 2) ...........................................................................5

Figure 2. Instrument panel (helicopters codes [C] [D])..................................................................................................6
Figure 1. Free air temperature indicator .........................................................................................................................7
Figure 1. Pitot-static system schematic ..........................................................................................................................2

Figure 2. Pitot-static system (sheet 1 of 3) .....................................................................................................................6
95-34-14 FLIGHT INSTRUMENTS - STAND-BY ATTITUDE INDICATOR (WHEN INSTALLED)
Figure 1. Stand-by attitude indicator ..............................................................................................................................2
95-Index
Page 4 Rev. 2
E-AB412-PT6T-2
TABLES
Table Page
Number Title Number
Table 1. Clock troubleshooting .................................................................................................................................... 1

Table 2. Free air temperature indicator troubleshooting ............................................................................................ 3
Table 3. Engine hourmeter system [A] [B] troubleshooting ....................................................................................... 4
Table 4. Engine hourmeter system [C] [D] troubleshooting ........................................................................................ 6
Table 1. Pitot tube and static ports heaters troubleshooting ......................................................................................... 4
Table 1. Airspeed indicator - troubleshooting .............................................................................................................. 1

Table 2. Altimeter - troubleshooting ............................................................................................................................ 2
Table 3. Vertical speed indicator - troubleshooting...................................................................................................... 3
95-Index
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E-AB412-PT6T-2
95-Index
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E-AB412-PT6T-2
95-29-30 PROPULSION AND HYDRAULIC INSTRUMENTS
95-29-30
PROPULSION AND HYDRAULIC INSTRUMENTS
1. PROPULSION AND HYDRAULIC INSTRUMENTS - DESCRIPTION
The propulsion and hydraulic instruments are electrically powered by ac or dc current. Operational checks for these
instruments are provided in Chapter 96.
2. PROPULSION AND HYDRAULIC INSTRUMENTS - DUAL TORQUE PRESSURE

INDICATOR [A] [B] [C]
The dual torque pressure indicator simultaneously displays torque output of each engine on inner dial and torque to
transmission (combined torque of both engines) on outer dial. Indicator receives torque indications from engine No. 1 and
engine No. 2 torque pressure transmitters. All indications are in percent of allowable torque.
3. PROPULSION AND HYDRAULIC INSTRUMENTS - TRIPLE TORQUE PRESSURE

INDICATOR [D]
The triple torque pressure indicator simultaneously displays torque output of each engine on right side of indicator dial and
mast torque on left side of indicator. The indicator receives signals from engine 1 and engine 2 torque sensors and a mast
torque signal is generated by mast torque monopole sensor, located inside transmission. Indications are in percent of
allowable torque.
4. PROPULSION AND HYDRAULIC INSTRUMENTS - ENGINE OIL PRESSURE AND

TEMPERATURE INDICATORS
No. 1 and No. 2 engine oil pressure and temperature indicators are dual type indicators registering temperature in degrees
Celsius and pressure in psi for each engine. Temperature portion receives temperature indications from an electrical
resistance-type bulb, and pressure portion receives pressure indications from engine oil pressure transmitter. Temperature
portion is powered from 28 Vdc emergency buses 1 and 2. Pressure portion is powered from 26 Vac buses 1 and 2.
5. PROPULSION AND HYDRAULIC INSTRUMENTS - FUEL PRESSURE INDICATORS
Engine No. 1 and No. 2 fuel pressure indicators register fuel pressure from indications received from fuel pressure
transmitters. System is powered from 26 Vac buses 1 and 2.
6. PROPULSION AND HYDRAULIC INSTRUMENTS - FUEL QUANTITY INDICATORS
The fuel quantity indicator provides readings of fuel supply quantity in lbs. as determined by position of fuel quantity
selector switch (FWD TANK, TOTAL, or MID TANK). System is powered from 28 Vdc emergency bus 1 and 2.
95-29-30
Page 1
E-AB412-PT6T-2
7. PROPULSION AND HYDRAULIC INSTRUMENTS - GAS PRODUCER TACHOMETER

INDICATORS
The engine No. 1 and No. 2 gas producer tachometer indicators register percent of rpm of engine No. 1 and No. 2 gas
producer speeds. Gas producer tachometer generators, one on each engine, send voltage signals to respective indicator
proportional to engine No. 1 and No. 2 gas producer speed. Gas producer tachometer indicator system is self-generating.
8. PROPULSION AND HYDRAULIC INSTRUMENTS - GEARBOX OIL PRESSURE AND

TEMPERATURE INDICATOR
The gearbox oil pressure and temperature indicator is a dual type indicator registering temperature in degrees Celsius and
pressure in psi of oil in combining gearbox. Temperature portion receives temperature indications from an electrical
resistance-type bulb, and pressure portion receives pressure indications from oil pressure transmitter. Temperature portion
is powered from 28 Vdc emergency bus 1 and pressure portion is powered by 28 Vac bus 2.
9. PROPULSION AND HYDRAULIC INSTRUMENTS - HYDRAULIC PRESSURE AND

TEMPERATURE INDICATOR
The system No. 1 and system No. 2 hydraulic pressure and temperature indicators are dual type indicators registering
hydraulic oil temperature in degrees Celsius and hydraulic pressure in psi. Pressure portion is powered from 26 Vac buses 1
and 2, and registers indications received from two hydraulic pressure transmitters. Temperature portion is powered from 28
Vdc essential buses 1 and 2, and registers indications received from two electrical resistance-type temperature bulbs.
10. PROPULSION AND HYDRAULIC INSTRUMENTS - TRANSMISSION OIL PRESSURE

AND TEMPERATURE INDICATOR
The transmission oil pressure and temperature indicator is a dual type indicator registering temperature in degrees Celsius
and pressure in psi. Temperature portion receives temperature indications from an electrical resistance-type bulb, and
pressure portion receives pressure indications from oil pressure transmitter. Temperature portion is powered by 28 Vdc
emergency bus No. 2, and pressure portion is powered by 26 Vac bus No. 1.
11. PROPULSION AND HYDRAULIC INSTRUMENTS - TRIPLE TACHOMETER

INDICATOR
The triple tachometer indicator contains three pointers and simultaneously registers engine No. 1 and engine No. 2 power
turbine and main rotor rpm in percent. Power is provided by three tachometer generators, mounted on engine No. 1, No. 2,
and transmission respectively. These systems are self-generating.
12. PROPULSION AND HYDRAULIC INSTRUMENTS - INTERTURBINE TEMPERATURE

(ITT) INDICATORS
The engine No. 1 and No. 2 ITT indicators register power turbine inlet air temperature received from bayonet-type
thermocouples mounted between gas producer turbine and power turbine in center engine compartments. Temperature
indications are in degrees Celsius.
95-29-30
Page 2
E-AB412-PT6T-2
95-31-10
INSTRUMENT SYSTEM
1. INSTRUMENT SYSTEM - DESCRIPTION
Maintenance information for flight, navigation, propulsion, hydraulic, and miscellaneous instruments installed in Models
412 helicopter is presented in following sections. All instruments except standby magnetic compass, engine hourmeter, and
free air temperature indicator are mounted in instrument panel.
2. INSTRUMENT SYSTEM - PANEL MOUNTED INSTRUMENTS
2-1. PANEL MOUNTED INSTRUMENTS - DESCRIPTION
1. The following maintenance procedures are applicable to all panel mounted instruments.
2. There are three types of instrument mountings used in this helicopter:
a. Front-mounted instruments that are secured by screws to instrument panel face with screws through front flange
of instrument.
b. Front-mounted instruments that are secured with clamps, with clamp adjusting screws accessible on instrument
panel face.
c. Back-mounted instruments that are secured to back of instrument panel with screws that mount through
instrument panel face.
2-2. PANEL MOUNTED INSTRUMENTS - REMOVAL
CAUTION
ENSURE ALL ELECTRICAL POWER IS OFF.
CAUTION
A GYRO MAY BE DAMAGED BY MOVING IT AFTER ELECTRICAL POWER

IS REMOVED BUT BEFORE THE GYRO ROTOR STOPS. ALLOW
APPROXIMATELY 15 MINUTES FOR INTERNAL GYRO IN STANDBY
ATTITUDE INDICATOR TO WIND DOWN AFTER ELECTRICAL POWER IS
REMOVED. WHEN REMOVING OR INSTALLING STANDBY ATTITUDE
INDICATOR, DO SO GENTLY WITH NO QUICK MOTION.
1. Disconnect electrical leads and/or instrument piping, as applicable, from back of instrument. Necessary access may be
gained through nose access door.
2. Protect ends with electrical tape and cap open piping, if applicable, and cap opening(s) on instrument.
95-31-10
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E-AB412-PT6T-2
3. Remove mounting screws or loosen mounting clamp screw. Carefully remove instrument from panel.
2-3. PANEL MOUNTED INSTRUMENTS - INSTALLATION
CAUTION
CAUTION
DO NOT TIGHTEN CLAMPS MORE THAN NECESSARY TO HOLD

INSTRUMENT, AS EXCESSIVE TENSION MAY DEFORM INSTRUMENT
CASE AND CAUSE ERRONEOUS READING OR CRACKED GLASS.
THE STANDBY ATTITUDE INDICATOR INCLUDES AN INTERNAL GYRO.

WHEN INSTALLING STANDBY ATTITUDE INDICATOR, DO SO GENTLY
WITH NO QUICK MOTION.
1. Carefully position instrument in panel and install mounting screws or tighten screw of mounting clamp.
2. Remove protective tape, caps and covers from electrical leads, piping and opening(s) on instruments.
NOTE
Leak check of pitot-static system (module 95-34-10 paragraph "3. Pitot-static system
- leak check") shall be performed, as applicable, whenever pitot/static piping is
disconnected, then reconnected.
3. Connect electrical leads and/or instrument piping, as applicable, to back of instrument.
2-4. PANEL MOUNTED INSTRUMENTS - INSPECTION
1. Inspect for loose, missing, or improperly installed hardware, loose or cracked cover glasses, and proper mounting.
2. Inspect instrument for legibility of range markings and faulty decals.
2-5. PANEL MOUNTED INSTRUMENTS - CLEANING
1. Wipe off dust and clean instrument cover glasses with clean, soft, lint-free cloth.
2-6. PANEL MOUNTED INSTRUMENTS - REPAIR OR REPLACEMENT
NOTE
All repairs must be conducted by an authorized instrument repair station.
1. Replace any inoperative, defective, or damaged instrument.
2. Replace instrument range markings as follows:
a. Refer to Flight Manual for range. Index cover glass to case with stripe of white lacquer.
95-31-10
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E-AB412-PT6T-2
b. Use prepared decals, suitable lacquer, or tape for markings and apply accurately to cover glass. Protect markings
with a light coat of clear adhesive varnish or lacquer.
3. INSTRUMENT SYSTEM - INSTRUMENT PANEL
3-1. INSTRUMENT PANEL - DESCRIPTION
The instrument panel (figure 1, figure 2) contains all flight, propulsion, navigation, and miscellaneous instruments except
magnetic compass, engine hourmeter, and free air temperature indicator. For information on various switches, warning
lights, and fire pull handles, refer to Chapter 96.
3-2. INSTRUMENT PANEL - REMOVAL
1. Disconnect battery quick-disconnect.
2. Disconnect instrument piping and all electrical connectors from back of panel and protect ends of electrical leads with
electrical tape; and cap open piping, if applicable, and cap openings on instrument.
3. Disconnect instrument panel stabilizing braces from lower right and lower left corners of instrument panel.
4. Disconnect two adjustment tube assemblies from behind right side of panel.
5. Remove remaining mounting screws from panel and remove instrument panel.
3-3. INSTRUMENT PANEL - INSTALLATION
1. Position instrument panel in place and install mounting screws.
2. Connect instrument panel stabilizing braces to instrument panel.
3. Connect two adjustment tube assemblies to right side of panel.
NOTE
Leak check of pitot-static system (module 95-34-10 paragraph "3. Pitot-static system
- leak check") shall be performed, as applicable, whenever pitot/static piping is
disconnected, then reconnected.
4. Remove protective caps, covers, and tape and connect instrument piping and all electrical connectors, as applicable.
5. Connect battery quick-disconnect.
3-4. INSTRUMENT PANEL - ADJUSTMENT
Instrument panel stabilizing braces and two adjustment tube assemblies located behind right side of instrument panel may
be adjusted to eliminate or minimize instrument panel vibration.
95-31-10
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E-AB412-PT6T-2
4. INSTRUMENT PANEL - NON-PANEL MOUNTED INSTRUMENTS
4-1. NON-PANEL MOUNTED INSTRUMENTS - DESCRIPTION
NOTE
Maintenance procedures are same as for panel mounted instruments.
1. The pilot standby magnetic compass is centered above right windshield.
2. The engine hourmeter is mounted on right side of pedestal near floor.
3. The bimetallic probe-type free air temperature indicator is mounted in the left forward portion of the upper right cabin
roof window assembly.
95-31-10
Page 4
E-AB412-PT6T-2
G6AB0845A
Figure 1. Instrument panel (helicopters codes [A] [B]) (sheet 1 of 2)
95-31-10
Page 5
E-AB412-PT6T-2
G6AB0846A
Figure 2. Instrument panel (helicopters codes [C] [D])
95-31-10
Page 6
E-AB412-PT6T-2
95-31-20
MISCELLANEOUS INSTRUMENTS
1. MISCELLANEOUS INSTRUMENTS - DESCRIPTION
The miscellaneous instruments installed consists of the clock, dual AC and DC voltmeters, dual DC ammeter, free air
temperature indicator and the engine hourmeter.
2. MISCELLANEOUS INSTRUMENTS - CLOCK
2-1. CLOCK - DESCRIPTION
The pilot clock (M29) or (4M5) and the copilot clock (M40) or (5M5) (when installed) are 8-day clocks with the added
stop-watch feature for elapsed time. The clocks have a sweep-second pointer and a minute-totalizer hand to indicate elapsed
time up to one hour. A control knob on the case starts the pointers when pressed, stop both pointers when pressed a second
time and returns both pointers when pressed a third time. A second control knob winds and sets the clocks.
2-2. CLOCK - TROUBLESHOOTING
Table 1. Clock troubleshooting
Clock does not run. Needs winding. Wind clock.
Defective instrument. Replace clock.
Clock does not keep time accurately. Defective instrument. Replace clock.
Pointers do not start, stop or return Control knob, pointer(s) or instrument Replace clock.
when control knob is pressed through defective.
three time cycles.
2-3. CLOCK - MAINTENANCE
For maintenance information of the clock, refer to module 95-31-10 "INSTRUMENT SYSTEM".
95-31-20
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E-AB412-PT6T-2
3. MISCELLANEOUS INSTRUMENTS - DUAL AC AND DC VOLTMETERS
3-1. DUAL AC AND DC VOLTMETERS - DESCRIPTION
The dual AC and DC voltmeters indicate and simultaneously monitor AC and DC bus voltage. The No. 1 dual voltmeter
indicates voltage present on the 115 V AC and 28 V DC No. 1 buses and No. 2 dual voltmeter indicates voltage present on
the 115 V AC and 28 V DC No. 2 buses.
For additional information refer to DC power subsystem and AC power subsystem, Chapter 96.
3-2. DUAL AC AND DC VOLTMETERS - TROUBLESHOOTING
Troubleshooting procedures are covered as a portion of the battery, external power, generator and inverter electrical systems,
refer to Chapter 96 Troubleshooting Electrical Systems.
3-3. DUAL AC AND DC VOLTMETERS - MAINTENANCE
For maintenance information on the indicator, refer to module 95-31-10 "INSTRUMENT SYSTEM".
4. MISCELLANEOUS INSTRUMENTS - DUAL DC AMMETER
4-1. DUAL DC AMMETER - DESCRIPTION
The dual DC ammeter indicates the current output in amperes of starter-generators No. 1 and No. 2 by monitoring the current
flow at each respective shunt.
For additional information refer to Chapter 96 generator system.
4-2. DUAL DC AMMETER - TROUBLESHOOTING
Troubleshooting procedures are covered as a portion of the generator electrical system, refer to Chapter 96, Troubleshooting
Electrical Systems.
4-3. DUAL DC AMMETER - MAINTENANCE
For maintenance information refer to module 95-31-10 "INSTRUMENT SYSTEM".
5. MISCELLANEOUS INSTRUMENTS - FREE AIR TEMPERATURE INDICATOR
5-1. FREE AIR TEMPERATURE INDICATOR - DESCRIPTION
The bi-metallic probe-type free air temperature indicator is windshield mounted at the top of the windshield just to the right
of the center post. The probe portion is exposed to outside temperatures through the windshield and is protected by a
sunshield. The indicator provides a direct reading of the outside air temperature in degrees celsius.
5-2. FREE AIR TEMPERATURE INDICATOR - REMOVAL
1. Unscrew and remove sunshield steel dished washer and one rubber washer from outside of windshield.
2. Remove indicator and other rubber washer from inside of windshield.
95-31-20
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E-AB412-PT6T-2
3. Place other rubber washer, flat side out, on probe outside of windshield. Seat washer shoulders in mounting hole.
Install steel dished washer, with outside edge curving toward windshield. Position indicator scale correctly before
tightening.
4. Place sunshield over probe and tighten securely.
5-3. FREE AIR TEMPERATURE INDICATOR - INSTALLATION
1. Place rubber washer over probe of the thermometer (figure 1) with flat side of washer next to indicator case.
2. Insert probe through mounting hole from inside windshield.
5-4. FREE AIR TEMPERATURE INDICATOR - INSPECTION
1. Inspect indicator for discoloration and leaking seals.
2. Check for security of mounting and that reading agrees with that of a standard indicator known to be correct.
5-5. FREE AIR TEMPERATURE INDICATOR - CLEANING
Clean indicator cover glass and sunshield-probe portion with a suitable soft, lint-free cloth.
5-6. FREE AIR TEMPERATURE INDICATOR - REPAIR OR REPLACEMENT
NOTE
All repairs of the free air temperature indicator must be conducted by an authorized
instrument repair station. Replace any inoperative, defective or damaged indicator.
5-7. FREE AIR TEMPERATURE INDICATOR - TROUBLESHOOTING
Table 2. Free air temperature indicator troubleshooting
Reading upscale of outside temperature. Missing or improperly installed sun- Check and install missing or properly
shield. install sunshield.
Defective indicator. Replace indicator
Reading downscale of outside tempera- Defective indicator. Replace indicator.

ture.
95-31-20
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E-AB412-PT6T-2
6. MISCELLANEOUS INSTRUMENTS - ENGINE HOURMETER SYSTEM [A] [B]
6-1. ENGINE HOURMETER SYSTEM [A] [B] - DESCRIPTION
With HOURMETER and ENG 1 RPM and ENG 2 RPM circuit breakers closed (rotor rpm indicator above 92.6±2%), the
hourmeter starts registering by receiving 28 V DC power from DC bus No. 1 through HOURMETER circuit breaker,
de-energized RELAY (K30) or (1K7) contacts, oil pressure switch (S90) or (S58) contacts, pin P of connector J100/1J6 and
to ground. When engine speed decreases (rotor rpm below 92%), RELAY (K30) or (1K7) receives 28 V DC signal from
(Z1) or (8Z1) pin U thus opening relay (K30) or (1K7) contacts and stopping hourmeter.
6-2. ENGINE HOURMETER SYSTEM [A] [B] - OPERATIONAL CHECK
1. Disconnect plug (P162) from C box oil pressure switch. Open Rotor RPM circuit breaker. Connect a temporary short
between pins B and C of (P162). Close HOURMETER circuit breaker. Check that the hourmeter operates.
2. Open HOURMETER circuit breaker. Remove temporary short installed in step a. Reconnect plug (P162) to C box oil
pressure switch. Check that plug is tight and properly mated.
6-3. ENGINE HOURMETER SYSTEM [A] [B] - TROUBLESHOOTING
Table 3. Engine hourmeter system [A] [B] troubleshooting
HOURMETER circuit breaker will not Circuit breaker defective. Replace circuit breaker.
reset.
Engine hourmeter defective. Replace hourmeter.
Electrical wiring defective. Repair or replace electrical wiring.
With DC 28 V ESS BUS 1 and 2 Defective relay. Replace relay.

energized, HOURMETER and RPM
WARN circuit breakers close and Defective pressure switch. Replace switch.
engines shut down. Hourmeter
registers.
No. 28 V DC signal from Pin. No. 28 V DC signal from Pin U of Refer chapter 96.
RPM Warning Box.
Defective diode. Replace diode.
Defective wiring in circuitry. Repair or replace wiring.
95-31-20
Page 4
E-AB412-PT6T-2
(Cont.)
Condition same as above except: Defective relay. Replace relay.

engines are running and the rotor RPM
is more than 96% Hourmeter does not Defective pressure switch. Replace switch.
register.
28 V DC signal present at Pin U or Refer to Chapter 96.
RPM Warning Box.
6-4. ENGINE HOURMETER SYSTEM [A] [B] - MAINTENANCE
The engine hourmeter is mounted on the right side of the pedestal near the floor. The hourmeter clock mechanism is
calibrated in hours and registers engine operating hours under flight power. Troubleshooting is covered as a portion of engine
hourmeter electrical system.
For maintenance information of the indicator refer to paragraph module 95-31-10 "INSTRUMENT SYSTEM".
7. MISCELLANEOUS INSTRUMENTS - ENGINE HOURMETER SYSTEM [C] [D]
7-1. ENGINE HOURMETER SYSTEM [C] [D] - DESCRIPTION
With HOURMETER (1CB24) and ENG 1 RPM (8CB1) and ENG 2 RPM circuit breaker (8CB2) closed (rotor rpm indicator
above 92.6%±2%), the HOURMETER (1M14) starts registering by receiving 28 V DC power from DC bus No. 2 through
HOURMETER circuit breaker, de-energized hourmeter relay (1K7) contacts, combining gearbox oil pressure switch (8S8)
contacts, pin P of engine 2 aft compartment connector (1J6), and to ground. When engine speed decreases (rotor rpm below
92%), hourmeter relay holding coil receivers 28 V DC signal from RPM limit detector (8Z1) pin F, thus opening hourmeter
relay contacts and stopping HOURMETER.
7-2. ENGINE HOURMETER SYSTEM [C] [D] - OPERATIONAL CHECK
1. Disconnect combining gearbox oil pressure switch connector (8S8P1) from combining gearbox oil pressure switch.
Open ROTOR RPM circuit breaker. Connect a temporary short between pins B and C of combining gearbox oil
pressure switch connector. Close HOURMETER circuit breaker. Check that the HOURMETER operates.
2. Open HOURMETER circuit breaker. Remove temporary short installed in step 1. Reconnect combining gearbox oil
pressure switch connector to combining gearbox oil pressure switch. Check that connector is tight and properly mated.
95-31-20
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E-AB412-PT6T-2
7-3. ENGINE HOURMETER SYSTEM [C] [D] - TROUBLESHOOTING
Table 4. Engine hourmeter system [C] [D] troubleshooting
HOURMETER circuit breaker will not Circuit breaker defective. Replace circuit breaker.
reset.
With DC 28 V BUS DC energized Defective relay. Replace relay.

HOURMETER and RPM WARM cir-
cuit breakers close and engines shut Defective pressure switch. replace switch.
down. Hourmeter registers.
No. 28 V DC signal from Pin. No. 28 V DC signal from Pin F of Refer to CHapter 96
RPM Warning Box.
Condition same as above except: Defective relay. Replace relay.

engines are running and the rotor RPM
is more than 96%. Hourmeter does not Defective pressure switch. Replace switch.
register.
28 V DC signal present at Pin F or Refer to Chapter 96.
RPM Warning Box.
7-4. ENGINE HOURMETER SYSTEM [C] [D] - MAINTENANCE
The engine hourmeter is mounted on the right side of the pedestal near the floor. the hourmeter clock mechanism is calibrated
in hours and registers engine operating hours under flight power Troubleshooting is covered as a portion of engine hourmeter
electrical system in Chapter 96.
For maintenance information of the indicator refer to module 95-31-10 "INSTRUMENT SYSTEM".
95-31-20
Page 6
E-AB412-PT6T-2
G6AB0642A
Figure 1. Free air temperature indicator
95-31-20
Page 7
E-AB412-PT6T-2
95-31-20
Page 8
E-AB412-PT6T-2
95-34-10
FLIGHT INSTRUMENTS - PITOT-STATIC SYSTEM
1. PITOT-STATIC SYSTEM - PILOT
1. The pilot pitot-static system (figure 1) consists of right pitot tube, right and left static ports, roof mounted static port,
alternate static air source, pilot airspeed indicator, barometric altimeter, vertical speed indicator, and appropriate tubing
and hardware for interconnection of system components.
2. The right pitot tube supplies pitot pressure (impact air) directly to pilot airspeed indicator and air data sensor (P/O
Flight Director kit). Right and left static ports are connected together and supply equalized static pressure to pilot
airspeed indicator, altimeter, vertical speed indicator and air data sensor (P/O Flight Director kit). Right pitot tube and
both static ports are equipped with electric heaters (optional for static ports) to provide all-weather capability.
3. An alternate static air source is provided by a pneumatic valve installed below the pilot instrument panel. Tubing and
fittings are included to connect pneumatic valve to pilot static ports and instruments. With the toggle of the pneumatic
valve set to PRI, static air is supplied to instruments from outside pilot static air ports. With the toggle set to ALTN,
an alternate static air source (inside cabin air) is selected and outside static ports are shut off.
2. PITOT-STATIC SYSTEM - COPILOT (WHEN INSTALLED)
1. The copilot pitot-static system (figure 1) consists of left pitot tube, left and right static ports, left roof-mounted static
port, airspeed indicator, barometric altimeter, vertical airspeed indicator, and appropriate tubing and hardware for
interconnection of system components.
2. The left pitot tube supplies pitot pressure (impact air) directly to copilot airspeed indicator, air data sensor (P/O Flight
Director kit), and air data computer (P/O Flight Data Recorder kit). Upper left, lower right, and left roof-mounted static
ports are connected together and supply equalized static pressure to copilot airspeed indicator, barometric altimeter,
vertical speed indicator, air data sensor (P/O Flight Director kit) and air data computer (P/O Flight Data Recorder kit).
Pitot tube and static ports are equipped with electric heaters (optional for static ports) to provide all-weather capability.
3. PITOT-STATIC SYSTEM - LEAK CHECK
SPECIAL TEST EQUIPMENT
TYPE OR MODEL NOMENCLATURE
T94 STATIC FIELD TESTER
ALTERNATE:
T95 PITOT-STATIC TESTER
95-34-10
Rev. 2 Page 1
E-AB412-PT6T-2
NOTES:
1 Applicable to helicopters with flight director kit installed.
2 Applicable to helicopters with flight data recorder installed.
G6AB0634B
Figure 1. Pitot-static system schematic
95-34-10
Page 2 Rev. 2
E-AB412-PT6T-2
3-1. LEAK CHECK - PITOT SYSTEM
1. Connect appropriate hose of Static Field Tester to pitot tube of system being checked, using appropriate adapter. Seal
drain line(s) of system being checked and check all connections for tightness.
2. Open both vent valves to allow pressure in lines to equalize. Close all five valves securely on test set.
3. Pump pressure into pressure tank on test set until sufficient pressure for test is indicated on pressure dial
(approximately 50.0 in Hg or 170 kPa).
CAUTION
VALVES ON TEST SET ARE SENSITIVE AND SHOULD BE OPERATED

SLOWLY AND WITH CARE TO AVOID POSSIBLE DAMAGE TO
INSTRUMENTS. THESE INSTRUMENTS ARE EASILY "PEGGED” AND
DAMAGED BY IMPROPER MANIPULATION OF THE VALVES ON TEST
SET.
4. Open pressure vent valve approximately 1/4 turn. Slowly open pressure source valve. Close pressure vent valve.
5. Close pressure source valve with helicopter airspeed indicator(s) reading 130 ± 4 knots. After 1 minute, check airspeed
indication has not dropped more than 10 knots. If limits are exceeded refer to module 95-34-13 paragraph "2-2.
Airspeed indicator - troubleshooting".
6. Slowly open pressure vent valve. Check airspeed indication returns to minimum limit of indicator.
7. Remove test set from helicopter. Remove seal from drain line(s).
3-2. LEAK CHECK - STATIC SYSTEM
NOTE
Ensure pilot STATIC SOURCE valve toggle is set to PRI when checking static
system.
1. Connect appropriate hose of Pitot-Static Tester to one static port of system being checked, using appropriate adapter.
Seal all drain lines and remaining static ports of system being checked and check all connections for tightness.
3. Pump vacuum side until sufficient vacuum for test is indicated on vacuum dial (approximately 20.0 in Hg or 68 kPa).
CAUTION
CLOSELY MONITOR BOTH HELICOPTER AND TEST SET INSTRUMENTS

TO ENSURE NO INDICATORS BECOME "PEGGED OUT". VALVES OF TEST
SET MUST BE MANIPULATED SLOWLY AND CAREFULLY TO AVOID
POSSIBLE INSTRUMENT DAMAGE.
4. Gradually open vacuum source valve. Check altimeter indicator reading increases.
5. When helicopter altimeter reads 1000 ft. above helicopter elevation, close vacuum source valve. Tap gently on altitude
indicator and check that, after 1 minute, loss in indicated altitude does not exceed 100 ft. Refer to troubleshooting
paragraph "3-2. Altimeter - troubleshooting" if limit is exceeded.
95-34-10
Rev. 2 Page 3
E-AB412-PT6T-2
6. Open vacuum vent valve and observe the helicopter and test set altitude indicators return to approximate ground level
readings.
7. Remove test set from helicopter. Remove seals from all drain lines and static ports.
4. PITOT-STATIC SYSTEM - OPERATIONAL CHECK
T94 STATIC FIELD TESTER
ALTERNATE:
T95 PILOT-STATIC TESTER
NOTE
Perform following procedure for pilot pitot-static system. Repeat procedure for
copilot pitot-static system, when installed.
1. Connect appropriate hoses of Static Field Tester to pitot tube and one static port (figure 2), using appropriate adapters.
Seal all drain lines and remaining static ports and check all connections for tightness.
3. Set barometric pressure dials on helicopter and test set altitude indicators to 29.92 ins. Hg. Gently tap on altimeters
and check barometric altimeter installed in helicopter indicates within parameters of FAR 43, Appendix E of test set
altitude indicator. If readings do not agree within this tolerance, replace barometric altimeter.
NOTE
Pressure in tank may be replenished as required for test.
4. Pump pressure into pressure tank on test set until sufficient pressure for test is indicated on pressure dial
(approximately 50 ins. Hg or 170 kPa).
CAUTION
VALVES ON TEST SET ARE SENSITIVE AND SHOULD BE OPERATED

SLOWLY AND WITH CARE TO AVOID POSSIBLE DAMAGE TO
INSTRUMENTS. THESE INSTRUMENTS ARE EASILY "PEGGED" AND
DAMAGED BY IMPROPER MANIPULATION OF THE VALVES ON TEST
SET.
5. Open pressure vent valve approximately 1/4 turn. Slowly open pressure source valve. Close pressure vent valve. Leave
pressure source valve open until airspeed indicator on test set reads 130 knots, then close pressure source valve.
Maintain this pressure by manipulation of pressure source valve as required. Gently tap on test set airspeed indicators
and check that airspeed indicator reads 130 ±4 knots.
6. Close pressure source valve with helicopter airspeed indicator(s) reading 130 ±4 knots. After 1 minute, check airspeed
indication has not dropped more than 10 knots. Refer to troubleshooting (module 95-34-13 paragraph "2-2. Airspeed
indicator - troubleshooting").
95-34-10
Page 4 Rev. 2
E-AB412-PT6T-2
7. Slowly open pressure vent valve. Check airspeed indication returns to minimum limit of indicator.
NOTE
Tank vacuum may be replenished as required for test.
8. Pump vacuum side until sufficient vacuum for test is indicated on vacuum dial (approximately 20.0 in Hg or 68 kPa).
CAUTION
CLOSELY MONITOR BOTH HELICOPTER AND TEST SET INSTRUMENTS

TO ENSURE NO INDICATORS BECOME "PEGGED" OUT. VALVES OF TEST
SET MUST BE MANIPULATED SLOWLY AND CAREFULLY TO AVOID
POSSIBLE INSTRUMENT DAMAGE.
9. Gradually open vacuum source valve. Check altimeter and airspeed indicator readings increase and vertical speed
indicator (VSI) shows a positive rate of climb.
10. Bring airspeed to approximately 130 knots and close vacuum source valve and pressure vent valve. Hold airspeed at
130 knots and increase altitude indications by manipulation of cross bleed and vacuum source valves. When helicopter
altimeter reads 1000 ft. above helicopter elevation, close cross bleed and vacuum source valves. Tap gently on test set
altitude indicators and check that, after 1 minute, loss in indicated altitude does not exceed 100 ft. Check VSI
indication, if not zero, is negative and does not exceed 100 fpm.
11. Open vacuum vent valve momentarily to gradually decrease vacuum. Check VSI indicates a negative rate of climb.
12. Continue to decrease vacuum until test set altitude indicator reads 1000 ft. Maintain this reading by manipulation of
vacuum source valve as required. Gently tap on altimeters and check barometric altimeter installed in helicopter
indicates within 40 ft. of test set indicator. If readings do not agree within this tolerance, replace barometric altimeter.
13. Open vacuum vent valve and observe helicopter and test set altitude indicators return to approximate ground level
readings.
14. Open both pressure and vacuum vent valves. After system pressures are equalized, remove test set from helicopter.
Remove seal placed on static port.
5. PITOT-STATIC SYSTEM - INSPECTION
1. Inspect pitot tube for clogged or obstructed inlet opening.
2. Inspect pitot tube for clogged drain hole on bottom of tube.
3. Inspect pitot and static lines for leaks and chafing.
4. Visually inspect parts, pitot and static lines, accessories and instruments of pitot static system and replace defective
components.
95-34-10
Rev. 2 Page 5
E-AB412-PT6T-2
G6AB0635A
Figure 2. Pitot-static system (sheet 1 of 3)
95-34-10
Page 6 Rev. 2
E-AB412-PT6T-2
G6AB0636A
95-34-10
Rev. 2 Page 7
E-AB412-PT6T-2
G6AB0637A
95-34-10
Page 8 Rev. 2
E-AB412-PT6T-2
6. PITOT-STATIC SYSTEM - HARDWARE
6-1. HARDWARE - REPAIR OR REPLACEMENT
1. Tighten, install or correct any loose, missing or improperly installed hardware.
7. PITOT-STATIC SYSTEM - PITOT AND STATIC LINES
7-1. PITOT AND STATIC LINES - DRAINING INSTRUCTIONS
1. Disconnect pitot and static lines from airspeed, altimeter, and vertical speed indicators and from air data sensors and
computer, if installed. Cap openings in indicators, sensors, and computer.
2. Blow static lines clean with filtered, compressed air.
3. Uncap openings and reconnect lines.
4. Perform leak check of pitot-static system, as applicable (paragraph "3-1. Leak check - pitot system" and/or paragraph
"3-2. Leak check - static system").
95-34-10
Rev. 2 Page 9
E-AB412-PT6T-2
95-34-10
Page 10 Rev. 2
E-AB412-PT6T-2
95-34-1 FLIGHT INSTRUMENTS - PITOT TUBE
95-34-11
FLIGHT INSTRUMENTS - PITOT TUBE
1. PITOT TUBE - REMOVAL
CAUTION
1. Disconnect pitot line from airspeed indicator. Cap opening on indicator and cap open piping.
2. Open clamps securing pitot line and create slack at base of pitot support by pulling line through grommet and clamps
until connector is within 1 or 2 inches from grommet.
3. Remove screws and lockwashers attaching pitot tube (detail A) to support and carefully pull tube from support until
electrical connector is exposed. Disconnect and tape ends of connector to prevent entrance of foreign material.
NOTE
Ensure there is adequate slack in electrical wire before pulling pitot tube.
4. Continue pulling pitot tube until pitot line coupling is exposed. Disconnect and cap or cover openings in line.
2. PITOT TUBE - INSTALLATION
CAUTION
1. Remove caps or covers from pitot lines and connect coupling.
2. Remove tape and connect electrical connector. While guiding pitot line and electrical wire through pitot base from
inside of nose compartment, place pitot tube in pitot support.
3. Install screws and lockwashers that attach pitot tube to pitot support.
4. Pull pitot line through grommet and open clamps to connect line to airspeed indicator.
5. Remove caps on airspeed indicator and connect pitot line to indicator.
6. Adjust pitot line through grommet and open clamps to ensure adequate slack with no binding. Close and secure clamps
to pitot line.
7. Perform leak check of pitot system (module 95-34-10 paragraph "3-1. Leak check - pitot system").
95-34-11
Page 1
E-AB412-PT6T-2
3. PITOT TUBE - CLEANING
MATERIALS REQUIRED
NUMBER NOMENCLATURE
C-304 SOLVENT
1. Clean pitot tube head and pitot support with a clean, lint-free cloth dampened with solvent (C-304).
95-34-11
Page 2
E-AB412-PT6T-2
95-34-12
FLIGHT INSTRUMENTS - PITOT TUBE AND STATIC PORT HEATERS
1. PITOT TUBE AND STATIC PORT HEATERS - DESCRIPTION
Pitot tube heaters prevent pitot tube from icing over. Heating elements utilize 28 Vdc and are energized manually with
PITOT HEATERS switch on overhead console. Static port heater elements are wired in parallel with respective pilot and
copilot pitot heater system at PITOT HEATERS switch. Static port heater elements, designed to prevent static ports from
icing over, utilize 28 Vdc power and are also energized by PITOT HEATERS switch.
2. PITOT TUBE AND STATIC PORT HEATERS - STATIC PORT HEATER ELEMENTS
2-1. STATIC PORT HEATER ELEMENTS - REMOVAL
MATERIALS REQUIRED
NUMBER NOMENCLATURE
C-308 ADHESIVE
NOTE
The following removal procedures are applicable to all four static port heater
elements.
1. Disconnect ground wire terminal, adjacent to static port.
2. Disconnect positive lead at splice.
3. Disconnect static tube from static port union.
4. Protect open end of static tube fitting with electrical tape.
5. Drill out two static port baffle rivets and remove baffle.
6. Remove burrs and metal particles around holes.
7. Apply a thin coat of adhesive (C-308) to any bare metal.
8. Drill out six attaching rivets.
9. Remove static port heater element and heat shield.
10. Remove burrs and metal particles around holes.
11. Apply a thin coat of adhesive (C-308) to any bare metal.
95-34-12
Page 1
E-AB412-PT6T-2
2-2. STATIC PORT HEATER ELEMENTS - INSTALLATION
MATERIALS REQUIRED
NUMBER NOMENCLATURE
C-308 ADHESIVE
NOTE
The following installation procedures are applicable to all four static port heater
elements.
1. Align and position heat shield and static port heater element on mounting surface of inside cabin skin.
2. Install with six rivets, MS20426AD3-6, with heads flush outboard.
NOTE
Do not allow sealant to enter vent holes.
3. Seal around static port heater element and heat shield with adhesive (C-308).
4. Remove protective tape from static port tube fitting.
5. Connect to static port.
6. Connect ground wire terminal, adjacent to static port.
7. Connect positive lead at splice.
8. Align and position static port baffle on mounting surface.
9. Install baffle with two rivets, MS20470AD3-6.
10. Perform leak check of static system (module 95-34-10 paragraph "3-1. Leak check - pitot system").
3. PITOT TUBE AND STATIC PORT HEATERS - STATIC PORT HEATER SYSTEM
3-1. STATIC PORT HEATER SYSTEM - INSPECTION
CAUTION
USE EXTREME CARE WHEN CHECKING STATIC PORT HEATER ELEMENT

WHILE IN OPERATION.
1. Inspect static tubing for leaks and chafing.
2. Inspect static tubing fittings, connectors, and hardware for proper installation.
3. Inspect wiring and leads for loose terminals, chafing, and damage.
4. Inspect static port heater element to ensure proper heating.
95-34-12
Page 2
E-AB412-PT6T-2
3-2. STATIC PORT HEATER SYSTEM - CLEANING
Clean static port heater elements with a clean, lint-free cloth dampened with approved solvent.
3-3. STATIC PORT HEATER SYSTEM - REPAIR OR REPLACEMENT
1. Tighten or replace loose or defective tubing, fittings, connectors, or hardware.
2. Repair or replace defective wiring.
3. Remove and replace defective static port heater element (paragraph "2-1. Static port heater elements - removal" and
paragraph "2-2. Static port heater elements - installation").
3-4. STATIC PORT HEATER SYSTEM - LEAKAGE TEST
1. Using a standard pitot/static test set, evacuate the static pressure system to an altimeter reading of 305 m (1,000 ft)
above the test point altitude.
2. Without additional pumping for a period of one minute, the loss of indicated altitude must not exceed 30 m (100 ft) on
the altimeter.
4. PITOT TUBE AND STATIC PORT HEATERS - OPERATIONAL CHECK
WARNING
CHECKING PITOT TUBE FOR HEAT WITH BARE HANDS CAN CAUSE
SERIOUS BURNS.
1. Close PITOT HTR PILOT circuit breaker. Place PITOT HEATERS switch on overhead console to ON. Check pilot
pitot tube heater and static port heaters are energized and beginning to heat.
2. Set PITOT HEATERS switch to OFF. Check pilot pitot tube heater and static port heaters are deenergized and cooling.
Open PITOT HTR PILOT circuit breaker.
3. Close PITOT HTR CPLT circuit breaker. Place PITOT HEATERS switch on overhead console to ON. Check copilot
pitot tube heater and static port heaters are energized and beginning to heat.
4. Set PITOT HEATERS switch to OFF. Check copilot pitot tube heater and static port heaters are deenergized and
cooling. Open PITOT HTR CPLT circuit breaker.
NOTE
Keep pitot tube heaters and static port heaters deenergized except for tests or when
usage is necessary.
95-34-12
Page 3
E-AB412-PT6T-2
5. PITOT TUBE AND STATIC PORT HEATERS - TROUBLESHOOTING
Table 1. Pitot tube and static ports heaters troubleshooting
Pitot tube heater fails to heat, with Defective PITOT HTR PILOT or Replace circuit breaker
PITOT HEATER switch positioned to CO-PILOT circuit breaker.
ON.
Defective PITOT HTR switch. Replace switch.
Defective heating element. Replace heating element.
95-34-12
Page 4
E-AB412-PT6T-2
95-34-13
FLIGHT INSTRUMENTS - PITOT-STATIC INSTRUMENTS
1. PITOT - STATIC INSTRUMENTS - DESCRIPTION
Pilot pitot-static instruments are located on right side of instrument panel. If copilot instrument kit is installed, a duplicate
set of instruments will be located on left side of instrument panel.
2. PITOT-STATIC INSTRUMENTS - AIRSPEED INDICATOR
2-1. AIRSPEED INDICATOR - DESCRIPTION
The airspeed indicator is a standard pitot-static instrument, single scaled and calibrated in knots. The indicator provides an
indicated airspeed of helicopter at any time during forward flight by measuring difference between impact air pressure from
pitot tube and static air pressure from static ports.
2-2. AIRSPEED INDICATOR - TROUBLESHOOTING
Refer to table 1 and perform checks as necessary to isolate trouble.
Table 1. Airspeed indicator - troubleshooting
Pointer fails to respond. Pitot line not connected. Connect line.
Pitot lines clogged. Disconnect pitot line(s) from airspeed indica-

tor, air data sensors and/or air data computer,
as required, and blow line(s) clear with clean,
dry air.
Pointer indicates incorrectly. Leak in pitot or static line. Repair or replace line.
Defective or leaking indicator. Replace indicator.
Pointer vibrates. Instrument loose in panel. Tighten instrument mounting screws.
Pointer oscillates. Leak in line. Repair or replace line.
Defective indicator. Replace indicator.
95-34-13
Page 1
E-AB412-PT6T-2
3. PILOT-STATIC INSTRUMENTS - ALTIMETER
3-1. ALTIMETER - DESCRIPTION
The barometric altimeter furnishes direct reading of helicopter height in feet above sea level. Altimeter is connected by static
lines to static pressure ports to sense atmospheric pressure. An external adjustment knob is provided to make compensation
for variations of prevailing barometric pressure. Pilot altimeter contains an altitude encoder that provides digitized altitude
signals to the transponder for transmission to the traffic control facilities. The encoding function of pilot altimeter is checked
in IFF Transponder System (Chapter 97)
3-2. ALTIMETER - TROUBLESHOOTING
Table 2. Altimeter - troubleshooting
Incorrect reading Leak in static pressure line Correct leak.
Clogged static port or line. Clean port or line.
95-34-13
Page 2
E-AB412-PT6T-2
4. PITOT-STATIC INSTRUMENTS - VERTICAL SPEED INDICATOR
4-1. VERTICAL SPEED INDICATOR - DESCRIPTION
The vertical speed indicator registers ascent and descent speed of helicopter in feet per minute. Vertical speed indicator is
connected to static air system to sense rate of atmospheric pressure change.
4-2. VERTICAL SPEED INDICATOR - TROUBLESHOOTING
Table 3. Vertical speed indicator - troubleshooting
Pointer off zero. Mechanism shifted. Return pointer to zero by turning adjustment
screw on face of instrument; tap bezel of indica-
tor lightly while adjusting.
Inaccurate readings. Loose connections in static line. Tighten connections.
Indicator case leaks Replace indicator.
Defective indicator Replace indicator.
Excessive pointer oscillation. Leak in static line. Tighten connections; replace leaky lines.
95-34-13
Page 3
E-AB412-PT6T-2
95-34-13
Page 4
E-AB412-PT6T-2
95-34-14 FLIGHT INSTRUMENTS - STANDBY ATTITUDE INDICATOR (WHEN INSTALLED)
95-34-14
FLIGHT INSTRUMENTS - STAND-BY ATTITUDE INDICATOR
(WHEN INSTALLED)
1. STAND-BY ATTITUDE INDICATOR (WHEN INSTALLED) - DESCRIPTION
NOTE
See module 98-34-07 for stand-by attitude indicator wiring diagrams and module
module 97-30-18 for battery segnalator.
The stand-by attitude indicator (figure 1) is installed on the pilot section of the instrument panel. The indicator displays
position of the aircraft attitude and provides continuous attitude information for a minimum of 9 minutes after loss of
electrical power. The indicator includes an electrically driven gyro whose vertical attitude is maintained by a mechanical
erection system. The share display pitch attitude by vertical motion with respect to the fixed reference aircraft symbol and
roof attitude by rotation motion of the roll pointer with respect to the fixed roll scale at the top of the indicator. The attitude
can be adjusted to zero indication by the pitch and roll cage knob. The indicator is powered by 28 Vdc and the circuit is
protected by STBY ATTD circuit breaker. The system includes an amber STBY BATT indicator light, positioned above the
stand-by attitude indicator, that provides visual indication of the battery status.
G6AB1046A
Figure 1. Stand-by attitude indicator
95-34-14
Rev. 2 Page 1
E-AB412-PT6T-2
95-34-14
Page 2 Rev. 2
E-AB412-PT6T-2
CHAPTER 96 - ELECTRICAL SYSTEM

Module Page
Number Title Number
96-21-01 HEATING SYSTEMS
1. Heating systems - description ................................................................................................................. 1

2. Heating systems - cabin heater system ................................................................................................... 1
2-1. Cabin heater system - description .................................................................................................. 1
2-2. Cabin heater system - operational check ....................................................................................... 1
2-3. Cabin heater system - troubleshooting .......................................................................................... 3
3. Heating systems - cabin temperature control group ............................................................................... 4
3-1. Cabin temperature control group - description .............................................................................. 4
3-2. Cabin temperature control group - rigging .................................................................................... 4
3-3. Cabin temperature control group - operational check ................................................................... 5
4. Heating systems - vent blower system .................................................................................................... 5
4-1. Vent blower system - description .................................................................................................. 5
4-2. Vent blower system - operational check ........................................................................................ 5
4-3. Vent blower system - troubleshooting ............................................................................................ 6
96-24-00 ELECTRICAL SYSTEM
1. Electrical system - description ................................................................................................................ 1

2. Electrical system - general maintenance information ............................................................................. 1
2-1. General maintenance information - visual inspection ................................................................... 1
2-2. General maintenance information - voltage measurements............................................................ 2
2-3. General maintenance information - continuity trace ..................................................................... 2
96-24-01 ELECTRICAL SYSTEM - REFERENCE DESIGNATORS [A] [B]
1. Reference designators [A] [B] - description ........................................................................................... 1
96-24-02 ELECTRICAL SYSTEM - REFERENCE DESIGNATORS [C] [D]
1. Reference designators [C] [D] - description ........................................................................................... 1
96-24-03 ELECTRICAL SYSTEM - PRIMARY AND SECONDARY ELECTRICAL POWER SYSTEMS
1. Primary and secondary electrical power systems - description .............................................................. 1
96-24-04 ELECTRICAL SYSTEM - POWER SOURCE COMPONENT DATA
1. power source component data - description ........................................................................................... 1
96-24-05 ELECTRICAL SYSTEM - EMERGENCY DC POWER
1. Emergency DC power - description ........................................................................................................ 1
96-24-06 ELECTRICAL SYSTEM - EMERGENCY AC POWER
1. Emergency AC power - description ........................................................................................................ 1
96-Index
Rev. 3 Page 1
E-AB412-PT6T-2

Module Page
Number Title Number
96-24-07 ELECTRICAL SYSTEM - OPERATIONAL CHECKS
1. Operational checks - description .............................................................................................................1
96-24-08 ELECTRICAL SYSTEM - TROUBLESHOOTING
1. Troubleshooting - description .................................................................................................................1
96-24-09 ELECTRICAL SYSTEM - MISCELLANEOUS ELECTRICAL COMPONENTS
1. Miscellaneous electrical components - description .................................................................................1

2. Miscellaneous electrical components - removal .....................................................................................1
3. Miscellaneous electrical components - installation..................................................................................2
4. Miscellaneous electrical components - inspection ..................................................................................2
5. Miscellaneous electrical components - cleaning ......................................................................................4
6. Miscellaneous electrical components - repair .........................................................................................4
96-24-10 ELECTRICAL SYSTEM - CONTROL PANELS
1. Control panels - description ....................................................................................................................1

2. Control panels - removal .........................................................................................................................1
3. Control panels - installation ....................................................................................................................1
4. Control panels - inspection ......................................................................................................................1
5. Control panels - repair .............................................................................................................................1
96-24-11 ELECTRICAL SYSTEM - CIRCUIT BREAKERS
1. Circuit breakers - description ..................................................................................................................1

2. Circuit breakers - removal .......................................................................................................................1
3. Circuit breakers - installation ...................................................................................................................2
4. Circuit breakers - inspection ...................................................................................................................2
5. Circuit breakers - repair/replacement ......................................................................................................2
96-24-12 ELECTRICAL SYSTEM - ELECTRICAL SAFETY AND HAZARDS
1. Electrical safety and hazards - general ....................................................................................................1

2. Electrical safety and hazards - safety practices .......................................................................................1
3. Electrical safety and hazards - standard practices ....................................................................................2
3-1. Standard practices - electrical maintenance or repairs ...................................................................2
3-2. Standard practices - electrical work in confined spaces .................................................................2
3-3. Standard practices - after electrical maintenance or repairs ...........................................................3
96-24-13 ELECTRICAL SYSTEM - SEMICONDUCTOR DEVICES
1. Semiconductor devices - description .......................................................................................................1

2. Semiconductor devices - maintenance practices .....................................................................................1
96-24-14 ELECTRICAL SYSTEM - TRACK MOUNTED RELAYS
1. Track mounted relays - description .........................................................................................................1

2. Track mounted relays - removal ..............................................................................................................1
3. Track mounted relays - installation .........................................................................................................1
96-Index
Page 2 Rev. 3
E-AB412-PT6T-2

Module Page
Number Title Number
4. Track mounted relays - inspection .......................................................................................................... 1

5. Track mounted relays - cleaning ............................................................................................................. 1
96-24-20 AC POWER SYSTEMS
1. AC power system - description ............................................................................................................... 1
96-24-21 AC POWER SYSTEMS - INVERTER SYSTEMS
1. Inverter systems - description ................................................................................................................. 1

1-1. Description - helicopters codes [A] [B] ......................................................................................... 1
1-2. Description - helicopters codes [C] [D] ......................................................................................... 1
2. Inverter systems - operational checks ..................................................................................................... 1
2-1. Operational checks - preliminary setup ......................................................................................... 1
2-2. Operational checks - inverter No. 1 circuitry ................................................................................ 2
2-3. Operational checks - inverter No. 2 circuitry ................................................................................ 2
2-4. Operational checks - inverter No. 1 and inverter No. 2 circuitry [C] [D] ..................................... 3
3. Inverter systems - inverter ...................................................................................................................... 3
3-1. Inverter - description ...................................................................................................................... 3
3-2. Inverter - removal ........................................................................................................................... 4
3-3. Inverter - installation ...................................................................................................................... 4
3-4. Inverter - inspection ....................................................................................................................... 4
3-5. Inverter - repair .............................................................................................................................. 4
4. Inverter systems - bus control relay [A] [B] ........................................................................................... 4
4-1. Bus control relay [A] [B] - description .......................................................................................... 4
4-2. Bus control relay [A] [B] - removal .............................................................................................. 5
4-3. Bus control relay [A] [B] - installation .......................................................................................... 5
5. Inverter systems - AC voltage sensing relay .......................................................................................... 5
5-1. AC voltage sensing relay - description .......................................................................................... 5
5-2. AC voltage sensing relay - removal ............................................................................................... 5
5-3. AC voltage sensing relay - installation .......................................................................................... 5
6. Inverter systems - troubleshooting........................................................................................................... 6
96-24-22 AC INDICATOR SYSTEMS
1. AC indicator systems - description ......................................................................................................... 1

2. AC indicator systems - torque pressure indicator systems [A] [B] [C] .................................................. 1
2-1. Torque pressure indicator systems [A] [B] [C] - description ........................................................ 1
2-2. Torque pressure indicator systems [A] [B] [C] - operational check .............................................. 1
2-3. Torque pressure indicator systems [A] [B] [C] - troubleshooting ................................................ 2
3. AC indicator systems - engine oil pressure indicator systems ................................................................ 3
3-1. Engine oil pressure indicator systems - description ...................................................................... 3
3-2. Engine oil pressure indicator systems - operational check ............................................................ 3
3-3. Engine oil pressure indicator systems - troubleshooting ................................................................ 4
4. AC indicator systems - transmission oil pressure indicator system ........................................................ 4
4-1. Transmission oil pressure indicator system - description .............................................................. 4
4-2. Transmission oil pressure indicator system - operational check ................................................... 4
4-3. Transmission oil pressure indicator system - troubleshooting ...................................................... 5
5. AC indicator systems - hydraulic pressure indicator systems ................................................................ 5
5-1. Hydraulic pressure indicator systems - description ....................................................................... 5
5-2. Hydraulic pressure indicator systems - operational check ............................................................. 5
5-3. Hydraulic pressure indicator systems - troubleshooting................................................................. 6
6. AC indicator systems - combining gearbox (c box) oil pressure indicator systems ............................... 6
96-Index
Rev. 3 Page 3
E-AB412-PT6T-2

Module Page
Number Title Number
6-1. Combining gearbox (c box) oil pressure indicator systems - description ......................................6
6-2. Combining gearbox (c box) oil pressure indicator systems - operational check ...........................6
6-3. Combining gearbox (c box) oil pressure indicator systems - troubleshooting................................7
7. AC indicator systems - fuel pressure indicator systems ..........................................................................7
7-1. Fuel pressure indicator systems - description ................................................................................7
7-2. Fuel pressure indicator systems - operational check ......................................................................7
7-3. Fuel pressure indicator systems - troubleshooting .........................................................................8
8. AC indicator systems - attitude director indicator systems......................................................................9
8-1. Attitude director indicator systems - description ...........................................................................9
8-2. Attitude director indicator systems - maintenance-rate gyro .........................................................9
8-3. Attitude director indicator systems - removal ................................................................................9
8-4. Attitude director indicator systems - installation ...........................................................................9
8-5. Attitude director indicator systems - cleaning ................................................................................9
8-6. Attitude director indicator systems - inspection .............................................................................9
8-7. Attitude director indicator systems - repair or replacement..........................................................10
8-8. Attitude director indicator systems - operational check ...............................................................10
8-9. Attitude director indicator systems - troubleshooting ..................................................................10
9. AC indicator systems - triple tachometer indicator systems .................................................................11
9-1. Triple tachometer indicator systems - description .......................................................................11
9-2. Triple tachometer indicator systems - operational check .............................................................11
9-3. Triple tachometer indicator systems - troubleshooting ................................................................12
10. AC indicator systems - gas producer tachometer indicator systems .....................................................12
10-1. Gas producer tachometer indicator systems - description ............................................................12
10-2. Gas producer tachometer indicator systems - operational check ..................................................13
10-3. Gas producer tachometer indicator systems - troubleshooting ....................................................13
11. AC indicator systems - fuel quantity indicator system [A] [B]..............................................................14
11-1. Fuel quantity indicator system [A] [B] - description ...................................................................14
11-2. Fuel quantity indicator system [A] [B] - troubleshooting ............................................................14
11-3. Fuel quantity indicator system [A] [B] - testing and calibration ..................................................15
96-24-30 DC POWER SYSTEM
1. DC power system - description ...............................................................................................................1
96-24-31 DC POWER SYSTEM - BATTERY SYSTEM
1. Battery system - description ....................................................................................................................1

2. Battery system - removal .........................................................................................................................1
3. Battery system - installation ....................................................................................................................1
4. Battery system - inspection .....................................................................................................................2
5. Battery system - operational check .........................................................................................................2
6. Battery system - maintenance .................................................................................................................5
7. Battery system - service ..........................................................................................................................5
8. Battery system - troubleshooting .............................................................................................................6
96-24-32 DC POWER SYSTEM - EXTERNAL POWER SYSTEM
1. External power system - description .......................................................................................................1

2. External power system - receptacle .........................................................................................................1
2-1. Receptacle - removal ......................................................................................................................1
2-2. Receptacle - installation .................................................................................................................1
2-3. Receptacle - inspection ...................................................................................................................2
2-4. Receptacle - repair ..........................................................................................................................2
96-Index
Page 4 Rev. 3
E-AB412-PT6T-2

Module Page
Number Title Number
3. External power system - operational check ............................................................................................ 2

4. External power system - troubleshooting ................................................................................................ 3
96-24-33 DC POWER SYSTEM - GENERATOR SYSTEM
1. Generator system - description ............................................................................................................... 1

2. Generator system - operational check ..................................................................................................... 1
2-1. Operational check - generator No. 1 system .................................................................................. 1
2-2. Operational check - generator No. 2 system .................................................................................. 2
2-3. Operational check - generator No. 1 and generator No. 2 system ................................................. 3
2-4. Operational check - voltage control paralleling adjustment .......................................................... 4
2-5. Operational check - nonessential bus system ................................................................................ 6
3. Generator system - troubleshooting ........................................................................................................ 6
96-24-34 DC POWER SYSTEM - STARTER AND IGNITER SYSTEMS
1. Starter and igniter systems - description ................................................................................................. 1

2. Starter and igniter systems - operational check ...................................................................................... 1
2-1. Operational check - starters ........................................................................................................... 1
2-2. Operational check - igniters ........................................................................................................... 2
3. Starter and igniter systems - troubleshooting ......................................................................................... 4
96-24-35 DC POWER SYSTEM - POWER DIODES
1. Power diodes - description ...................................................................................................................... 1

2. Power diodes - removal .......................................................................................................................... 1
3. Power diodes - installation ...................................................................................................................... 1
4. Power diodes - inspection ....................................................................................................................... 1
5. Power diodes - functional checkout ........................................................................................................ 2
96-24-36 DC INDICATOR SYSTEMS
1. DC indicator systems - description ......................................................................................................... 1

2. DC indicator systems - mast torque measurement system [D] ............................................................... 1
2-1. Mast torque measurement system [D] - description ...................................................................... 1
2-2. Mast torque measurement system [D] - mast torque indication check .......................................... 1
2-3. Mast torque measurement system [D] - operational check ............................................................ 2
2-4. Mast torque measurement system [D] - zero torque calibration .................................................... 3
2-5. Mast torque measurement system [D] - mast torque system flight check ...................................... 5
2-6. Mast torque measurement system [D] - calibration check ............................................................ 5
2-7. Mast torque measurement system [D] - engine torque pressure indicating system........................ 6
3. DC indicator systems - engine oil temperature indicator system ......................................................... 11
3-1. Engine oil temperature indicator system - description ................................................................ 11
3-2. Engine oil temperature indicator system - operational check ...................................................... 11
3-3. Engine oil temperature indicator system - troubleshooting ......................................................... 11
4. DC indicator systems - transmission oil temperature indicator system ................................................ 12
4-1. Transmission oil temperature indicator system - description ...................................................... 12
4-2. Transmission oil temperature indicator system - operational check ............................................ 12
4-3. Transmission oil temperature indicator system - troubleshooting ............................................... 12
5. DC indicator systems - combining gearbox (c box) oil temperature indicator system ......................... 13
5-1. Combining gearbox (c box) oil temperature indicator system - description ............................... 13
5-2. Combining gearbox (c box) oil temperature indicator system - operational check ..................... 13
5-3. Combining gearbox (c box) oil temperature indicator system - troubleshooting ........................ 13
96-Index
Rev. 3 Page 5
E-AB412-PT6T-2

Module Page
Number Title Number
6. DC indicator systems - engine hourmeter system .................................................................................14

6-1. Engine hourmeter system - description ........................................................................................14
6-2. Engine hourmeter system - operational check .............................................................................14
6-3. Engine hourmeter system - troubleshooting..................................................................................15
7. DC indicator systems - turn and slip (part of attitude director indicator) .............................................15
7-1. Turn and slip (part of attitude director indicator) - description ....................................................15
7-2. Turn and slip (part of attitude director indicator) - operational check .........................................16
8. DC indicator systems - interturbine temperature (ITT) indicator systems ............................................16
8-1. Interturbine temperature (ITT) indicator systems - description ...................................................16
8-2. Interturbine temperature (ITT) indicator systems - operational check ........................................16
8-3. Interturbine temperature (ITT) indicator systems - troubleshooting ............................................17
9. DC indicator systems - hydraulic oil temperature indicator system ......................................................18
9-1. Hydraulic oil temperature indicator system - description ............................................................18
9-2. Hydraulic oil temperature indicator system - operational check ..................................................18
9-3. Hydraulic oil temperature indicator system - troubleshooting .....................................................18
10. DC indicator systems - fuel quantity indicator system [C] [D]..............................................................19
10-1. Fuel quantity indicator system [C] [D] - testing and calibration ..................................................19
10-2. Fuel quantity indicator system [C] [D] - thermistor check ...........................................................22
10-3. Fuel quantity indicator system [C] [D] - troubleshooting ............................................................22
11. DC indicator systems - utility (No. 3) hydraulic pressure and temperature indicator system [B] [C]...23
11-1. utility (No. 3) hydraulic pressure and temperature indicator system [B] [C] - description ..........23
11-2. utility (No. 3) hydraulic pressure and temperature indicator system [B] [C] - operational check23
96-24-51 DC ELECTRICAL SYSTEM EQUIPMENT - BATTERY
1. Battery - description ................................................................................................................................1

2. Battery - removal .....................................................................................................................................1
3. Battery - installation ................................................................................................................................1
4. Battery - inspection ..................................................................................................................................2
5. Battery - service ......................................................................................................................................2
96-24-52 DC ELECTRICAL SYSTEM EQUIPMENT - EXTERNAL POWER RECEPTACLE
1. External power receptacle - description .................................................................................................1

1-1. Description - helicopters codes [A] [B] .........................................................................................1
1-2. Description - helicopters code [C] .................................................................................................1
2. External power receptacle - removal ......................................................................................................1
3. External power receptacle - installation .................................................................................................1
4. External power receptacle - inspection ...................................................................................................2
5. External power receptacle - repair ..........................................................................................................2
96-24-53 DC ELECTRICAL SYSTEM EQUIPMENT - STARTER GENERATOR
1. Starter generator - description ................................................................................................................1
96-24-54 DC ELECTRICAL SYSTEM EQUIPMENT - DC CONTROL BOX
1. DC control box - description ..................................................................................................................1

2. DC control box - removal .......................................................................................................................1
3. DC control box - installation ..................................................................................................................1
96-Index
Page 6 Rev. 3
E-AB412-PT6T-2

Module Page
Number Title Number
96-24-55 DC ELECTRICAL SYSTEM EQUIPMENT - CURRENT TRANSFORMER
1. Current transformer - description .......................................................................................................... 1

2. Current transformer - removal ............................................................................................................... 1
3. Current transformer - installation .......................................................................................................... 1
96-24-56 DC ELECTRICAL SYSTEM EQUIPMENT - INGNITION EXCITER
1. Ignition exciter - description .................................................................................................................. 1

2. Ignition exciter - removal ...................................................................................................................... 1
3. Ignition exciter - installation .................................................................................................................. 1
96-24-57 DC ELECTRICAL SYSTEM EQUIPMENT - DC EXTERNAL POWER RELAY
1. DC external power relay - description ................................................................................................... 1

2. DC external power relay - removal ........................................................................................................ 1
3. DC external power relay - installation ................................................................................................... 1
96-24-58 DC ELECTRICAL SYSTEM EQUIPMENT - START RELAY
1. Start relay - description .......................................................................................................................... 1

2. Start relay - removal .............................................................................................................................. 1
3. Start relay - installation .......................................................................................................................... 1
96-24-59 DC ELECTRICAL SYSTEM EQUIPMENT - START CONTROL RELAY
1. Start control relay - description ............................................................................................................. 1

2. Start control relay - removal .................................................................................................................. 1
3. Start control relay - installation ............................................................................................................. 1
96-24-60 DC ELECTRICAL SYSTEM EQUIPMENT - NO. 1 AND NO. 2 DC GENERATOR RELAY
1. No.1 and No. 2 DC generator relay - description ................................................................................... 1

2. No.1 and No. 2 DC generator relay - removal ........................................................................................ 1
3. No.1 and No. 2 DC generator relay - installation ................................................................................... 1
96-24-61 DC ELECTRICAL SYSTEM EQUIPMENT - NON ESSENTIAL BUS RELAY
1. Non essential bus relay - description ...................................................................................................... 1

2. Non essential bus relay - removal ........................................................................................................... 1
3. Non essential bus relay - installation ...................................................................................................... 1
96-24-62 DC ELECTRICAL SYSTEM EQUIPMENT - NON ESSENTIAL BUS CONTROL RELAY
1. Non essential bus control relay - description .......................................................................................... 1

2. Non essential bus control relay - removal .............................................................................................. 1
3. Non essential bus control relay - installation .......................................................................................... 1
96-24-63 DC ELECTRICAL SYSTEM EQUIPMENT - NO. 1 AND NO. 2 BATTERY BUS RELAY
1. No. 1 and No. 2 battery bus relay - description ...................................................................................... 1

2. No. 1 and No. 2 battery bus relay - removal ........................................................................................... 1
96-Index
Rev. 3 Page 7
E-AB412-PT6T-2

Module Page
Number Title Number
3. No. 1 and No. 2 battery bus relay - installation .......................................................................................1
96-24-64 DC ELECTRICAL SYSTEM EQUIPMENT - BATTERY INTERLOCK RELAY
1. Battery interlock relay - description ........................................................................................................1

2. Battery interlock relay - removal ............................................................................................................1
3. Battery interlock relay - installation ........................................................................................................1
96-24-65 DC ELECTRICAL SYSTEM EQUIPMENT - NON ESSENTIAL BUS SENSOR
1. Non essential bus sensor - description ....................................................................................................1

2. Non essential bus sensor - removal .........................................................................................................1
3. Non essential bus sensor - installation ....................................................................................................1
96-25-01 POWERED PASSENGER STEP SYSTEM (KIT)
1. Powered passenger step system (kit) - description ..................................................................................1

2. Powered passenger step system (kit) - operational check .......................................................................1
96-25-02 EMERGENCY FLOATS SYSTEM
1. Emergency floats system - description ....................................................................................................1

2. Emergency floats system - operational check .........................................................................................1
3. Emergency floats system - troubleshooting ............................................................................................1
4. Emergency floats system - maintenance .................................................................................................1
5. Emergency floats system - text box ........................................................................................................2
5-1. Text box - description ....................................................................................................................2
5-2. Text box - removal .........................................................................................................................2
5-3. Text box - installation ....................................................................................................................2
5-4. Text box - disassembly ...................................................................................................................2
5-5. Text box - assembly .......................................................................................................................2
6. Emergency floats system - control panel ................................................................................................3
6-1. Control panel - description .............................................................................................................3
6-2. Control panel - removal ..................................................................................................................3
6-3. Control panel - installation .............................................................................................................3
6-4. Control panel - inspection ..............................................................................................................3
6-5. Control panel - repair or replacement ............................................................................................3
7. Emergency floats system - float switches ...............................................................................................3
7-1. Float switches - description ............................................................................................................3
7-2. Float switches - removal ................................................................................................................3
7-3. Float switches - installation ............................................................................................................4
7-4. Float switches - inspection .............................................................................................................4
7-5. Float switches - repair or replacement ...........................................................................................4
96-25-03 CARGO HOOK CONTROL CIRCUIT
1. Cargo hook control circuit - description .................................................................................................1

2. Cargo hook control circuit - operational check .......................................................................................1
3. Cargo hook control circuit - troubleshooting ..........................................................................................1
96-26-01 ENGINE FIRE EXTINGUISHER SYSTEMS
1. Engine fire extinguisher systems - description .......................................................................................1
96-Index
Page 8 Rev. 3
E-AB412-PT6T-2

Module Page
Number Title Number
2. Engine fire extinguisher systems - operational check ............................................................................ 1
96-30-01 WINDSHIELD WIPER SYSTEMS
1. Windshield wiper systems - description ................................................................................................. 1

2. Windshield wiper systems - operational check ....................................................................................... 1
96-31-30 VOICE/FLIGHT DATA RECORDER SYSTEM (P/N 412-705-001-101 AND 103)
1. Voice/flight data recorder system ........................................................................................................... 1

2. Flight data recorder system - description ................................................................................................ 1
3. Flight data recorder system - removal procedures .................................................................................. 1
3-1. Removal procedures - Flight Data Recorder (FDR) ...................................................................... 1
3-2. Removal procedures - Air Data Computer (ADC) ........................................................................ 1
3-3. Removal procedures - Flight Data Acquisition Unit (FDAU) ....................................................... 2
3-4. Removal procedures - accelerometer ............................................................................................. 2
4. Flight data recorder system - installation procedures ............................................................................. 2
4-1. Installation procedures - Flight Data Recorder (FDR) .................................................................. 2
4-2. Installation procedures - Air Data Computer (ADC) ..................................................................... 3
4-3. Installation procedures - Flight Data Acquisition Unit (FDAU) ................................................... 3
4-4. Installation procedures - accelerometer ......................................................................................... 3
5. Flight data recorder system - inspection procedures .............................................................................. 3
6. Flight data recorder system - cleaning procedures ................................................................................. 4
7. Flight data recorder system - Repair or replacement .............................................................................. 4
8. Flight data recorder system - functional test............................................................................................ 5
9. Voice/flight data recorder system - retrieval of data ............................................................................. 11
10. Cockpit Voice Recorder system - description ...................................................................................... 14
11. Cockpit Voice Recorder system - removal procedures ........................................................................ 14
11-1. Removal procedures - Cockpit Voice Recorder (CVR) .............................................................. 14
11-2. Removal procedures - Recorder Control Unit (RCU) ................................................................. 14
11-3. Removal procedures - impact switch ........................................................................................... 14
11-4. Removal procedures - mounting tray .......................................................................................... 14
12. Cockpit Voice Recorder SYSTEM - installation procedures ................................................................ 15
12-1. Installation procedures - Cockpit Voice Recorder (CVR) ........................................................... 15
12-2. Installation procedures - Recorder Control Unit (RCU) ............................................................. 15
12-3. Installation procedures - impact switch ....................................................................................... 15
12-4. Installation procedures - mounting tray ....................................................................................... 15
13. Cockpit Voice Recorder system - inspection procedures ..................................................................... 15
14. Cockpit Voice Recorder system - cleaning procedures ........................................................................ 16
15. Cockpit Voice Recorder system - repair or replacement ...................................................................... 16
16. Cockpit Voice Recorder system - functional check............................................................................... 17
96-31-50 CAUTION AND WARNING SYSTEM
1. Caution and warning system - description .............................................................................................. 1
96-31-51 CAUTION AND WARNING SYSTEM - OPERATION
1. Operation - description ........................................................................................................................... 1

2. Operation - operational test ..................................................................................................................... 1
2-1. Operational test - master caution light system ............................................................................... 1
3. Operation - operational check.................................................................................................................. 6
3-1. Operational check - caution panel light system ............................................................................. 6
96-Index
Rev. 3 Page 9
E-AB412-PT6T-2

Module Page
Number Title Number
4. Operation - advisory panel ......................................................................................................................6

4-1. Advisory panel - description ..........................................................................................................6
4-2. Advisory panel - operational check ................................................................................................6
4-3. Advisory panel - troubleshooting....................................................................................................7
96-31-52 CAUTION AND WARNING SYSTEM - CAUTION LIGHT SYSTEMS
1. Caution light systems - operational check ...............................................................................................1

1-1. Operational check - DC generator caution light system ................................................................1
1-2. Operational check - generator No. 1 and No. 2 overheat caution light system ..............................1
1-3. Operational check - inverter No. 1 and No. 2 caution light system ...............................................1
1-4. Operational check - transmission oil pressure caution light system ..............................................2
1-5. Operational check - transmission oil temperature caution light system .........................................2
1-6. Operational check - combining gearbox oil pressure caution light system ....................................2
1-7. Operational check - combining gearbox oil temperature caution light system ..............................3
1-8. Operational check - particle separator caution light system ..........................................................3
1-9. Operational check - governor manual control caution light system ...............................................3
1-10. Operational check - engine chip detector caution light system ......................................................3
1-11. Operational check - combining gearbox chip detector caution light system .................................4
1-12. Operational check - transmission chip detector caution light system ............................................4
1-13. Operational check - forty-two/ninety degree (42°/90°) gearbox chip detector caution
light systems....................................................................................................................................5
1-14. Operational check - door lock caution light system .......................................................................5
1-15. Operational check - fuel boost caution light system [A] [B] .........................................................5
1-16. Operational check - fuel boost caution light system [C] [D] .........................................................6
1-17. Operational check - fuel filter caution light system .......................................................................6
1-18. Operational check - fuel low caution light system [A] [B] .............................................................7
1-19. Operational check - fuel low caution light system [C] [D] ............................................................7
1-20. Operational check - engine No. 1 and no. 2 fuel valve caution light system .................................8
1-21. Operational check - engine No. 1 and no. 2 fuel transfer caution light system [C] [D] ................8
1-22. Operational check - fuel crossfeed valve caution light system [A] [B] .........................................8
1-23. Operational check - fuel crossfeed valve caution light system [C] [D] .........................................9
1-24. Operational check - hydraulic caution light system .......................................................................9
1-25. Operational check - external power caution light system .............................................................10
1-26. Operational check - battery sensor temperature caution light system [A] [B] .............................10
1-27. Operational check - battery sensor temperature caution light system [C] [D] ............................11
1-28. Operational check - battery caution light system .........................................................................11
1-29. Operational check - heater air line caution light system [A] [B] ..................................................13
1-30. Operational check - heater air line caution light system [C] [D] .................................................13
1-31. Operational check - AFCS caution light system ..........................................................................13
1-32. Operational check - rotor brake caution light system ..................................................................14
1-33. Operational check - caution panel caution light system ...............................................................14
1-34. Operational check - No. 3 utility hydraulic system oil pressure caution light system [B] [C] ....14
96-31-53 CAUTION AND WARNING SYSTEM - ROTOR BRAKE WARNING SYSTEM
1. Rotor brake warning system - description ...............................................................................................1

2. Rotor brake warning system - operational check ....................................................................................1
3. Rotor brake warning system - adjustment ...............................................................................................1
96-Index
Page 10 Rev. 3
E-AB412-PT6T-2

Module Page
Number Title Number
96-31-54 CAUTION AND WARNING SYSTEM - RPM LIMIT WARNING SYSTEMS
1. RPM limit warning systems - description ............................................................................................... 1

2. RPM limit warning systems - operational check (without engines operating) [A] [B] .......................... 1
3. RPM limit warning systems - operational check (without engines operating) [C] [D] .......................... 1
4. RPM limit warning systems - operational check and alignment (with engines operating) ..................... 2
5. RPM limit warning systems - engine low RPM warning check and alignment ..................................... 5
6. RPM limit warning systems - troubleshooting ....................................................................................... 5
7. RPM limit warning systems - rpm warning box ..................................................................................... 6
7-1. RPM warning box - removal ......................................................................................................... 6
7-2. RPM warning box - installation ..................................................................................................... 6
7-3. RPM warning box - inspection, repair or replacement .................................................................. 6
96-31-55 CAUTION AND WARNING SYSTEM - FIRE DETECTION WARNING SYSTEM
1. Fire detection warning system - description ........................................................................................... 1

2. Fire detection warning system - operational check ................................................................................ 1
2-1. Operational check - engine No. 1 fire detection warning .............................................................. 1
2-2. Operational check - engine No. 2 fire detection warning .............................................................. 1
3. Fire detection warning system - troubleshooting..................................................................................... 2
4. Fire detection warning system - amplifier unit ........................................................................................ 3
4-1. Amplifier unit - removal ................................................................................................................ 3
4-2. Amplifier unit - installation ........................................................................................................... 3
4-3. Amplifier unit - inspection, repair or replacement ........................................................................ 3
5. Fire detection warning system - baggage compartment ......................................................................... 3
5-1. baggage compartment - description ............................................................................................... 3
5-2. baggage compartment - operational check .................................................................................... 3
5-3. baggage compartment - troubleshooting ....................................................................................... 4
96-31-56 CAUTION AND WARNING SYSTEM - HYDRAULIC FILTER CLOGGED WARNING

SYSTEM
1. Hydraulic filter clogged warning system - description ........................................................................... 1

2. Hydraulic filter clogged warning system - operational check ................................................................ 1
96-32-00 LIGHTING SYSTEM
1. Lighting system - description ................................................................................................................. 1
96-33-00 INTERIOR LIGHTING SYSTEMS
1. Interior lighting systems - general .......................................................................................................... 1
96-33-10 INTERIOR LIGHTING SYSTEMS - COCKPIT LIGHTS SYSTEM
1. Cockpit lights system - description ......................................................................................................... 1

2. Cockpit lights system - removal ............................................................................................................. 1
3. Cockpit lights system - installation ......................................................................................................... 1
4. Cockpit lights system - operational check .............................................................................................. 1
5. Cockpit lights system - troubleshooting .................................................................................................. 2
96-Index
Rev. 3 Page 11
E-AB412-PT6T-2

Module Page
Number Title Number
96-33-11 INTERIOR LIGHTING SYSTEMS - APPROACH PLATE AND MAP LIGHTS SYSTEM
1. Approach plate and map lights system - description ...............................................................................1

2. Approach plate and map lights system - operational check ....................................................................1
96-33-12 INTERIOR LIGHTING SYSTEMS - DOME LIGHTS SYSTEM
1. Dome lights system - description ............................................................................................................1

2. Dome lights system - removal .................................................................................................................1
3. Dome lights system - lamps replacement ................................................................................................1
4. Dome lights system - installation ............................................................................................................1
5. Dome lights system - operational check .................................................................................................1
6. Dome lights system - troubleshooting .....................................................................................................2
96-33-13 INTERIOR LIGHTING SYSTEMS - INSTRUMENT PANEL LIGHTS SYSTEM
1. Instrument panel lights system - description ...........................................................................................1

2. Instrument panel lights system - operational check ................................................................................1
2-1. Operational check - pilot instruments and passenger warning lighting check ...............................1
2-2. Operational check - copilot lighting check ....................................................................................1
3. Instrument panel lights system - troubleshooting ...................................................................................2
96-33-14 INTERIOR LIGHTING SYSTEMS - ENGINE INSTRUMENT LIGHTS SYSTEM
1. Engine instrument lights system - description ........................................................................................1

2. Engine instrument lights system - operational check ..............................................................................1
3. Engine instrument lights system - troubleshooting .................................................................................1
96-33-15 INTERIOR LIGHTING SYSTEMS - INSTRUMENT SECONDARY LIGHTS SYSTEM
1. Instrument secondary lights system - description ...................................................................................1

2. Instrument secondary lights system - removal ........................................................................................1
3. Instrument secondary lights system - installation ...................................................................................1
4. Instrument secondary lights system - operational check .........................................................................1
5. Instrument secondary lights system - troubleshooting .............................................................................2
96-33-16 INTERIOR LIGHTING SYSTEMS - PEDESTAL LIGHTS SYSTEM
1. Pedestal lights system - description ........................................................................................................1

2. Pedestal lights system - operational check ..............................................................................................1
3. Pedestal lights system - troubleshooting .................................................................................................1
96-33-17 INTERIOR LIGHTING SYSTEMS - OVERHEAD CONSOLE LIGHTS SYSTEM
1. Overhead console lights system - description .........................................................................................1

2. Overhead console lights system - operational check ..............................................................................1
3. Overhead console lights system - troubleshooting ..................................................................................1
96-33-18 INTERIOR LIGHTING SYSTEMS - UTILITY LIGHTS
1. Utility lights - description .......................................................................................................................1
96-Index
Page 12 Rev. 3
E-AB412-PT6T-2

Module Page
Number Title Number
96-33-19 INTERIOR LIGHTING SYSTEMS - POWER SUPPLY (PS3, PS4 OR PS5)
1. Power supply (PS3, PS4 or PS5) - removal ............................................................................................ 1

2. Power supply (PS3, PS4 or PS5) - installation ....................................................................................... 1
96-33-30 INTERIOR LIGHTING SYSTEMS - BAGGAGE COMPARTMENT LIGHTS SYSTEM
1. Baggage compartment lights system - description ................................................................................. 1

2. Baggage compartment lights system - removal ...................................................................................... 1
3. Baggage compartment lights system - installation ................................................................................. 1
4. Baggage compartment lights system - operational check ....................................................................... 1
5. Baggage compartment lights system - maintenance ............................................................................... 1
6. Baggage compartment lights system - troubleshooting .......................................................................... 2
96-33-40 EXTERIOR LIGHTING SYSTEMS
1. Exterior lighting systems - description ................................................................................................... 1
96-33-41 EXTERIOR LIGHTING SYSTEMS - POSITION LIGHTS SYSTEM
1. Position lights system - description ........................................................................................................ 1

2. Position lights system - removal ............................................................................................................. 1
3. Position lights system - installation ........................................................................................................ 1
4. Position lights system - operational check .............................................................................................. 1
5. Position lights system - troubleshooting.................................................................................................. 2
96-33-42 EXTERIOR LIGHTING SYSTEMS - ANTICOLLISION LIGHTS SYSTEM
1. Anticollision lights system - description ................................................................................................ 1

2. Anticollision lights system - removal ..................................................................................................... 1
3. Anticollision lights system - installation ................................................................................................ 1
4. Anticollision lights system - operational check ...................................................................................... 1
5. Anticollision lights system - troubleshooting .......................................................................................... 2
96-33-43 EXTERIOR LIGHTING SYSTEMS - SEARCHLIGHT SYSTEM
1. Searchlight system - description ............................................................................................................. 1

2. Searchlight system - removal .................................................................................................................. 1
3. Searchlight system - lamp replacement .................................................................................................. 1
4. Searchlight system - installation ............................................................................................................. 2
5. Searchlight system - operational check .................................................................................................. 2
6. Searchlight system - troubleshooting....................................................................................................... 3
96-33-44 EXTERIOR LIGHTING SYSTEMS - LANDING LIGHT SYSTEM
1. Landing light system - description .......................................................................................................... 1

2. Landing light system - removal .............................................................................................................. 1
3. Landing light system - lamp replacement ............................................................................................... 1
4. Landing light system - installation .......................................................................................................... 1
5. Landing light system - light adjustment ................................................................................................. 1
6. Landing light system - operational check ................................................................................................ 2
7. Landing light system - troubleshooting .................................................................................................. 2
96-Index
Rev. 3 Page 13
E-AB412-PT6T-2

Module Page
Number Title Number
1. Flight control systems - description ........................................................................................................1

2. Flight control systems - force trim system ..............................................................................................1
2-1. Force trim system - description ......................................................................................................1
2-2. Force trim system - operational check ...........................................................................................1
2-3. Force trim system - troubleshooting ...............................................................................................2
3. Flight control systems - hydraulic control systems .................................................................................2
3-1. Hydraulic control systems - description .........................................................................................2
3-2. Hydraulic control systems - operational check [A] [B] .................................................................2
3-3. Hydraulic control systems - operational check [C] [D] .................................................................4
3-4. Hydraulic control systems - troubleshooting .................................................................................6
96-73-01 ENGINE CONTROL AND ACCESSORIES SYSTEMS
1. Engine control and accessories systems - description .............................................................................1

2. Engine control and accessories systems - fuel control heater .................................................................1
2-1. Fuel control heater - operational check ..........................................................................................1
2-2. Fuel control heater - troubleshooting ..............................................................................................2
3. Engine control and accessories systems - fuel boost pump system ........................................................2
3-1. Fuel boost pump system - description ............................................................................................2
3-2. Fuel boost pump system - operational check .................................................................................3
3-3. Fuel boost pump system - troubleshooting ....................................................................................3
4. Engine control and accessories systems - fuel transfer pump systems ...................................................4
4-1. Fuel transfer pump system - description [C] [D] ...........................................................................4
4-2. Fuel transfer pump system - operational check ..............................................................................4
4-3. Fuel transfer pump system - troubleshooting .................................................................................5
5. Engine control and accessories systems - fuel shutoff valve systems .....................................................5
5-1. Fuel shutoff valve systems - description ........................................................................................5
5-2. Fuel shutoff valve systems - operational check .............................................................................6
5-3. Fuel shutoff valve systems - troubleshooting .................................................................................7
6. Engine control and accessories systems - fuel control valve system ......................................................9
6-1. Fuel control valve system - description ..........................................................................................9
6-2. Fuel control valve system - operational check ...............................................................................9
6-3. Fuel control valve system - troubleshooting ................................................................................10
7. Engine control and accessories systems - fuel interconnect valve system ............................................10
7-1. Fuel interconnect valve system - description ...............................................................................10
7-2. Fuel interconnect valve system - operational check .....................................................................11
8. Engine control and accessories systems - fuel crossfeed valve system ................................................12
8-1. Fuel crossfeed valve system - description ....................................................................................12
8-2. Fuel crossfeed valve system - operational check .........................................................................13
9. Engine control and accessories systems - governor RPM actuator system [A] [B] [C] .......................14
9-1. Governor RPM actuator system [A] [B] [C] - description ...........................................................14
9-2. Governor RPM actuator system [A] [B] [C] - operational check ................................................14
9-3. Governor RPM actuator system [A] [B] [C] - troubleshooting ...................................................14
10. Engine control and accessories systems - governor RPM actuator system [D] .....................................15
10-1. Governor RPM actuator system [D] - description .......................................................................15
10-2. Governor RPM actuator system [D] - operational check .............................................................15
11. Engine control and accessories systems - sump drain system ..............................................................15
11-1. Sump drain system - description ..................................................................................................15
11-2. Sump drain system - operational check ........................................................................................16
11-3. Sump drain system - troubleshooting ...........................................................................................16
96-Index
Page 14 Rev. 3
E-AB412-PT6T-2

Module Page
Number Title Number
12. Engine control and accessories systems - idle stop release solenoid system ........................................ 17
12-1. Idle stop release solenoid system - description ............................................................................ 17
12-2. Idle stop release solenoid system - operational check ................................................................. 17
12-3. Idle stop release solenoid system - troubleshooting ..................................................................... 18
13. Engine control and accessories systems - engine particle separator system ......................................... 19
13-1. Engine particle separator system - description ............................................................................ 19
13-2. Engine particle separator system - operational check .................................................................. 19
13-3. Engine particle separator system - troubleshooting ..................................................................... 20
96-Index
Rev. 3 Page 15
E-AB412-PT6T-2
FIGURES
Figure Page
Number Title Number
Figure 1. Installation of shorting device.........................................................................................................................6

Figure 2. Temperature control group..............................................................................................................................7
Figure 1. Fuselage equipment location - electrical (helicopters codes [A] [B]) (sheet 1 of 11) ....................................3
Figure 2. Fuselage equipment location - electrical (helicopters codes [C] [D]) (sheet 1 of 11) ..................................14
Figure 3. Nose compartment equipment location - electrical (helicopters codes [A] [B]) (sheet 1 of 2) ....................25
Figure 4. Nose compartment equipment location - electrical (helicopters codes [C] [D]) (sheet 1 of 2) ....................27
Figure 5. Transmission equipment location - electrical (helicopters codes [A] [B]) ...................................................29
Figure 6. Transmission equipment location - electrical (helicopters codes [C] [D]) ...................................................31
Figure 7. Engine equipment location - electrical (helicopters codes [A] [B]) (sheet 1 of 4) .......................................33
Figure 8. Engine equipment location - electrical (helicopters codes [C] [D]) (sheet 1 of 4) .......................................37
Figure 9. Tailboom equipment location - electrical (helicopters codes [A] [B]) .........................................................41
Figure 10. Tailboom equipment location - electrical (helicopters codes [C] [D]) .........................................................42
Figure 11. Fuel cell equipment location - electrical (helicopters codes [C] [D])...........................................................43
Figure 1. Overhead console (helicopters codes [A] [B])................................................................................................2

Figure 2. Overhead console (helicopters codes [C] [D])................................................................................................3
Figure 3. Pedestal panels ................................................................................................................................................4
Figure 4. Instrument panel (helicopters codes [A] [B])..................................................................................................5
Figure 5. Instrument panel (helicopters codes [C] [D])..................................................................................................6
Figure 1. Track mounted relay - removal/installation (typical)......................................................................................2
Figure 1. AC electrical power system - block diagram (helicopters codes [A] [B])......................................................2
Figure 2. AC electrical power system - block diagram (helicopters codes [C] [D])......................................................3
Figure 1. Test setup for fuel quantity indicator calibration, dry tanks .........................................................................17
Figure 1. Voltage control paralleling adjustment .........................................................................................................10
Figure 1. Simplified electrical bus wiring (helicopters codes [A] [B]) ..........................................................................3
Figure 2. Simplified electrical bus wiring (helicopters codes [C] [D]) ..........................................................................4
Figure 3. Power diode functional checkout (helicopters codes [A] [B]) (sheet 1 of 2)..................................................5
Figure 4. Power diode functional checkout (helicopters codes [C] [D]) (sheet 1 of 2)..................................................7
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Page 16 Rev. 3
E-AB412-PT6T-2
FIGURES (CONT.D)
Figure Page
Number Title Number
Figure 1. Signal conditioner control panel..................................................................................................................... 6

Figure 2. Engine combining gearbox data plate ............................................................................................................ 9
Figure 3. Torque transmitter ........................................................................................................................................ 10
Figure 1. Installation of shorting device ........................................................................................................................ 3
96-31-30 VOICE/FLIGHT DATA RECORDER SYSTEM (P/N 412-705-001-101 AND 103)
Figure 1. Simplified block diagram flight data recorder system.................................................................................. 12

Figure 2. Flight data recorder system equipment location........................................................................................... 13
Figure 3. Simplified block diagram cockpit voice recorder system ............................................................................ 19
Figure 4. Cockpit voice recorder system equipment location...................................................................................... 20
Figure 1. Master caution panel (helicopters codes [A] [B]) .......................................................................................... 2

Figure 2. Master caution panel (helicopters codes [C] [D]) .......................................................................................... 3
Figure 1. Battery temp sensor test harness (only) wiring diagram .............................................................................. 12
Figure 1. Limit detector unit .......................................................................................................................................... 4
Figure 1. Installation of shorting device ........................................................................................................................ 8
96-Index
Rev. 3 Page 17
E-AB412-PT6T-2
TABLES
Table Page
Number Title Number
Table 1. Cabin heater system troubleshooting ..............................................................................................................3

Table 2. Vent blower system - troubleshooting ............................................................................................................6
Table 1. Reference designators (helicopters codes [A] [B]) .........................................................................................1
Table 1. Reference designators (helicopters codes [C] [D]) ........................................................................................1
Table 1. Power source components data .......................................................................................................................1
Table 1. Electrical Wire Interconnection System (EWIS) ............................................................................................2
Table 1. Inverter systems troubleshooting ....................................................................................................................6
Table 1. Torque pressure indicator system troubleshooting .........................................................................................2

Table 2. Engine oil pressure indicator system troubleshooting ....................................................................................4
Table 3. Transmission oil pressure indicator system troubleshooting ..........................................................................5
Table 4. Hydraulic pressure indicator troubleshooting .................................................................................................6
Table 5. Combining gearbox oil pressure indicator systems troubleshooting ..............................................................7
Table 6. Fuel pressure indicator troubleshooting ..........................................................................................................8
Table 7. Attitude director indicator system troubleshooting.......................................................................................10
Table 8. Triple tachometer indicator systems troubleshooting ...................................................................................12
Table 9. Gas producer tachometer indicator systems troubleshooting........................................................................13
Table 10. Fuel quantity indicator system [A] [B] troubleshooting ...............................................................................14
Table 1. Battery system troubleshooting.......................................................................................................................6
Table 1. External power system troubleshooting ..........................................................................................................3
Table 1. Generator system troubleshooting...................................................................................................................6
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Page 18 Rev. 3
E-AB412-PT6T-2
TABLES (CONT.D)
Table Page
Number Title Number
Table 1. Starter and igniter systems troubleshooting.................................................................................................... 4
Table 1. Mast torque temperature sensor resistance values.......................................................................................... 2

Table 2. Engine oil temperature indicator system troubleshooting ............................................................................ 11
Table 3. Transmission oil temperature indicator system troubleshooting .................................................................. 12
Table 4. Combining gearbox oil temperature troubleshooting ................................................................................... 13
Table 5. Engine hourmeter system troubleshooting ................................................................................................... 15
Table 6. Interturbine temperature (ITT) indicator system troubleshooting ................................................................ 17
Table 7. Hydraulic oil temperature indicator system troubleshooting ....................................................................... 18
Table 8. Fuel quantity indicator system [C] [D] troubleshooting............................................................................... 22
Table 1. Cargo hook control circuit troubleshooting.................................................................................................... 1
Table 1. Master caution light and advisory panel troubleshooting............................................................................... 7
Table 1. Rpm limit warning systems troubleshooting .................................................................................................. 5
Table 1. Fire detection warning system troubleshooting.............................................................................................. 2

Table 2. Baggage compartment troubleshooting .......................................................................................................... 4
96-33-10 INTERIOR LIGHTING SYSTEMS - COCKPIT LIGHTS SYSTEM
Table 1. Cockpit lights system troubleshooting ........................................................................................................... 2
96-33-12 INTERIOR LIGHTING SYSTEMS - DOME LIGHTS SYSTEM
Table 1. Dome lights system troubleshooting .............................................................................................................. 2
96-33-13 INTERIOR LIGHTING SYSTEMS - INSTRUMENT PANEL LIGHTS SYSTEM
Table 1. Instrument panel lights system troubleshooting ............................................................................................. 2
96-33-14 INTERIOR LIGHTING SYSTEMS - ENGINE INSTRUMENT LIGHTS SYSTEM
Table 1. Engine instrument lights system troubleshooting........................................................................................... 1
96-33-15 INTERIOR LIGHTING SYSTEMS - INSTRUMENT SECONDARY LIGHTS SYSTEM
Table 1. Instrument secondary lights system troubleshooting...................................................................................... 2
96-Index
Rev. 3 Page 19
E-AB412-PT6T-2
TABLES (CONT.D)
Table Page
Number Title Number
96-33-16 INTERIOR LIGHTING SYSTEMS - PEDESTAL LIGHTS SYSTEM
Table 1. Pedestal lights system troubleshooting ...........................................................................................................1
96-33-17 INTERIOR LIGHTING SYSTEMS - OVERHEAD CONSOLE LIGHTS SYSTEM
Table 1. Overhead console lights system troubleshooting............................................................................................1
96-33-30 INTERIOR LIGHTING SYSTEMS - BAGGAGE COMPARTMENT LIGHTS SYSTEM
Table 1. Baggage compartment light system troubleshooting ......................................................................................2
96-33-41 EXTERIOR LIGHTING SYSTEMS - POSITION LIGHTS SYSTEM
Table 1. Position lights system troubleshooting............................................................................................................2
96-33-42 EXTERIOR LIGHTING SYSTEMS - ANTICOLLISION LIGHTS SYSTEM
Table 1. Anticollision lights system troubleshooting....................................................................................................2
96-33-43 EXTERIOR LIGHTING SYSTEMS - SEARCHLIGHT SYSTEM
Table 1. Searchlight system troubleshooting ...............................................................................................................3
96-33-44 EXTERIOR LIGHTING SYSTEMS - LANDING LIGHT SYSTEM
Table 1. Landing light system troubleshooting.............................................................................................................2
Table 1. Force trim system troubleshooting..................................................................................................................2

Table 2. Hydraulic control systems troubleshooting.....................................................................................................6
Table 1. Fuel control heater troubleshooting ................................................................................................................2

Table 2. Fuel boost pump system troubleshooting........................................................................................................3
Table 3. Fuel transfer pump system troubleshooting ....................................................................................................5
Table 4. Fuel shutoff valve systems troubleshooting....................................................................................................7
Table 5. Fuel control valve system troubleshooting ...................................................................................................10
Table 6. Governor RPM actuator system [A] [B] [C] troubleshooting.......................................................................14
Table 7. Sump drain system troubleshooting ..............................................................................................................16
Table 8. Idle stop release solenoid system troubleshooting ........................................................................................18
Table 9. Engine particle separator system troubleshooting ......................................................................................20
96-Index
Page 20 Rev. 3
E-AB412-PT6T-2
96-21-01
HEATING SYSTEMS
1. HEATING SYSTEMS - DESCRIPTION
Heating systems (electrical portion) include cabin heater and vent blower systems. Refer to Chapter 98 for applicable wiring
diagrams.
2. HEATING SYSTEMS - CABIN HEATER SYSTEM
2-1. CABIN HEATER SYSTEM - DESCRIPTION
The bleed air heating system mixes engine bleed air with ambient air and distributes mixed air in cabin area. The system has
two electrical control circuits, outlet air control and temperature control. The outlet air control controls amount of heated air
needed for cabin heating and defrosting. The temperature control combines engine bleed air with outside air for distribution
in heating system. Overheat switches and relays are provided as protective devices to prevent excessively hot air from
entering distribution system. Particle separator relays are provided as safety devices to cause bleed air flow to be shut off
when rpm at either engine is below normal operational limits.
2-2. CABIN HEATER SYSTEM - OPERATIONAL CHECK
WARNING
FIRE EXTINGUISHER CONTAINERS ARE PRESSURIZED AND EQUIPPED

WITH PYROTECHNIC CARTRIDGES. PRIOR TO ACTIVATING FIRE PULL
HANDLES, FIRE EXTINGUISHER SQUIB ELECTRICAL CONNECTORS
SHALL BE DISCONNECTED AND JUMPER WIRES INSTALLED ON SQUIB
(FIGURE 1).
1. Open ROTOR, ENG 1 and ENG 2 RPM WARN circuit breakers.
2. Close CABIN HTR circuit breaker.
3. Set AFT OUTLET switch ON.
4. Check aft outlet valve and door post outlet valve open.
5. Move manual defrost lever to full ON position.
6. Check aft outlet valve and door post outlet valve return to closed position.
7. Move manual defrost lever to full OFF position.
8. Check aft outlet valve and door post outlet valve return to maximum open position.
9. Set AFT OUTLET switch to OFF.
96-21-01
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E-AB412-PT6T-2
10. Check aft outlet valve and door post outlet valve close.
11. Set HEATER switch to ON.
12. Check both bleed air valves energize.
13. Connect a temporary short between wire H10C22 on heater overheat switch and helicopter structure.
14. After 30 second time delay, check both bleed air valves deenergize and CABIN HTR circuit breaker trips.
15. Remove short installed in step 12. and reset CABIN HTR circuit breaker.
17. Pull out FIRE 1 PULL handle switch.
18. Check both bleed air valves deenergize.
19. Push in FIRE 1 PULL handle switch.
21. Pull out FIRE 2 PULL handle switch.
23. Push in FIRE 2 PULL handle switch.
24. Check both bleed air valves are energized.
25. Close ENG 1 RPM, ENG 2 RPM, and ROTOR RPM circuit breakers.
27. Open ENG 1 RPM, ENG 2 RPM, and ROTOR RPM circuit breakers.
28. Check both bleed air valves are energized.
29. Rotate cabin temperature controller from HOT to COLD.
30. Verify cabin temperature motor shaft rotates counterclockwise (viewed looking at bleed air duct).
31. Repeat step 30., rotating from COLD to HOT position and checking for clockwise rotation.
32. Perform operational check of bleed air pressure valve with both engines running as follows:
a. Start both engines in accordance with Flight Manual procedures and set SYSTEM SELECTOR switch to
HEATER.
b. Shut down engine 1 after reaching operating RPM. Cabin heater will automatically cease to function even if
bleed air valve in system 2 is operating normally.
NOTE
A faulty valve will permit cabin heater to continue to function.
c. Start engine 1 and shut down engine 2. Cabin heater will automatically cease to function even if the bleed air
valve in system 1 is operating normally.
96-21-01
Page 2
E-AB412-PT6T-2
d. Shut down engine
33. Turn electrical power off
2-3. CABIN HEATER SYSTEM - TROUBLESHOOTING
Table 1. Cabin heater system troubleshooting
No bleed flow to mixing valve. Ruptured bleed air line. Refer to Chapter 21
No voltage to bleed air valve. Check for 28 Vdc at plug pin T. If no

voltage exists, check the following:
Wiring - repair as necessary. Check
breaker - replace if required.
No bleed air flow thru mixing valve. No voltage to mixing valve. Check for voltage at plug pin A. If no
voltage exists, check wiring and repair
as necessary. If wiring is OK, check
circuit breakers and replace if required.
Inadequate air pressure. Refer to Chapter 21
Inoperative mixing valve. If bleed air no voltage exists, and

replace mixing valve. Refer to Chapter
21 for valve replacement.
Temperature of heated ventilation air Faulty selector dial cable. Replace cable. Refer to Chapter 21.
will not modulate
Faulty temperature sensor. Refer to Chapter 21.
Ventilation air all hot. Plugged line from mixing valve to Check line from mixing valve to
sensor. sensor, if plugged clear obstruction.
Ventilation air all cool. Faulty temperature selector dial cable. Replace cable. Refer to Chapter 21.
Faulty temperature sensor. Check for leaking or disconnected line

from mixing valve to sensor and repair
as necessary. Refer to Chapter 21.
No air out of door post outlets. No voltage to door post outlet valve. Check for voltage at plug pin B and E.
If no voltage exists, check wiring and
repair as necessary. Check the circuit
breaker and replace if required.
Inoperative limit switch on console. Check for proper operation of limit

switch on console defrost lever.
96-21-01
Page 3
E-AB412-PT6T-2
(Cont.)
Inability to cutoff air to door post No voltage to door post outlet valve. Check voltage at plug pin B and E. If
outlets. no voltage exists, check the wiring
and repair as necessary. Check the
circuit breakers and replace if required.
Inoperative limit switch on console. Check for proper operation of limit

switch on console defrost lever.
HEATER caution light illuminates Defective overheat switch. Replace switch.

with heat switch on or off.
Defective wiring. Check wiring and repair as necessary.
HEATER caution light “ON” when Defective overheat switch. Replace switch.
heat switch is ON.
Defective wiring. Check wiring and repair as necessary.
3. HEATING SYSTEMS - CABIN TEMPERATURE CONTROL GROUP
3-1. CABIN TEMPERATURE CONTROL GROUP - DESCRIPTION
An electrical cabin temperature control group (figure 2) is provided and consists of a direct current positioning motor (4,
figure 2) and associated servocontroller (5, figure 2) unit. The function of this control group is to provide a convenient means
of controlling duct air temperature in distribution system.
3-2. CABIN TEMPERATURE CONTROL GROUP - RIGGING
NOTE
With electrical power on, air temperature control (2, figure 2) is phased with the
motor as follows:
1. Remove electrical connector from motor (4).
2. Remove flex shaft (3) between air temperature control (2) and motor (4).
3. Remove bracket screws and remove motor (4) from bracket.
4. Move servocontroller (5) knob to full COLD position.
5. Attach electrical harness to servocontroller (5).
6. Rotate air temperature control (2) tang counterclockwise to stop position.
7. Mount motor (4) in bracket, but do not tighten bracket screws.
8. Attach electrical connector to motor (4).
9. Attach flex shaft (3) between air temperature control and motor.
96-21-01
Page 4
E-AB412-PT6T-2
10. Remove electrical harness attached in step 5.
11. Tighten motor mounting screws.
3-3. CABIN TEMPERATURE CONTROL GROUP - OPERATIONAL CHECK
2. Set HEATER switch to ON.
3. Check bleed air valves actuate.
4. Rotate hand control on cabin temperature controller through its entire range, from cold position to hot position.
5. Motor travel shall correspond with control position within 3%.
NOTE
Direction of motor travel shall be same as direction of hand control rotation when
viewed from end of motor opposite the shaft. Motor shall develop a minimum of 5
in.-lbs (0,56 Nm) torque throughout total travel. Time required to travel through
270 of arc shall not exceed 45 seconds. Full load current should not exceed 1,0
ampere with 28 Vdc input voltage applied.
6. Rotate hand control on cabin temperature controller from HOT to COLD position.
7. Check motor travel corresponds with control position within 3%.
8. Check motor travel is in same direction as direction of knob rotation.
9. Time required to travel through 270° of arc shall not exceed 45 seconds.
4. HEATING SYSTEMS - VENT BLOWER SYSTEM
4-1. VENT BLOWER SYSTEM - DESCRIPTION
A right and left vent blower is provided. Electrical circuit includes two 28 Vdc blower motors, control switch, and VENT
BLO circuit breaker. Both blowers are energized with VENT BLOWER switch on overhead console.
4-2. VENT BLOWER SYSTEM - OPERATIONAL CHECK
1. Set NON-ESNTL BUS switch to MANUAL.
2. Close VENT BLO circuit breaker.
3. Set VENT BLOWER switch to ON.
4. Check right and left vent blowers operate.
5. Set VENT BLOWER switch to OFF.
6. Check right and left vent blowers are not operating.
96-21-01
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E-AB412-PT6T-2
4-3. VENT BLOWER SYSTEM - TROUBLESHOOTING
Table 2. Vent blower system - troubleshooting
Both vent blowers fail to start, VENT Defective VENT BLOWER circuit Replace circuit breaker.
BLOWER switch positioned to ON. breaker.
Defective VENT BLOWER switch. Replace switch.
Only one blower runs with VENT Defective blower motor. Replace blower.
BLOWER switch positioned to ON.
G6AB0757A
Figure 1. Installation of shorting device
96-21-01
Page 6
E-AB412-PT6T-2
G6AB0758A
Figure 2. Temperature control group
96-21-01
Page 7
E-AB412-PT6T-2
96-21-01
Page 8
E-AB412-PT6T-2
96-24-00
ELECTRICAL SYSTEM
1. ELECTRICAL SYSTEM - DESCRIPTION
The electrical system of the helicopter supplies the following electrical power; Vdc direct current, 115/26 V 400 Hz single
phase alternating current.
The direct current can be supplied by two (starter) generators, by the battery or by an external source through the external
power receptacle located on the RH side of the helicopter nose.
The direct current electrical system, with return line grounded to the structure, supplies the equipment for the engine, the
navigation and communication equipment, the instruments, the armament units and the lighting system.
The alternating current is supplied by two static inverters that supplies power to the navigation instruments, the engine and
special instruments.
Maintenance of electrical circuitry, electrical equipment, and electrical components installed on the Model 412 helicopter is
presented in the following text.
Control panels for ac and dc electrical systems are located on the overhead console. All extended range fuel system circuit
breakers referred to in this chapter are located in circuit breaker panels mounted on overhead console. Control relays, power
relays, voltage regulators and other equipment required to control, regulate, and effect power transfer and malfunction
monitoring are located in respective compartments. For equipment location, refer to figure 1 through figure 11 and
module 96-24-01 "ELECTRICAL SYSTEM - REFERENCE DESIGNATORS [A] [B]" through module 96-24-02
"ELECTRICAL SYSTEM - REFERENCE DESIGNATORS [C] [D]" (reference designators list). Refer to Chapter 98 for
schematic and wiring diagrams.
Perform operational checks to ensure no new malfunctions have been introduced when equipment is replaced and/or
airframe wiring is repaired/replaced. When performing operational checks, external power should be utilized whenever
possible. Using battery power may deplete the battery and prevent engine start.
2. ELECTRICAL SYSTEM - GENERAL MAINTENANCE INFORMATION
2-1. GENERAL MAINTENANCE INFORMATION - VISUAL INSPECTION
1. Inspect electrical and electronic equipment installation items for dirt and corrosion. The surfaces should be free of dirt,
grease, and fungus.
2. Remove moisture, dust and loose dirt with a clean soft cloth.
WARNING
CLEANING COMPOUND IS FLAMMABLE AND ITS FUMES ARE TOXIC.

PROVIDE ADEQUATE VENTILATION. DO NOT USE NEAR A FLAME.
3. Remove grease, fungus, and ground-in dirt from the equipment case and mounting, use a cloth dampened (not wet)
with cleaning compound.
96-24-00
Page 1
E-AB412-PT6T-2
2-2. GENERAL MAINTENANCE INFORMATION - VOLTAGE MEASUREMENTS
NOTE
Make certain the multimeter AN/PSM-6A or equivalent is in normal condition.
Select applicable voltage range for the most accurate reading to match the value
given on the respective electrical system wiring diagrams.
Perform voltage measurements (AC and DC) where applicable if equipment and airframe component(s) of the respective
system malfunction while conducting the operational procedures. Check voltage of respective systems at test points and
terminal boards on the airframe as per system wiring diagrams.
Check the primary voltage input on load side of respective circuit breaker as per system wiring diagram.
2-3. GENERAL MAINTENANCE INFORMATION - CONTINUITY TRACE
Conduct resistance measurement (continuity trace) using resistance selection, on multimeter AN/PSM-6A or equivalent
with primary electrical power removed from the helicopter. Apply continuity trace for localization of INVISIBLE defects
of connectors, conductors, terminal boards, diodes, resistors, capacity, transistors, relays, inductors, switches, selectors, and
equipment. For a logical approach to a rapid analysis of faulty airframe conductors and components with an electrical
system, that cannot be determined by visual inspection, follow the suggested sequential steps below:
NOTE
If respective system does not perform normally during operational test procedures,
remove dc power from helicopter and apply continuity trace to suspected
components and/or equipment within the circuitry.
NOTE
Under certain conditions of component and/or equipment malfunction it may be
necessary to make voltage measurements and/or continuity trace combinations to
pinpoint the trouble.
1. Analyze the respective system by System-Wiring diagram for airframe inter unit conductor paths (Single, parallel and
series): consider resistors, diodes and relay holding coils and etc. which may alter the sum total resistance of conductor
paths.
NOTE
On Multimeter, check that the meter movement is free and the ohms selection and
ranges will zero ohms adjust knob.
NOTE
When performing resistance measurements, select the range to give the most
accurate reading of the path (conductor, resistor, diode relay holding coil transistor
and condenser) selected from the electrical system wiring diagram.
2. Check continuity and resistance of individual conductors within the respective interconnecting cabling.
3. Check continuity and resistance of individual conductors for abnormal conductivity with adjacent conductors,
shielding and common ground.
4. Check resistors for normal value.
5. Check diodes for front to back ratio.
6. Check condensers for stowage factor (Deflection and rate of return of multimeter pointer).
96-24-00
Page 2
E-AB412-PT6T-2
G6AB0647A
Figure 1. Fuselage equipment location - electrical (helicopters codes [A] [B]) (sheet 1 of 11)
96-24-00
Page 3
E-AB412-PT6T-2
G6AB0648A
96-24-00
Page 4
E-AB412-PT6T-2
G6AB0649A
96-24-00
Page 5
E-AB412-PT6T-2
G6AB0650A
96-24-00
Page 6
E-AB412-PT6T-2
G6AB0651A
96-24-00
Page 7
E-AB412-PT6T-2
G6AB0652A
96-24-00
Page 8
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G6AB0653A
96-24-00
Page 9
E-AB412-PT6T-2
G6AB0654A
96-24-00
Page 10
E-AB412-PT6T-2
G6AB0655A
96-24-00
Page 11
E-AB412-PT6T-2
G6AB0656A
96-24-00
Page 12
E-AB412-PT6T-2
G6AB0657A
96-24-00
Page 13
E-AB412-PT6T-2
G6AB0672A
Figure 2. Fuselage equipment location - electrical (helicopters codes [C] [D]) (sheet 1 of 11)
96-24-00
Page 14
E-AB412-PT6T-2
G6AB0673A
96-24-00
Page 15
E-AB412-PT6T-2
G6AB0674A
96-24-00
Page 16
E-AB412-PT6T-2
G6AB0675A
96-24-00
Page 17
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G6AB0676A
96-24-00
Page 18
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G6AB0677A
96-24-00
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G6AB0678A
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G6AB0679A
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G6AB0680A
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G6AB0681A
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G6AB0682A
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E-AB412-PT6T-2
G6AB0696A
Figure 3. Nose compartment equipment location - electrical (helicopters codes [A] [B]) (sheet 1 of 2)
96-24-00
Page 25
E-AB412-PT6T-2
G6AB0697A
Figure 3. Nose compartment equipment location - electrical (helicopters codes [A] [B]) (sheet 2 of 2)
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G6AB0700A
Figure 4. Nose compartment equipment location - electrical (helicopters codes [C] [D]) (sheet 1 of 2)
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G6AB0702A
Figure 4. Nose compartment equipment location - electrical (helicopters codes [C] [D]) (sheet 2 of 2)
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G6AB0707A
Figure 5. Transmission equipment location - electrical (helicopters codes [A] [B])
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HELICOPTER CODE D
G6AB0708A
Figure 6. Transmission equipment location - electrical (helicopters codes [C] [D])
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G6AB0709A
Figure 7. Engine equipment location - electrical (helicopters codes [A] [B]) (sheet 1 of 4)
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G6AB0710A
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G6AB0711A
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G6AB0712A
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G6AB0713A
Figure 8. Engine equipment location - electrical (helicopters codes [C] [D]) (sheet 1 of 4)
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G6AB0714A
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G6AB0715A
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G6AB0716A
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G6AB0718A
Figure 9. Tailboom equipment location - electrical (helicopters codes [A] [B])
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G6AB0719A
Figure 10. Tailboom equipment location - electrical (helicopters codes [C] [D])
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G6AB0720A
Figure 11. Fuel cell equipment location - electrical (helicopters codes [C] [D])
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ELECTRICAL SYSTEM - REFERENCE DESIGNATORS [A] [B]
1. REFERENCE DESIGNATORS [A] [B] - DESCRIPTION
In this paragraph is shown the reference designators list for the helicopters codes [A] [B]. Refer to table 1.
Table 1. Reference designators (helicopters codes [A] [B])
REF DES NOMENCLATURE
A3 PANEL, ENGINE AND FUEL
A5 PANEL, MASTER CAUTION
A10 PANEL, MISCELLANEOUS CONTROL
A13 PANEL, RESISTOR
A14 PANEL, RESISTOR
B1 SYNCHRO, TRANSMITTER TORQUE, LEFT
B2 SYNCHRO, TRANSMITTER TORQUE, RIGHT
B3 TRANSMITTER, ENGINE OIL PRESURE, LEFT
B4 TRANSMITTER, ENGINE OIL PRESSURE, RIGHT
B5 TRANSMITTER, FUEL PRESSURE, LEFT
B6 TRANSMITTER, FUEL PRESSURE, RIGHT
B7 TRANSMITTER, TRANSMISSION OIL PRESSURE
B8 MOTOR, GOVERNOR RPM ACTUATOR
B13 MOTOR, COPILOT WINDSHIELD WIPER
B14 MOTOR, PILOT WINDSHIELD WIPER
B15 MOTOR, PARTICLE SEPARATOR, LEFT ACTUATOR
B16 MOTOR, PARTICLE SEPARATOR, RIGHT ACTUATOR
B22 TRANSMITTER, C BOX OIL PRESSURE
B27 MOTOR, INVERTER BLOWER
BT1 BATTERY
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(Cont.)
CB5 CB, XMSN CHIP POS IND
CB5 CB, 28 VDC AUX RECEPT
CP1 TRANSMITTER, FUEL QUANTITY TRANSMITTER
CP2 CONN, TEE, FUEL QUANTITY
CP3 CONN, TEE FUEL QUANTITY
CP4 CONN, TEE, FUEL QUANTITY
CR9 DIODE, EXTERNAL POWER RELAY
CR19 DIODE, PARTICLE SEPARATOR RELAY
CR20 DIODE, PARTICLE SEPARATOR RELAY
CR47 DIODE, LIGHTING
CR71 DIODE, BATTERY INTERLOCK
CR73 DIODE, START RELAY 2
CR92 DIODE, RPM WARNING
DS5 RELEASE, CARGO
DS7 LIGHT, ANTI-COLLISION, LOWER
DS8 LIGHT, ANTI-COLLISION, UPPER
DS9 LIGHT, COPILOT UTILITY
DS10 LIGHT, PILOT UTILITY
DS11 LIGHT, DOME
DS12 LIGHT, SEARCH
DS13 LIGHT, LANDING
DS15 LIGHT, LEFT POSITION
DS16 LIGHT, RIGHT POSITION
DS17 LIGHT, TAIL
DS18 LIGHT, BAGGAGE COMPT
DS21 LIGHT, BAGGAGE FIRE TEST
DS28 INDICATOR, HYDRAULIC FILTER CLOG
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(Cont.)
DS29 LIGHT, LEFT UTILITY
DS30 LIGHT, RIGHT UTILITY
DS31 LIGHT, ENG 1 OUT
DS32 LIGHT, ENG 2 OUT
DS37 LIGHT, COPILOT MASTER CAUTION
DS38 LIGHT, PILOT MASTER CAUTION
DS39 LIGHT, COPILOT RPM CAUTION
DS40 LIGHT, PILOT RPM CAUTION
DS41 LIGHT, OUTSIDE AIR TEMPERATURE
DS50 INDICATOR, SUMP CHIP
DS51 INDICATOR, PLANETARY CHIP
DS52 INDICATOR, UPPER MAST CHIP
E1 DETECTOR, TRANSMISSION MAGNETIC CHIP
E2 DETECTOR, ENGINE GEARBOX
E3 DETECTOR, ENGINE 1 FORWARD
E4 DETECTOR, ENGINE 2 FORWARD
E5 DETECTOR, ENGINE 1 AFT
E6 DETECTOR, ENGINE 2 AFT
E7 DETECTOR, 42 GEARBOX MAGNETIC CHIP
E8 DETECTOR, 90 GEARBOX MAGNETIC CHIP
E17 DETECTOR, TRANSMISSION UPPER MAST
E26 DETECTOR, TRANSMISSION PLANETARY
G1 STARTER-GENERATOR, ENGINE 1
G2 STARTER-GENERATOR, ENGINE 2
G3 GENERATOR, GAS PRODUCER 1 TACH
G4 GENERATOR, GAS PRODUCER 2 TACH
G5 GENERATOR, POWER TURBINE 1 TACH
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(Cont.)
G6 GENERATOR, POWER TURBINE 2 TACH
G7 GENERATOR, ROTOR TACH
HR3 HEATER, PILOT LEFT STATIC PORT
HR4 HEATER, PILOT RIGHT STATIC PORT
J3 CONN, EXTERNAL POWER
J33 CONN, INSTRUMENT PANEL LEFT
J34 CONN, INSTRUMENT PANEL RIGHT
J41 CONN, TRANSMISSION
J46 CONN, PILOT CYCLIC STICK
J47 CONN, COPILOT CYCLIC STICK
J48 CONN, PILOT COLLECTIVE
J49 CONN, COPILOT COLLECTIVE
J56 CONN, 28V DC AUXILIARY RECEPTACLE
J57 CONN, PYLON LEFT
J58 CONN, PYLON RIGHT
J59 CONN, ENGINE 1 FORWARD COMPARTMENT
J60 CONN, ENGINE 2 FORWARD COMPARTMENT
J61 CONN, ROOF GENERATOR
J62 CONN, ROOF GENERATOR
J63 CONN, LEFT FIRE DETECT LEFT FWD ENG COMPT
J64 CONN, RIGHT FIRE DETECT LEFT FWD ENG COMPT
J67 CONN, LEFT FIRE DETECT RIGHT FWD ENG COMPT
J68 CONN, RIGHT FIRE DETECT RIGHT FWD ENG COMPT
J95 CONN, CENTER ENGINE COMPARTMENT
J96 CONN, CENTER ENGINE COMPARTMENT
J98 CONN, FIRE DETECT — EXT 2 AFT ENGINE COMPARTMENT
J99 CONN, ENGINE 1 AFT COMPARTMENT
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(Cont.)
J100 CONN, ENGINE 2 AFT COMPARTMENT
J117 CONN, TAILBOOM
J118 CONN, TAILBOOM
J129 CONN, CARGO SLING
J145 CONN, FUEL QUANTITY INLINE RIGHT
J146 CONN, FUEL QUANTITY INLINE RIGHT
J147 CONN, FUEL QUANTITY INLINE TEE
J168 CONN, HEATER COMPARTMENT
J195 CONN, STEP ACTUATOR
J355 CONN, ANTI-COLLISION LIGHT UPPER
J506 CONN, INSTRUMENT PANEL
J3018 CONN, PITCH SYSTEM 1 TRANSDUCER
J3020 CONN, YAW SYSTEM 1 TRANSDUCER
J3022 CONN, ROLL SYSTEM 1 TRANSDUCER
J3043 CONN, PYLON LEFT
K1 RELAY, EXTERNAL POWER
K2 RELAY, NON-ESSENTIAL BUS 2
K3 RELAY, STARTER GENERATOR 1
K4 RELAY, STARTER GENERATOR 2
K5 RELAY, STARTER 1
K6 RELAY, STARTER 2
K7 RELAY, STARTER CONTROL 1
K8 RELAY, STARTER CONTROL 2
K9 RELAY, BATTERY BUS 1
K10 RELAY, BATTERY BUS 2
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(Cont.)
K15 RELAY, IDLE STOP DELAY 1
K16 RELAY, IDLE STOP DELAY 2
K18 RELAY, HEATER
K26 RELAY, PARTICLE SEPARATOR 1
K27 RELAY, PARTICLE SEPARATOR 2
K30 RELAY, HOURMETER
K33 RELAY, NON-ESSENTIAL BUS
K42 RELAY, EMERGENCY FLOAT ARM
K52 RELAY, CAUTION PANEL FAIL
K57 RELAY, BATTERY INTERLOCK
L1 SOLENOID, FUEL CONTROL VALVE
L2 SOLENOID, FUEL CONTROL VALVE
L3 SOLENOID, HYDRAULIC BYPASS 1
L4 SOLENOID, HYDRAULIC BYPASS 2
L5 SOLENOID, IDLE STOP 1
L6 SOLENOID, IDLE STOP 2
L8 SOLENOID, MAGNETIC BRAKE ANTI TORQUE
L9 SOLENOID, MAGNETIC BRAKE FORWARD AND AFT
L10 SOLENOID, MAGNETIC BRAKE LATERAL
L14 SOLENOID, BLEED AIR VALVE 2
L15 SOLENOID, BLEED AIR VALVE 1
M1 INDICATOR, COPILOT ATTITUDE
M2 INDICATOR, PILOT ATTITUDE
M3 INDICATOR, ENGINE 1 FUEL PRESSURE
M4 INDICATOR, ENGINE 2 FUEL PRESSURE
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(Cont.)
M5 INDICATOR, ENGINE 1 OIL TEMPERATURE AND PRESSURE
M6 INDICATOR, ENGINE 2 OIL TEMPERATURE AND PRESSURE
M11 INDICATOR, COPILOT TRIPLE TACHOMETER
M12 INDICATOR, PILOT TRIPLE TACHOMETER
M13 INDICATOR, DUAL AMMETER
M15 INDICATOR, COMBINING GEARBOX OIL PRESSURE AND TEMPERATURE
M16 INDICATOR, TRANSMISSION OIL TEMPERATURE AND PRESSURE
M17 INDICATOR, ENGINE 1 GAS PRODUCER TACHOMETER
M18 INDICATOR, ENGINE 2 GAS PRODUCER TACHOMETER
M19 INDICATOR, COPILOT DUAL TORQUE
M20 INDICATOR, PILOT DUAL TORQUE
M21 INDICATOR, DUAL VOLTMETER 1
M22 INDICATOR, DUAL VOLTMETER 2
M23 INDICATOR, ENGINE NO. 1 INTERTURBINE TEMPERATURE
M24 INDICATOR, ENGINE NO. 2 INTERTURBINE TEMPERATURE
M25 INDICATOR, FUEL QUANTITY
M26 INDICATOR, HOURMETER
M28 INDICATOR, PILOT STANDBY COMPASS
M29 CLOCK, PILOT
M30 INDICATOR, PILOT AIRSPEED
M31 INDICATOR, PILOT VERTICAL SPEED
M32 ALTIMETER, PILOT
M33 INDICATOR, COPILOT ALTIMETER
M34 INDICATOR, COPILOT RATE OF CLIMB
M35 INDICATOR, COPILOT AIRSPEED
M36 INDICATOR, NO. 1 HYDRAULIC PRESSURE AND TEMPERATURE
M37 INDICATOR, NO. 2 HYDRAULIC PRESSURE AND TEMPERATURE
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(Cont.)
M40 CLOCK, COPILOT
P1 CONN, COPILOT PITOT HEATER
P2 CONN, PILOT PITOT HEATER
P10 CONN, DC CONTROL PANEL 2
P11 CONN, DC CONTROL PANEL 1
P15 CONN, COPILOT ATTITUDE
P27 CONN, COPILOT ROTOR TACH GEN
P29 CONN, COPILOT DUAL TORQUE
P35 CONN, ROTOR TACH GENERATOR
P36 CONN, TRANSMISSION OIL PRESSURE SWITCH
P37 CONN, TRANSMISSION OIL TEMPERATURE
P38 CONN, MISCELLANEOUS PANEL
P39 CONN, TRANSMISSION OIL PRESSURE
P41 CONN, TRANSMISSION
P42 CONN, CAUTION PANEL
P44 CONN, ENGINE-FUEL PANEL RIGHT
P45 CONN, ENGINE-FUEL PANEL LEFT
P51 CONN, COPILOT WINDSHIELD WASHER
P52 CONN, PILOT WINDSHIELD WASHER
P53 CONN, FIRE DETECT 1 AMPLIFIER
P54 CONN, FIRE DETECT 2 AMPLIFIER
P57 CONN, PYLON LEFT
P58 CONN, PYLON RIGHT
P59 CONN, ENGINE 1 FORWARD COMPARTMENT
P60 CONN, ENGINE 2 FORWARD COMPARTMENT
P61 CONN, ROOF GENERATOR 1
P62 CONN, ROOF GENERATOR 2
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(Cont.)
P63 CONN, LEFT FIRE DETECT LEFT FWD ENG COMPT
P64 CONN, RIGHT FIRE DETECT LEFT FWD ENG COMPT
P67 CONN, LEFT FIRE DETECT RIGHT FWD ENG COMPT
P68 CONN, RIGHT FIRE DETECT RIGHT FWD ENG COMPT
P73 CONN, ENGINE 1 OIL PRESSURE SWITCH
P74 CONN, ENGINE 2 OIL PRESSURE SWITCH
P77 CONN, ENGINE 1 OIL TEMPERATURE
P78 CONN, ENGINE 2 OIL TEMPERATURE
P79 CONN, ENGINE 1 OIL PRESSURE TRANSMITTER
P80 CONN, ENGINE 2 OIL PRESSURE TRANSMITTER
P81 CONN, FUEL PRESSURE TRANSMITTER
P82 CONN, FUEL PRESSURE TRANSMITTER
P83 CONN, LEFT OIL TANK CHIP DETECT
P84 CONN, RIGHT OIL TANK CHIP DETECT
P85 CONN, ENGINE FUEL HEAT 1
P86 CONN, ENGINE FUEL HEAT 2
P87 CONN, FUEL CONTROL VALVE 1
P88 CONN, FUEL CONTROL VALVE 2
P89 CONN, GAS PRODUCER TACH 1
P90 CONN, GAS PRODUCER TACH 2
P91 CONN, IGNITER 1
P92 CONN, IGNITER 2
P93 CONN, PARTICLE SEPARATOR ACTUATOR 1
P94 CONN, PARTICLE SEPARATOR ACTUATOR 2
P95 CONN, CENTER ENGINE COMPARTMENT
P96 CONN, CENTER ENGINE COMPARTMENT
P97 CONN, FIRE DETECT-EXT 1 AFT ENG COMPARTMENT
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(Cont.)
P98 CONN, FIRE DETECT-EXT 2 AFT ENG COMPARTMENT
P99 CONN, ENGINE 1 AFT COMPARTMENT
P100 CONN, ENGINE 2 AFT COMPARTMENT
P101 CONN, LEFT FIRE DETECT AFT ENG COMPARTMENT
P102 CONN, RIGHT FIRE DETECT AFT ENG COMPARTMENT
P103 CONN, LEFT FIRE DETECT AFT ENG COMPARTMENT
P104 CONN, RIGHT FIRE DETECT AFT ENG COMPARTMENT
P105 CONN, HYDRAULIC 2 TEMPERATURE
P106 CONN, HYDRAULIC 1 TEMPERATURE
P107 CONN, C BOX OIL TEMPERATURE BULB
P109 CONN, TORQUE TRANSMITTER 1
P110 CONN, TORQUE TRANSMITTER 2
P111 CONN, POWER TURBINE TACH 1
P112 CONN, POWER TURBINE TACH 2
P113 CONN, CHIP DETECTOR AFT 1
P114 CONN, CHIP DETECTOR AFT 2
P115 CONN, CHIP DETECTOR CENTER
P116 CONN, ANTI COLLISION LIGHT UPPER
P118 CONN, SMOKE DETECTOR
P119 CONN, SMOKE DETECTOR AMPLIFIER
P120 CONN, SMOKE DETECTOR AMPLIFIER
P121 CONN, FUEL SHUTOFF LEFT
P122 CONN, FUEL SHUTOFF RIGHT
P123 CONN, FORWARD FUEL INTERCONNECT VALVE
P124 CONN, AFT FUEL INTERCONNECT VALVE
P125 CONN, FUEL CROSSFEED VALVE
P126 CONN, HYDRAULIC BYPASS SOLENOID VALVE 1
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(Cont.)
P134A CONN, FUEL QUANTITY TANK UNIT RIGHT
P135A CONN, FUEL QUANTITY TANK UNIT RIGHT
P137A CONN, FUEL QUANTITY TANK UNIT LEFT
P138A CONN, FUEL QUANTITY TANK UNIT LEFT
P139A CONN, FUEL QUANTITY TANK UNIT AFT
P140A CONN, FUEL QUANTITY TANK UNIT AFT
P145A CONN, FUEL QUANTITY INLINE RIGHT
P146A CONN, FUEL QUANTITY INLINE RIGHT
P147A CONN, FUEL QUANTITY INLINE TEE
P147B CONN, FUEL QUANTITY INLINE TEE
P149C CONN, FUEL QUANTITY INLINE TEE
P162 CONN, C BOX OIL PRESSURE
P165 CONN, COPILOT ENGINE 1 TACH GENERATOR
P166 CONN, COPILOT ENGINE 2 TACH GENERATOR
P167 CONN, DOOR POST ACTUATOR
P171 CONN, HYDRAULIC 2 PRESSURE SOLENOID
P173 CONN, HYDRAULIC 2 FILTER SWITCH
P174 CONN, HYDRAULIC 1 FILTER SWITCH
P175 CONN, IDLE STOP RELAY 1
P176 CONN, IDLE STOP RELAY 2
P177 CONN, BLEED AIR VALVE
P178 CONN, BLEED AIR VALVE
P181 CONN, C BOX OIL PRESSURE TRANSMITTER
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(Cont.)
P182 CONN, FUEL 1 DIFFERENCE PRESSURE SWITCH
P183 CONN, FUEL 2 DIFFERENCE PRESSURE SWITCH
P184 CONN, C BOX OIL TEMPERATURE SWITCH
P185 CONN, MISCELLANEOUS PANEL
P186 CONN, STANDBY COMPASS
P187 CONN, AFT OUTLET VALVE
P189 CONN, COPILOT ALTIMETER
P192 CONN, COPILOT AIRSPEED
P193 CONN, COPILOT RATE OF CLIMB
P196 CONN, COPILOT 5 VOLT POWER SUPPLY
P197 CONN, ENGINE INSTRUMENT 5 VOLT POWER SUPPLY
P198 CONN, PILOT 5 VOLT POWER SUPPLY
P212 CONN, HYDRAULIC 1 TRANSMITTER
P219 CONN, HYDRAULIC 2 TRANSMITTER
P222 CONN, WINTERIZATION VALVE
P223 CONN, HEATER CONTROL VALVE
P229 CONN, HYDRAULIC 2 TEMPERATURE BULB
P230 CONN, HYDRAULIC 1 TEMPERATURE BULB
P238 CONN, COPILOT DUAL TORQUE
P239 CONN, HEATER RELAY
P281 CONN, BATTERY TEMPERATURE SENSOR
P286 CONN, ITT COMPENSATOR 1
P291 CONN, COPILOT MASTER CAUTION LIGHT
P293 CONN, COPILOT RPM CAUTION LIGHT
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(Cont.)
P294 CONN, ENGINE INSTRUMENT 5 VOLT POWER SUPPLY
P295 CONN, COPILOT CLOCK
P296 CONN, COPILOT STANDBY CMPS
P299 CONN, HYDRAULIC 2 PRESSURE SWITCH
P300 CONN, HYDRAULIC 1 PRESSURE SWITCH
P350 CONN, CABIN TEMPERATURE SERVO
P351 CONN, CABIN TEMPERATURE MOTOR
P3000 CONN, COPILOT THREE AXIS SENSOR
P3001 CONN, COPILOT RATE GYRO
P3002 CONN, PILOT THREE AXIS SENSOR
P3003 CONN, PILOT RATE GYRO
P3043 CONN, PYLON LEFT
P3052 CONN, RPM WARNING ENGINE 2
P3053 CONN, RPM WARNING ENGINE 1
PPS3 POWER SUPPLY, 5 VOLT COPILOT INSTRUMENT
PPS4 POWER SUPPLY, 5 VOLT ENGINE INSTRUMENT
PPS5 POWER SUPPLY, 5 VOLT PILOT INSTRUMENT
PPS6 POWER SUPPLY, 5 VOLT ENGINE INSTRUMENT
Q4 TRANSISTOR, SECONDARY INSTRUMENT LIGHT
Q5 TRANSISTOR, OVERHEAD CONSOLE LIGHT
Q6 TRANSISTOR, PEDESTAL LIGHT
Q7 TRANSISTOR, OVERHEAD CONSOLE LIGHT
R9 SHUNT, GENERATOR 1
R10 SHUNT, GENERATOR 2
R57 RESISTOR, TRANSFORMER
R58 RESISTOR, TRANSFORMER
S1 SWITCH, HANDLE NO. 1 EMERGENCY FIRE PULL
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(Cont.)
S2 SWITCH, HANDLE NO. 2 EMERGENCY FIRE PULL
S3 SWITCH, FIRE EXTINGUISHER
S5 SWITCH, FIRE DETECTOR PRESS TO TEST
S7 SWITCH, FUEL QUANTITY SELECT
S23 SWITCH, START
S26 SWITCH, TRANSMISSION OIL TEMPERATURE
S28 SWITCH, TRANSMISSION OIL PRESSURE
S31 SWITCH, AFT OUTLET LIMIT
S41 SWITCH, FUEL DRAIN VALVE 1
S42 SWITCH, FUEL DRAIN VALVE 2
S65 SWITCH, PILOT WINDSHIELD WIPER CONTROL
S71 SWITCH, LEFT PASSENGER DOOR
S72 SWITCH, RIGHT PASSENGER DOOR
S73 SWITCH, ENGINE 1 OIL PRESSURE
S74 SWITCH, ENGINE 2 OIL PRESSURE
S81 SWITCH, HEATER OVERHEAT
S82 SWITCH, BAGGAGE COMPARTMENT DOOR
S85 SWITCH, BAGGAGE FIRE TEST
S90 SWITCH, C BOX OIL PRESSURE
S94 SWITCH, HYDRAULIC FILTER
S95 SWITCH, HYDRAULIC FILTER
S100 SWITCH, FUEL 1 DIFFERENCE PRESSURE
S101 SWITCH, FUEL 2 DIFFERENCE PRESSURE
S102 SWITCH, C BOX OIL TEMPERATURE
S105 SWITCH, EXTERNAL POWER
S185 SWITCH, NONESSENTIAL BUS SENSOR
S186 SWITCH, NONESSENTIAL BUS SENSOR
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(Cont.)
S187 SWITCH, OVERHEAT, HEATER AIR LINE
S191 SWITCH, HEATER SENSOR
S206 SWITCH, NO. 1 HYDRAULIC PRESSURE
S207 SWITCH, NO. 2 HYDRAULIC PRESSURE
S209 SWITCH, NO. 1 GENERATOR OVERHEAT
S240 SWITCH, PILOT GYRO (VG FAST) ERECT
S241 SWITCH, COPILOT GYRO (VG FAST) ERECT
T1 TRANSFORMER, CURRENT
TB1 TB, NOSE RACK GROUND
TB6 TB, COCKPIT LIGHT RIGHT
TB7 TB, COCKPIT LIGHT LEFT
TB9 TB, AFT ROOF LIGHT
TB10 TB, RIGHT HAND FUEL CELL
TB11 TB, LEFT HAND FUEL CELL
TB12 TB, PEDESTAL LIGHTING
TB14 TB, SECONDARY INSTRUMENT LIGHT
TB15 TB, PEDESTAL LIGHTING
TB27 TB, 5 VOLT LIGHT POWER
TB28 TB, 5 VOLT LIGHT GROUND
TB29 TB, DC-AC GROUND
TB33 TB, RPM WARNING
TB50 TB, ATTITUDE SYSTEMS
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(Cont.)
TB51 TB, ATTITUDE SYSTEMS
TB52 TB, NONESSENTIAL
TB80 TB, TRANSMISSION CHIP DETECTOR
Z1 DETECTOR, RPM LIMIT
Z4 AMPLIFIER, FIRE DETECTOR, LEFT
Z5 BULB, TRANSMISSION OIL TEMPERATURE
Z6 AMPLIFIER, FIRE DETECTOR, RIGHT
Z7 BULB, ENGINE OIL TEMPERATURE LEFT
Z8 BULB, ENGINE OIL TEMPERATURE RIGHT
Z9 UNIT, IGNITION LEFT
Z10 UNIT, IGNITION RIGHT
Z11 AMPLIFIER, SMOKE DETECTOR
Z12 DETECTOR, BAGGAGE COMPT SMOKE
Z22 UNIT, DC CONTROL 2
Z23 UNIT, DC CONTROL 1
Z24 BULB, GEARBOX OIL TEMPERATURE
Z27 UNIT, ITT COMPENSATOR 1
Z28 UNIT, ITT COMPENSATOR 2
Z52 GYRO, RATE OF TURN
Z54 SENSOR, BATTERY TEMPERATURE
2CB1 CB, EMERGENCY BUS 1
2K3 RELAY, EMERGENCY BUS INTERLOCK
2300DS1 ANNUNCIATOR, RIGHT AFT INT/CALL
2300DS2 ANNUNCIATOR, LEFT AFT INT/CALL
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(Cont.)
3K1 RELAY, AC VOLTAGE SENSOR NO. 1
3K3 RELAY, AC BUS CONTROL
3K1P1 CONN, AC VOLTAGE SENSOR NO. 1
3K2P1 CONN, AC VOLTAGE SENSOR NO. 2
3PS1 INVERTER 1
3PS2 INVERTER 2
3PS1P1 CONN, INVERTER 1
3405DS1 INDICATOR, PILOT HORIZONTAL SITUATION
3405DS2 INDICATOR, COPILOT HORIZONTAL SITUATION
3405DS3 INDICATOR, COURSE SELECT
3405S1 SWITCH, COURSE SET
3405S3 SWITCH, PILOT NAV BEARING POINTER
3405S4 SWITCH, COPILOT NAV BEARING POINTER
3408DS1 INDICATOR, RADAR ALTIMETER
3412CP1 INDICATOR, PILOT MARKER BEACON
3412CP2 INDICATOR, COPILOT MARKER BEACON
3414DS1 INDICATOR, DME MASTER
8DS41 LIGHT, COPILOT INDICATOR
8DS42 LIGHT, PILOT INDICATOR
8K1 RELAY, EMERGENCY FLOAT/CARGO RELEASE DIM
8R15 RESISTOR, PILOT MAP LIGHT
8R16 RESISTOR, COPILOT MAP LIGHT
8S31 SWITCH, FORE AND AFT PROXIMITY
8S32 SWITCH, LATERAL PROXIMITY
9A1P1 CONN, 3 AXIS HELIPILOT COMPUTER 1
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(Cont.)
9A2P1 CONN, 3 AXIS HELIPILOT COMPUTER 2
9A3P1 CONN, HELIPILOT CONTROLLER
9S3P2 CONN, HELIPILOT CONTROLLER
9A4P1 CONN, TRIM COMPUTER CONNECTOR
9A5P1 CONN, FLIGHT DIRECTOR COMPUTER
9A6 SELECTOR, FLIGHT DIRECTOR MODE
9A7P1 CONN, ALTITUDE SENSOR
9A8P1 CONN, AIRSPEED SENSOR
9A9J1 CONN, ROLL DETENT
9A10J1 CONN, PITCH DETENT
9A11P1 CONN, AFCS INDICATOR ASSEMBLY
9B1J1 CONN, PITCH SERIES ACTUATOR SYSTEM 1
9B2J1 CONN, ROLL SERIES ACTUATOR SYSTEM 1
9B3J1 CONN, YAW SERIES ACTUATOR SYSTEM 1
9B6P1 CONN, PITCH TRIM ACTUATOR
9B7P1 CONN, ROLL TRIM ACTUATOR
9DS53 INDICATOR, FT OFF/DCPL
9J2 CONN, RIGHT AFCS
9J4 CONN, LEFT AFCS
9J5 CONN, LEFT AFCS
9K1 RELAY, RELAY
9MT4J1 CONN, PITCH SYSTEM 2 TRANSDUCER
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(Cont.)
9MT5J1 CONN, ROLL SYSTEM 2 TRANSDUCER
9MT6P1 CONN, COLLECTIVE STICK TRANSDUCER
9P2 CONN, RIGHT AFCS
9P4 CONN, LEFT AFCS
9P5 CONN, LEFT AFCS
9TB1 TB, AFCS SYSTEM 1
9TB3 TB, AFCS ACTUATOR AND TRANSDUCER
9TB4 TB, AFCS FLIGHT DIRECTOR
24J3 CONN, ROTOR TRACK
3405DS2P1 CONN, COPILOT HSI
3407L1 COMPENSATOR, DUAL REMOTE
3407MP1 GYRO, PILOT ATTITUDE
3407MP2 GYRO, COPILOT ATTITUDE
3407MP1P1 CONN, PILOT ATTITUDE GYRO
3407MP2P1 CONN, COPILOT ATTITUDE GYRO
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ELECTRICAL SYSTEM - REFERENCE DESIGNATORS [C] [D]
1. REFERENCE DESIGNATORS [C] [D] - DESCRIPTION
In this paragraph is shown the reference designators list for the helicopters codes [C] [D]. Refer to table 1.
Table 1. Reference designators (helicopters codes [C] [D])
TB14 TB, SECONDARY INSTRUMENT LIGHT
1A1 PANEL, ENGINE AND FUEL CONTROL
1A1K1 RELAY, FUEL CROSSFEED
1A1P1 CONN, ENGINE — FUEL PANEL LEFT
1A1P2 CONN, ENGINE — FUEL PANEL RIGHT
1A1S1 SWITCH, ENGINE 1 FUEL
1A1S2 SWITCH, ENGINE 2 FUEL
1A1S3 SWITCH, ENGINE 1 GOV
1A1S4 SWITCH, ENGINE 2 GOV
1A1S5 SWITCH, ENGINE 1 BOOST PUMP
1A1S6 SWITCH, ENGINE 2 BOOST PUMP
1A1S7 SWITCH, FUEL INTCON
1A1S8 SWITCH, FUEL XFEED
1A1S9 SWITCH, FUEL XFEED/INTCON
1A1S12 SWITCH, ENGINE 1 FUEL TRANS
1A1S13 SWITCH, ENGINE 2 FUEL TRANS
1A2S1 SWITCH, FIRE EXTINGUISHER
1A2S2 SWITCH, FIRE EXTINGUISHER PRESS TO TEST
1A2S5 SWITCH, BAGGAGE FIRE TEST
1A3S1 SWITCH, FIRE 1 PULL
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(Cont.)
1A4S1 SWITCH, FIRE 2 PULL HANDLE
1A5 SIGNAL CONDITIONER NO. 1
1A5P1 CONN, SIGNAL CONDITIONER NO. 1
1A6 SIGNAL CONDITIONER NO. 2
1A6P1 CONN, SIGNAL CONDITIONER NO. 2
1A7 SIGNAL CONDITIONER, MAST TORQUE
1A7P1 CONN, MAST TORQUE SIGNAL CONDITIONER
1A8 SENSOR, MAST TEMPERATURE
1A8P1 CONN, MAST TEMPERATURE SENSOR
1A9 SENSOR, TRANSMISSION MAST TORQUE
1A9P1 CONN, TRANSMISSION MAST TORQUE SENSOR
1A10 SIGNAL FILTER, TORQUE
1A10P1 CONN, TORQUE SIGNAL FILTER
1B1 TRANSMITTER, ENGINE 1 OIL PRESSURE
1B1P1 CONN, ENGINE 1 OIL PRESSURE TRANSMITTER
1B2 TRANSMITTER, ENGINE 2 OIL PRESSURE
1B2P1 CONN, ENGINE 2 OIL PRESSURE TRANSMITTER
1B3 SYNCHRO, TRANSMITTER TORQUE, ENGINE 1
1B3P1 CONN, ENGINE 1 TRANSMITTER TORQUE SYNCHRO
1B4 SYNCHRO, TRANSMITTER TORQUE, ENGINE 2
1B4P1 CONN, ENGINE 2 TRANSMITTER TORQUE SYNCHRO
1B5 TRANSMITTER, TRANSMISSION OIL PRESSURE
1B5P1 CONN, TRANSMISSION OIL PRESSURE TRANSMITTER
1B6 TRANSMITTER, C BOX OIL PRESSURE
1B6P1 CONN, C BOX OIL PRESSURE TRANSMITTER
1B7 ACTUATOR, GOVERNOR RPM
1B8 TRANSMITTER, FUEL PRESSURE, ENGINE 2
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(Cont.)
1B8P1 CONN, ENGINE 2 FUEL PRESSURE TRANSMITTER
1B9 TRANSMITTER, FUEL PRESSURE, ENGINE 1
1B9P1 CONN, ENGINE 1 FUEL PRESSURE TRANSMITTER
1B10 VALVE, FUEL CROSSFEED
1B10P1 CONN, FUEL CROSSFEED VALVE
1B12 VALVE, AFT FUEL INTERCONNECT
1B12P1 CONN, AFT FUEL INTERCONNECT VALVE MOTOR
1B13 MOTOR, NO. 1 FUEL SHUTOFF VALVE
1B13P1 CONN, NO. 1 FUEL SHUTOFF VALVE MOTOR
1B14 MOTOR, NO. 2 FUEL SHUTOFF VALVE
1B14P1 CONN, NO. 2 FUEL SHUTOFF VALVE MOTOR
1B15 ACTUATOR NO. 1, PARTICLE SEPARATOR
1B15J1 CONN, PARTICLE SEPARATOR ACTUATOR NO. 1
1B15P1 CONN, PARTICLE SEPARATOR ACTUATOR NO. 1
1B16 ACTUATOR NO. 2 PARTICLE SEPARATOR
1B16J1 CONN, PARTICLE SEPARATOR ACTUATOR NO. 2
1B16P1 CONN, PARTICLE SEPARATOR ACTUATOR NO. 2
1B17 PUMP, LEFT LOWER FORWARD CELL TRANSFER
1B18 PUMP, RIGHT LOWER FORWARD CELL TRANSFER
1B19 PUMP, NO. 1 (LEFT) BOOST
1B20 PUMP, NO. 2 (RIGHT) BOOST
1B22 ACTUATOR, ENGINE 2 RPM GOVERNOR
1CB36 CB, XMSN CHIP POSN IND
1CB50 CB, MAST TORQUE
1CR3 DIODE, IDLE STOP
1CR4 DIODE, IDLE STOP
1G1 GENERATOR, POWER TURBINE 1 TACH
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(Cont.)
1G1P1 CONN, POWER TURBINE 1 TACH GENERATOR
1G2 GENERATOR, POWER TURBINE 2 TACH
1G2P1 CONN, POWER TURBINE 2 TACH GENERATOR
1G3 GENERATOR, GAS PRODUCER 1 TACH
1G3P1 CONN, GAS PRODUCER 1 TACH GENERATOR
1G4 GENERATOR, GAS PRODUCER 2 TACH
1G4P1 CONN, GAS PRODUCER 2 TACH GENERATOR
1G7 GENERATOR, ROTOR TACH
1G7P1 CONN, ROTOR TACH GENERATOR
1HR1 HEATER, FUEL CONTROL NO. 1
1HR1P1 CONN, FUEL CONTROL NO. 1 HEATER
1HR2 HEATER, FUEL CONTROL NO. 2
1HR2P1 CONN, FUEL CONTROL NO. 2 HEATER
1J1 CONN, ENGINE 1 FORWARD COMPARTMENT
1J2 CONN, ENGINE 2 FORWARD COMPARTMENT
1J3 CONN, CENTER ENGINE COMPARTMENT
1J4 CONN, CENTER ENGINE COMPARTMENT
1J5 CONN, ENGINE 1 AFT COMPARTMENT
1J6 CONN, ENGINE 2 AFT COMPARTMENT
1J7 CONN, PYLON LEFT
1J8 CONN, PYLON RIGHT
1J9 CONN, TRANSMISSION
1J10 CONN, AUXILIARY FUEL
1J11 CONN, FIRE DETECT — EXT 1 AFT ENGINE COMPARTMENT
1J12 CONN, FIRE DETECT — EXT 2 AFT ENGINE COMPARTMENT
1J13 CONN, AUXILIARY FUEL
1K1 RELAY, START CONTROL NO. 1
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(Cont.)
1K2 RELAY, START CONTROL NO. 2
1K3 RELAY, IDLE STOP DELAY ENG 1
1K3P1 CONN, IDLE STOP DELAY 1 RELAY
1K4 RELAY, IDLE STOP DELAY ENG 2
1K4P1 CONN, IDLE STOP DELAY 2 RELAY
1K5 RELAY, PARTICLE SEPARATOR 1
1K6 RELAY, PARTICLE SEPARATOR 2
1K7 RELAY, HOURMETER
1K8 RELAY, FUEL TRANSFER 2
1K9 RELAY, FUEL TRANSFER 1
1K10 RELAY, INTERCONNECT TEST 2
1K11 RELAY, INTERCONNECT TEST 1
1K12 RELAY, TRANSFER TEST 2
1K13 RELAY, TRANSFER TEST 1
1K14 RELAY, FUEL INTERCONNECT NORMAL
1K15 RELAY, FUEL INTERCONNECT CLOSE
1K16 RELAY, FUEL INTERCONNECT OPEN
1L1 SOLENOID, FUEL CONTROL VALVE NO. 1
1L1P1 CONN, FUEL CONTROL VALVE NO. 1 SOLENOID
1L2 SOLENOID, FUEL CONTROL VALVE NO. 2
1L2P1 CONN, FUEL CONTROL VALVE NO. 2 SOLENOID
1L5 SOLENOID, IDLE STOP 1
1L6 SOLENOID, IDLE STOP 2
1L7 SOLENOID, LOWER LEFT MAIN CELL SUMP DRAIN VALVE
1L8 SOLENOID, LOWER RIGHT MAIN
1A1S7 CELL SUMP DRAIN VALVE
1MT1 TRANSDUCER, ENGINE 1 TORQUE
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(Cont.)
1MT1P1 CONN, ENGINE 1 TORQUE TRANSDUCER
1MT2 TRANSDUCER, ENGINE 2 TORQUE
1MT2P1 CONN, ENGINE 2 TORQUE TRANSDUCER
1M1 INDICATOR, ENGINE 1 OIL TEMPERATURE AND PRESSURE
1M2 INDICATOR, ENGINE 2 OIL TEMPERATURE AND PRESSURE
1M3 INDICATOR, ENGINE 1 GAS PRODUCER TACHOMETER
1M4 INDICATOR, ENGINE 2 GAS PRODUCER TACHOMETER
1M5 INDICATOR, TRANSMISSION OIL TEMPERATURE AND PRESSURE
1M6 INDICATOR, COMBINING GEARBOX OIL PRESSURE AND

TEMPERATURE
1M7 INDICATOR, FUEL QUANTITY
1M8 INDICATOR, ENGINE 2 FUEL PRESSURE
1M9 INDICATOR, ENGINE 1 FUEL PRESSURE
1M10 INDICATOR, ENGINE 2 INTERTURBINE TEMPERATURE
1M11 INDICATOR, ENGINE 1 INTERTURBINE TEMPERATURE
1M14 HOURMETER
1P1 CONN, ENGINE 1 FORWARD COMPARTMENT
1P2 CONN, ENGINE 2 FORWARD COMPARTMENT
1P3 CONN, CENTER ENGINE COMPARTMENT
1P4 CONN, CENTER ENGINE COMPARTMENT
1P5 CONN, ENGINE 1 AFT COMPARTMENT
1P6 CONN, ENGINE 2 AFT COMPARTMENT
1P7 CONN, PYLON LEFT
1P8 CONN, PYLON RIGHT
1P9 CONN, TRANSMISSION
1P11 CONN, FIRE DETECT — EXT 1 AFT ENG COMPARTMENT
1P12 CONN, FIRE DETECT — EXT 2 AFT ENG COMPARTMENT
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(Cont.)
1S1 SWITCH, SUMP DRAIN VALVE 1
1S2 SWITCH, SUMP DRAIN VALVE 2
1S4 SWITCH, FUEL QUANTITY SELECT
1S5 SWITCH, NO. 1 FUEL PRESSURE
1S6 SWITCH, NO. 2 FUEL PRESSURE
1S7 SWITCH, DIGITS TEST
1TB1 TB, FUEL SYSTEM
1XK7 SOCKET, HOURMETER
1Z1 BULB, ENGINE 1 OIL TEMPERATURE
1Z1P1 CONN, ENGINE 1 OIL TEMPERATURE BULB
1Z2 BULB, ENGINE 2 OIL TEMPERATURE
1Z2P1 CONN, ENGINE 2 OIL TEMPERATURE BULB
1Z5 BULB, TRANSMISSION OIL TEMPERATURE
1Z5P1 CONN, TRANSMISSION OIL TEMPERATURE BULB
1Z6 BULB, COMBINING GEARBOX OIL TEMPERATURE
1Z6P1 CONN, COMBINING GEARBOX OIL TEMPERATURE
1Z9 UNIT, IGNITION, ENGINE 1
1Z9P1 CONN, ENGINE 1 IGNITION UNIT
1Z10 UNIT, IGNITION, ENGINE 2
1Z10P1 CONN, ENGINE 2 IGNITION UNIT
1Z11 UNIT, ITT COMPENSATOR 1
1Z11P1 CONN, ITT COMPENSATOR 1 UNIT
1Z12 UNIT, ITT COMPENSATOR 2
1Z14TB1 TB, RIGHT HAND FUEL CELL
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(Cont.)
1Z15P1 CONN, LEFT HAND AFT FUEL QUANTITY TANK UNIT
1Z15TB1 TB, LEFT HAND FUEL CELL
1Z16P1 CONN, RIGHT HAND AFT FUEL QUANTITY TANK UNIT
1Z17P1 CONN, LEFT HAND UPPER OUTER FUEL QUANTITY TANK UNIT
1Z18P1 CONN, RIGHT HAND UPPER OUTER FUEL QUANTITY TANK UNIT
2BT1 BATTERY
2BT1P1 BATTERY DISCONNECT
2BT1P2 CONN, BATTERY
2CB13 CB, 28 V DC AUX RECPT
2CB16 CB, NO. 2 BUS BATTERY SWITCH
2CB17 CB, NO. 1 BUS BATTERY SWITCH
2CR23 DIODE, BATTERY INTERLOCK
2CR24 DIODE, START RELAY 2
2CR25 DIODE, START RELAY 1
2CR28 DIODE, EXTERNAL POWER RELAY
2CR33 DIODE, EMERGENCY DC BUS 1
2CR34 DIODE, EMERGENCY DC BUS 2
2G1 STARTER-GENERATOR, ENGINE 1
2G2 STARTER-GENERATOR, ENGINE 2
2J1 RECPT, EXTERNAL POWER
2J2 CONN, 28 V DC AUX RECPT
2J3 CONN, ROOF GENERATOR 1
2J4 CONN, ROOF GENERATOR 2
2K1 RELAY, EXTERNAL POWER
2K2 RELAY, NONESSENTIAL BUS 2
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(Cont.)
2K3 RELAY, NO. 1 GENERATOR
2K4 RELAY, NO. 2 GENERATOR
2K5 RELAY, NO. 1 START-GEN
2K6 RELAY, NO. 2 START-GEN
2K7 RELAY, NO. 1 BUS/BAT CONTROL
2K8 RELAY, NO. 2 BUS/BAT CONTROL
2K9 RELAY, NONESSENTIAL BUS
2K12 RELAY, BATTERY INTERLOCK
2K16 RELAY, NO. 2 EMERGENCY BUS POWER
2K17 RELAY, NO. 1 EMERGENCY BUS POWER
2M1 INDICATOR, DUAL AMMETER
2P3 CONN, ROOF GENERATOR 1
2P4 CONN, ROOF GENERATOR 2
2R1 SHUNT, NO. 1 GENERATOR
2R2 SHUNT, NO. 2 GENERATOR
2R7 RESISTOR, TRANSFORMER
2R8 RESISTOR, TRANSFORMER
2S5 SENSOR, FEEDER POWER
2S6 SENSOR, FEEDER POWER
2S11 AUXILIARY POWER START SWITCH
2T1 XFMR, NO. 1 CURRENT SENSING
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(Cont.)
2TB1 TB, EMERGENCY BUS INTERLOCK
2TB2 TB, NONESSENTIAL
2Z1 PANEL, NO. 1 DC CONTROL
2Z1P1 CONN, DC CONTROL UNIT 1
2Z2 PANEL, NO. 2 DC CONTROL
2Z2P1 CONN, DC CONTROL UNIT 2
3CB11 CB, INVERTER 1 EMERGENCY INTERLOCK
3CB12 CB, INVERTER 1 EMERGENCY INTERLOCK
3K1P1 CONN, AC VOLTAGE SENSOR RELAY NO. 1
3K2P1 CONN, AC VOLTAGE SENSOR RELAY NO. 2
3K4 RELAY, INVERTER 2 INTERLOCK
3K5 RELAY, INVERTER 1 EMERGENCY BUS
3PS1 INVERTER 1
3PS2 PRODUCER
4A1J1 CONN, PILOT CYCLIC STICK
4A2J1 CONN, PILOT COLLECTIVE
4M2 INDICATOR, DUAL VOLTMETER 2
4M3 INDICATOR, PILOT ALTIMETER
4M4 INDICATOR, PILOT VERTICAL SPEED
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(Cont.)
4M5 CLOCK, PILOT
4M6 INDICATOR, PILOT STANDBY COMPASS
4M6P1 CONN, PILOT STANDBY COMPASS
4M7 INDICATOR, PILOT TRIPLE TACHOMETER
4M8 INDICATOR, PILOT DUAL TORQUE
4M10 INDICATOR, PILOT ATTITUDE
4M11 INDICATOR, PILOT AIRSPEED
4TB1 TB, RIGHT COCKPIT LIGHT
4Z1 GYRO, PILOT RATE SWITCHING
4Z1P1 CONN, PILOT RATE GYRO
5A1J1 CONN, COPILOT CYCLIC STICK
5A2J1 CONN, COPILOT COLLECTIVE
5M1 INDICATOR, COPILOT AIRSPEED
5M1P1 CONN, COPILOT AIRSPEED INDICATOR
5M2 INDICATOR, DUAL VOLTMETER 1
5M3 INDICATOR, COPILOT ALTIMETER
5M3P1 CONN, COPILOT ALTIMETER
5M4 INDICATOR, COPILOT VERTICAL SPEED
5M4P1 CONN, COPILOT VERTICAL SPEED INDICATOR
5M5 CLOCK, COPILOT
5M6P1 CONN, COPILOT STANDBY COMPASS
5M7 INDICATOR, COPILOT TRIPLE TACHOMETER
5M7P1 CONN, COPILOT TRIPLE TACHOMETER
5M8 INDICATOR, COPILOT DUAL TORQUE
5M8P1 CONN, COPILOT DUAL TORQUE INDICATOR
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(Cont.)
5M8P2 CONN, COPILOT DUAL TORQUE INDICATOR
5M9P1 CONN, COPILOT ATTITUDE INDICATOR
5TB1 TB, LEFT COCKPIT LIGHT
5Z1P1 CONN, COPILOT RATE GYRO
5Z18A1 PANEL, MASTER CAUTION
8A1P2 CONN, MASTER CAUTION PANEL
8CR8 DIODE, TRANSMISSION CHIP
8CR12 DIODE, SEARCHLIGHT
8DS1 LIGHT, ENG 1 OUT
8DS2 LIGHT ENG 2 OUT
8DS3 LIGHT, ANTI-COLLISION, LOWER
8DS4 LIGHT, PILOT MASTER CAUTION
8DS5 LIGHT, COPILOT MASTER CAUTION
8DS5P1 CONN, COPILOT MASTER CAUTION LIGHT
8DS6 LIGHT, PILOT RPM CAUTION
8DS7 LIGHT, COPILOT RPM CAUTION
8DS7P1 CONN, COPILOT RPM CAUTION LIGHT
8DS8 LIGHT, ANTICOLLISION, UPPER
8DS8P1 CONN, UPPER ANTICOLLISION LIGHT
8DS9 LIGHT, COPILOT UTILITY
8DS10 LIGHT, PILOT UTILITY
8DS11 LIGHT, OUTSIDE AIR TEMPERATURE
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(Cont.)
8DS12 LIGHT, SEARCH
8DS13 LIGHT, LANDING
8DS15 LIGHT, LEFT POSITION, UPPER
8DS16 LIGHT, RIGHT POSITION, LOWER
8DS17 LIGHT, LEFT POSITION, LOWER
8DS19 LIGHT, BAGGAGE COMPARTMENT
8DS20 LIGHT, BAGGAGE COMPARTMENT
8DS21 LIGHT, BAGGAGE FIRE TEST
8DS27 LIGHT, LEFT TAIL
8DS29 LIGHT, LEFT UTILITY
8DS30 LIGHT, RIGHT UTILITY
8DS31 LIGHT, LEFT DOME
8DS32 LIGHT, CENTER DOME
8DS33 LIGHT, RIGHT DOME
8DS34 INDICATOR, SUMP, XMSN CHIP
8DS35 INDICATOR PLANETARY, XMSN CHIP
8DS36 INDICATOR, UPPER MAST, XMSN CHIP
8DS41 LIGHT, COPILOT INDICATOR
8DS42 LIGHT, PILOT INDICATOR
8DS44 LIGHT, PILOT OVERTORQUE WARNING
8DS45 LIGHT, COPILOT OVERTORQUE WARNING
8E1 DETECTOR, TRANSMISSION MAGNETIC CHIP
8E2 DETECTOR, ENGINE GEARBOX MAGNETIC CHIP
8E2P1 CONN, ENGINE GEARBOX MAGNETIC CHIP DETECTOR
8E3 DETECTOR, ENGINE 1 FORWARD MAGNETIC CHIP
8E3P1 CONN, ENGINE 1 FORWARD MAGNETIC CHIP DETECTOR
8E4 DETECTOR, ENGINE 2 FORWARD MAGNETIC CHIP
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(Cont.)
8E4P1 CONN, ENGINE 2 FORWARD MAGNETIC CHIP DETECTOR
8E5 DETECTOR, ENGINE 1 AFT MAGNETIC CHIP
8E5P1 CONN, ENGINE 1 AFT MAGNETIC CHIP DETECTOR
8E6 DETECTOR, ENGINE 2 AFT MAGNETIC CHIP
8E6P1 CONN, ENGINE 2 AFT MAGNETIC CHIP DETECTOR
8E7 DETECTOR, 42 GEARBOX MAGNETIC CHIP
8E8 DETECTOR, 90 GEARBOX MAGNETIC CHIP
8E9 DETECTOR, TRANSMISSION PLANETARY MAGNETIC CHIP
8E10 DETECTOR, TRANSMISSION UPPER MAST MAGNETIC CHIP
8E11 MONITOR/DETECTOR, TRANSMISSION OIL
8E11P1 CONN, TRANSMISSION OIL MONITOR/DETECTOR
8J1 CONN, LEFT FIRE DETECT LEFT FWD ENG COMPT
8J2 CONN, RIGHT FIRE DETECT RIGHT FWD ENG COMPT
8J3 CONN, RIGHT FIRE DETECT LEFT FWD ENG COMPT
8J4 CONN, LEFT FIRE DETECT RIGHT FWD ENG COMPT
8J5 CONN, ANTICOLLISION LIGHT, UPPER CONN, TAILBOOM
8J7 CONN, PYLON LEFT
8K1 RELAY, CAUTION PANEL FAIL
8K2 RELAY, EMERGENCY FLOAT/CARGO RELEASE DIM
8K3 RELAY, AFCS CAUTION LIGHT
8P1 CONN, LEFT FIRE DETECT LEFT FWD ENG COMPT
8P2 CONN, RIGHT FIRE DETECT RIGHT FWD ENG COMPT
8P3 CONN, RIGHT FIRE DETECT LEFT FWD ENG COMPT
8P4 CONN, LEFT FIRE DETECT RIGHT FWD ENG COMPT
8P7 CONN, PYLON LEFT
8PS1 POWER SUPPLY, 5 V DC COPILOT INSTR LT
8PS1P1 CONN, 5-VOLT COPILOT INSTRUMENT POWER SUPPLY
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(Cont.)
8PS2 POWER SUPPLY, 5 V DC ENG INSTR LT
8PS2P1 CONN, 5-VOLT ENGINE INSTRUMENT POWER SUPPLY
8PS3 POWER SUPPLY, 5 V DC PILOT INSTR LT
8PS3P1 CONN, 5-VOLT PILOT INSTRUMENT POWER SUPPLY
8PS4 POWER SUPPLY, 5 V DC ENG INSTR LT
8PS4P1 CONN, 5 VOLT ENGINE INSTRUMENT POWER SUPPLY
8Q1 TRANSISTOR, 28 V DC CONSOLE LTS
8Q2 TRANSISTOR, 28 V DC CONSOLE LTS
8Q3 TRANSISTOR, 28 V DC PEDESTAL LTS
8Q4 TRANSISTOR, 28 V DC SEC INST LTS
8R15 RESISTOR, PILOT MAP LIGHT
8R16 RESISTOR, COPILOT MAP LIGHT
8S1 SWITCH, TRANSMISSION OIL TEMPERATURE
8S1P1 CONN, TRANSMISSION OIL TEMPERATURE SWITCH
8S2 SWITCH, TRANSMISSION OIL PRESSURE
8S2P1 CONN, TRANSMISSION OIL PRESSURE SWITCH
8S3 SWITCH, LEFT PASSENGER DOOR
8S4 SWITCH, RIGHT PASSENGER DOOR
8S5 SWITCH, ENGINE 1 OIL PRESSURE
8S5P1 CONN, ENGINE 1 OIL PRESSURE SWITCH
8S6 SWITCH, ENGINE 2 OIL PRESSURE
8S6P1 CONN, ENGINE 2 OIL PRESSURE SWITCH
8S7 SWITCH, BAGGAGE COMPARTMENT DOOR
8S8 SWITCH, COMBINING GEARBOX OIL PRESSURE
8S8P1 CONN, COMBINING GEARBOX OIL PRESSURE SWITCH
8S9 SWITCH, FUEL 1 DIFFERENTIAL PRESSURE
8S9P1 CONN, FUEL 1 DIFFERENTIAL PRESSURE SWITCH
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(Cont.)
8S10 SWITCH, FUEL 2 DIFFERENTIAL PRESSURE
8S10P1 CONN, FUEL 2 DIFFERENTIAL PRESSURE SWITCH
8S11 SWITCH, COMBINING GEARBOX OIL TEMPERATURE
8S11P1 CONN, COMBINING GEARBOX OIL TEMPERATURE SWITCH
8S12 SWITCH, EXTERNAL POWER
8S13P1 CONN, NO. 1 HYDRAULIC TEMPERATURE SWITCH
8S14P1 CONN, NO. 2 HYDRAULIC TEMPERATURE SWITCH
8S15 SWITCH, NO. 1 HYDRAULIC PRESSURE
8S15P1 CONN, NO. 1 HYDRAULIC PRESSURE SWITCH
8S16 SWITCH, NO. 2 HYDRAULIC PRESSURE
8S16P1 CONN, NO. 2 HYDRAULIC PRESSURE SWITCH
8S17 SWITCH, NO. 1 GENERATOR OVERHEAT
8S31 SWITCH, FORE AND AFT PROXIMITY
8S32 SWITCH, LATERAL PROXIMITY
8TB1 TB, PILOT LIGHTING
8TB2 TB, RPM WARNING
8TB3 TB, 5 VOLT LIGHT POWER
8TB4 TB, AFT ROOF LIGHT
8TB8 TB, TRANSMISSION CHIP DETECTOR
8TB9 TB, FIRE DETECTOR TEST
8TB10 TB, PROXIMITY SWITCH
8XK1 SOCKET, HOURMETER
8Z1 DETECTOR, RPM LIMIT
8Z1P1 CONN, RPM LIMIT DETECTOR
8Z1P2 CONN, RPM LIMIT DETECTOR
8Z2 DETEC, NO. 2 CONTROL FIRE
8Z2P1 CONN, RIGHT FIRE DETECTOR AMPLIFIER
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(Cont.)
8Z3 DETEC, NO. 1 CONTROL FIRE
8Z3P1 CONN, LEFT FIRE DETECTOR AMPLIFIER
8Z4 AMPLIFIER, SMOKE DETECTOR CONTROL
8Z4P1 CONN, SMOKE DETECTOR AMPLIFIER
8Z4P2 CONN, SMOKE DETECTOR AMPLIFIER
8Z5 DETECTOR, BAGGAGE COMPT SMOKE
8Z5J1 CONN, BAGGAGE COMPT SMOKE DETECTOR
8Z5P1 CONN, BAGGAGE COMPT SMOKE DETECTOR
8Z8P1 CONN, RIGHT FIRE DETECT AFT ENG COMPARTMENT
8Z8P2 CONN, LEFT FIRE DETECT AFT ENG COMPARTMENT
8Z9P1 CONN, RIGHT FIRE DETECT AFT ENG COMPARTMENT
8Z9P2 CONN, LEFT FIRE DETECT AFT ENG COMPARTMENT
8Z10 SENSOR, BATTERY TEMPERATURE
8Z10P1 CONN, BATTERY TEMPERATURE SENSOR
9A1 COMPUTER, 3 AXIS HELIPILOT NO. 1
9A2 COMPUTER, 3 AXIS HELIPILOT NO. 2
9A4 COMPUTER, TRIM
9A4P1 CONN, TRIM COMPUTER
9A5P1 CONN, FLIGHT DIRECTOR COMPUTER
9A6 SELECTOR, FLIGHT DIRECTOR MODE
9A7P1 CONN, ALTITUDE SENSOR
9A8P1 CONN, AIRSPEED SENSOR
9A9J1 CONN, ROLL DETENT
9A10J1 CONN, PITCH DETENT
9A11P1 CONN, AFCS INDICATOR ASSEMBLY
96-24-02
Page 17
E-AB412-PT6T-2
(Cont.)
9A14 AMPLIFIER, ISOLATION
9A15 AMPLIFIER, ISOLATION
9B3J1 CONN, YAW SERIES ACTUATOR SYSTEM 1
9B6 ACTUATOR, PITCH TRIM
9B7 ACTUATOR, ROLL TRIM
9B8P1 CONN, HYDRAULIC PRESSURE TRANSMITTER NO. 2
9B9P1 CONN, HYDRAULIC PRESSURE TRANSMITTER NO. 1
9C1 CAPACITOR, PITCH TRIM
9C2 CAPACITOR, ROLL TRIM
9DS1 INDICATOR, HYDRAULIC FILTER CLOG
9J4 CONN, LEFT AFCS
9J5 CONN, LEFT AFCS
9K1 RELAY, HYDRAULIC INTERLOCK
9L1 SOLENOID, HYDRAULIC BYPASS 1
9L1P1 CONN, HYDRAULIC BYPASS 1 SOLENOID
96-24-02
Page 18
E-AB412-PT6T-2
(Cont.)
9L2 SOLENOID, HYDRAULIC BYPASS 2
9L2P1 CONN, HYDRAULIC BYPASS 2 SOLENOID
9L8 SOLENOID, MAGNETIC BRAKE ANTITORQUE
9L8J1 CONN, MAGNETIC BRAKE ANTITORQUE SOLENOID
9L8P1 CONN, MAGNETIC BRAKE ANTITORQUE SOLENOID
9M1 INDICATOR, NO. 1 HYDRAULIC PRESSURE AND TEMPERATURE
9M2 INDICATOR, NO. 2 HYDRAULIC PRESSURE AND TEMPERATURE
9MT1J1 CONN, PITCH SYSTEM 1 TRANSFER
9MT3J1 CONN, YAW SYSTEM 1 TRANSDUCER
9MT4J1 CONN, PITCH SYSTEM 2 TRANSDUCER
9MT6P1 CONN, COLLECTIVE STICK TRANSDUCER
9P4 CONN, LEFT AFCS
9P5 CONN, LEFT AFCS
9S1 SWITCH, HYDRAULIC 1 FILTER
9S1P1 CONN, HYDRAULIC 1 FILTER SWITCH
9S2 SWITCH, HYDRAULIC 2 FILTER SWITCH
9S3 SWITCH, PILOT GYRO (VG FAST) ERECT
9S4 SWITCH, COPILOT GYRO (VG FAST) ERECT
9TB4 TB, AFCS FLIGHT DIRECTOR
96-24-02
Page 19
E-AB412-PT6T-2
(Cont.)
9Z1P1 CONN, HYDRAULIC 1 TEMPERATURE BULB
9Z2P1 CONN, HYDRAULIC 2 TEMPERATURE BULB
10A1 PANEL, RESISTOR
10A2 PANEL, RESISTOR
10B1 MOTOR, COPILOT WINDSHIELD WIPER
10B1P1 CONN, COPILOT WINDSHIELD WIPER MOTOR
10B2 MOTOR, PILOT WINDSHIELD WIPER
10B2P1 CONN, PILOT WINDSHIELD WIPER MOTOR
10B5P1 CONN, CABIN TEMPERATURE MOTOR
10HR1P1 CONN, COPILOT PITOT HEATER
10HR2P1 CONN, PILOT PITOT HEATER PORT
10K1 RELAY, HEATER
10K1P1 CONN, HEATER RELAY
10L2P1 CONN, DOOR POST OUTLET VALVE
10L3 SOLENOID, BLEED AIR VALVE 1
10L3P1 CONN, BLEED AIR VALVE 1 SOLENOID
10L4 SOLENOID, BLEED AIR VALVE 2
10L4P1 CONN, BLEED AIR VALVE 2 SOLENOID
10L5P1 CONN, AFT OUTLET VALVE
10S1 SWITCH, AFT OUTLET LIMIT
10S2 SWITCH, OVERHEAT, HEATER AIR LINE
10S3 SWITCH, HEATER OVERHEAT
10Z1P1 CONN, CABIN TEMPERATURE CONTROLLER
22J1 CONN, LEFT NOSE
22J2 CONN, RIGHT NOSE
96-24-02
Page 20
E-AB412-PT6T-2
(Cont.)
22J7 CONN, LEFT BEAM
22J8 CONN, RIGHT BEAM
22J10 CONN, RIGHT BEAM
22J11 CONN, LEFT DOOR POST
22J12 CONN, RIGHT WINDSHIELD POST
22J14 CONN, LEFT WINDSHIELD POST
22J16 CONN, RIGHT INSTRUMENT PANEL
22J17 CONN, LEFT INSTRUMENT PANEL
22P8 CONN, RIGHT BEAM
22P16 CONN, RIGHT INSTRUMENT PANEL
22P17 CONN, LEFT INSTRUMENT PANEL
22WT1 MODULE, GROUND
22WT8 MODULE, DC-AC GROUND
96-24-02
Page 21
E-AB412-PT6T-2
(Cont.)
22WT9 MODULE, DC-AC GROUND
22WT10 MODULE, 5 VOLT LIGHT GROUND
2301DS1 ANNUNCIATOR, COPILOT AFT INT/CALL/ON
2301DS2 ANNUNCIATOR RIGHT AFT INT/CALL/ON
24A1 PANEL, MISCELLANEOUS CONTROL
24A1P1 CONN, MISCELLANEOUS CONTROL PANEL
24A1P2 CONN, MISCELLANEOUS CONTROL PANEL
24A6J1 CONN, BALANCER
24DS1 LIGHT, CARGO RELEASE ARM
24J2 CONN, STEP ACTUATOR
24K1 RELAY, CARGO HOOK RELEASE
24K10 RELAY, EMERGENCY FLOAT ARM
24S10 SWITCH, WIPERS PILOT
24CR10 DIODE
24CR4 DIODE
24CR5 DIODE
24CR6 DIODE
24CR7 DIODE
24CR8 DIODE
24CR9 DIODE
24HR1 LH WSHLD HTR
24HR2 RH WSHLD HTR
24K6 RELAY
96-24-02
Page 22
E-AB412-PT6T-2
(Cont.)
24K7 RELAY
24K8 RELAY
24K9 RELAY
24R1 RESISTOR
24S11 SWITCH, WSHLD HEAT
24S12 SWITCH, WSHLD HEAT
24TB1 TB
24TB2 TB
24TB3 TB
24Z2J1 CONN, CARGO SLING
24XK8 CONN, RELAY
24XK9 CONN, RELAY
3405DS1 INDICATOR, COPILOT HORIZONTAL SITUATION
3405DS1P1 CONN, COPILOT HORIZONTAL SITUATION INDICATOR
3405DS2 INDICATOR, PILOT HORIZONTAL SITUATION
3405DS3 INDICATOR, COURSE SELECT
3405S1 SWITCH, COPILOT NAV BEARING POINTER
3405S2 SWITCH, PILOT NAV BEARING POINTER
3405S3 SWITCH, COURSE SET
3407L1 COMPENSATOR, DUAL REMOTE COMPASS
3407MP1 SENSOR, THREE-AXIS REFERENCE NO. 1 (COPILOT)
3407MP1P1 CONN, SENSOR, THREE-AXIS REFERENCE NO. 1 (COPILOT)
3407MP1P2 CONN, SENSOR, THREE-AXIS REFERENCE NO. 1 (COPILOT)
3407MP2 SENSOR, THREE-AXIS REFERENCE NO. 2 (PILOT)
3407MP2P1 CONN, SENSOR, THREE-AXIS REFERENCE NO. 2 (PILOT)
3407MP2P2 CONN, SENSOR, THREE-AXIS REFERENCE NO. 2 (PILOT)
3408DS1 INDICATOR, RADAR ALTIMETER
96-24-02
Page 23
E-AB412-PT6T-2
(Cont.)
3414DS1 INDICATOR, COPILOT MARKER BEACON
3414DS2 INDICATOR, PILOT MARKER BEACON
96-24-02
Page 24
E-AB412-PT6T-2
96-24-03 ELECTRICAL SYSTEM - PRIMARY AND SECONDARY ELECTRICAL POWER SYSTEMS
96-24-03
ELECTRICAL SYSTEM - PRIMARY AND SECONDARY ELECTRICAL
POWER SYSTEMS
1. PRIMARY AND SECONDARY ELECTRICAL POWER SYSTEMS - DESCRIPTION
The Model 412 helicopter electrical power system provides 28 volts dc, 115 volts ac and 26 volts ac for helicopter electrical
equipment, avionics systems and instruments. It also provides electrical engine starting capability and emergency battery
power.
Primary 28 Vdc electrical power is supplied by two 30 volt, 200 ampere starter-generators, one mounted on each engine.
Output voltage of each generator is monitored and regulated by a dc control unit. Dc control units provide overvoltage and
reverse current protection and control paralleled generator operation so the starter-generators share total load requirements
within 20 amperes. Each generator supplies power to a main dc bus and two interconnected nonessential buses. Each main
dc bus, in turn, serves as a feeder for the two essential dc buses and two emergency buses.
Electrical separation between main buses and between starter-generators is accomplished through use of circuit breakers and
isolation diodes. If one starter-generator or engine should fail, both nonessential buses are automatically dropped and all
essential and emergency loads are supplied by the remaining starter-generator. An override switch is installed so the pilot
may, at his discretion, manually restore power to the nonessential buses.
This arrangement allows automatic dc load shedding for 30 minutes powered by 40 ampere-hour battery. Should a flight of
longer duration be required on battery only, the pilot may set NORMAL EMERG LOAD switch to EMERG LOAD position.
This provides load shedding for a 76 minute flight.
Secondary power is supplied by two identical 450 volt-ampere,115/26 volt, 400 Hz, single phase, solid state inverters. One
inverter is energized by each essential dc bus. Inverter No. 1 supplies power to 115 Vac and 26 Vac buses 1 and 2, and
Inverter No. 2 supplies power to 115 Vac and 26 Vac bus 3. The inverters are completely independent of each other. If an
inverter fails, all ac loads are energized by the remaining inverter.
26 Vac and 115 Vac emergency power is supplied by inverters No. 1 and No. 2 when inverter switches are in the ON position.
Starting power is normally supplied by a 24 volt battery. An external power receptacle located in the nose of the helicopter
allows an external power source to be used for engine starting and ground checkout operations.
NOTE
A simplified single line schematic diagram of the electrical power system, showing
interconnection of components, is found in this chapter.
96-24-03
Page 1
E-AB412-PT6T-2
96-24-03
Page 2
E-AB412-PT6T-2
96-24-04
ELECTRICAL SYSTEM - POWER SOURCE COMPONENT DATA
1. POWER SOURCE COMPONENT DATA - DESCRIPTION
The individual power-system components and their respective ratings are shown in table 1.
Table 1. Power source components data
STARTER
ITEM BATTERY INVERTER
GENERATOR
No. Units 2 1 2
Rating 200 Amps* 40 Ah** 450 VA
Overload capacity 300A (5 sec), 225A (2 min) - 675 VA (5 min)
Voltage 30 Vdc 24 Vdc 115/26 Vac
Manufacturer - Marathon -
Voltage Reg. 3.6 V MAX - ± 4.3 V
Frequency/Regulation - - 400 Hz ± 1%
Power Factor - - 9 lead to 8 lag.
* Derated to 150 amperes in this installation.

** Based on 1 hour discharge rate.
96-24-04
Page 1
E-AB412-PT6T-2
96-24-04
Page 2
E-AB412-PT6T-2
96-24-05 ELECTRICAL SYSTEM - EMERGENCY DC POWER
96-24-05
ELECTRICAL SYSTEM - EMERGENCY DC POWER
1. EMERGENCY DC POWER - DESCRIPTION
If a starter-generator or engine fails, the remaining starter-generator can supply all essential dc loads. The 24 volt, 40
ampere-hour battery provides a second source of emergency power if both starter-generators fail.
96-24-05
Page 1
E-AB412-PT6T-2
96-24-05
Page 2
E-AB412-PT6T-2
96-24-06 ELECTRICAL SYSTEM - EMERGENCY AC POWER
96-24-06
ELECTRICAL SYSTEM - EMERGENCY AC POWER
1. EMERGENCY AC POWER - DESCRIPTION
If an inverter fails, all ac loads are powered by the remaining inverter.
96-24-06
Page 1
E-AB412-PT6T-2
96-24-06
Page 2
E-AB412-PT6T-2
96-24-07 ELECTRICAL SYSTEM - OPERATIONAL CHECKS
96-24-07
ELECTRICAL SYSTEM - OPERATIONAL CHECKS
1. OPERATIONAL CHECKS - DESCRIPTION
Throughout this chapter, when performing operational checks, external power should be utilized whenever possible.
Performing operational checks on battery power may deplete the charge in the battery.
Perform operational checks to ensure no new malfunctions have been introduced when components have been repaired or
replaced, and/or airframe wiring has been repaired or replaced.
Operational checks for each applicable system are collocated with the system maintenance procedures. Also, use system
diagrams, wiring diagrams (Chapter 98) in accomplishing operational checks or functional tests.
96-24-07
Rev. 1 Page 1
E-AB412-PT6T-2
96-24-07
Page 2 Rev. 1
E-AB412-PT6T-2
96-24-08ELECTRICAL SYSTEM - TROUBLESHOOTING
96-24-08
ELECTRICAL SYSTEM - TROUBLESHOOTING
1. TROUBLESHOOTING - DESCRIPTION
The following troubleshooting procedures are general in nature and may be used as a guide to find a malfunction in an
electrical system. Make sure the system and component operation is understood prior to doing any troubleshooting.
1. Make sure electrical power is applied to the system being checked. Make sure ground connections meet required
bonding values and are tight and properly installed. Refer to Chapter 98 for the applicable wiring diagrams.
2. Make sure the switches, relays, diodes, and other electrical components are not defective.
3. Examine the wires, connectors and terminal junctions. Make sure they are in good condition. Make sure the
connections are properly connected and tightened.
4. Make sure that each component of a system operates correctly.
96-24-08
Rev. 1 Page 1
E-AB412-PT6T-2
96-24-08
Page 2 Rev. 1
E-AB412-PT6T-2
96-24-09
ELECTRICAL SYSTEM - MISCELLANEOUS ELECTRICAL COMPONENTS
1. MISCELLANEOUS ELECTRICAL COMPONENTS - DESCRIPTION
The miscellaneous electrical components include but are not limited to: relays, contactors, solenoids, rheostats, switches,
leads, connectors, wires, receptacles, shock mounts, capacitors, diodes, resistors and panel lights.
2. MISCELLANEOUS ELECTRICAL COMPONENTS - REMOVAL
MATERIALS REQUIRED
NUMBER NOMENCLATURE
C-136 CAPS AND PLUGS
CAUTION
BEFORE ATTEMPTING TO REMOVE AN ELECTRICAL/ELECTRONIC

COMPONENT, DISCONNECT ELECTRICAL POWER SOURCE.
1. Disconnect the battery.
2. Make sure all of the other sources of DC power are disconnected.
NOTE
To assist with reinstallation, it is recommended that the wires be identified for their
installed location and orientation prior to removal.
3. Identify the connectors or wires connected to the component.
4. Disconnect these electrical connectors or wires from the component.
5. Install caps and/or plugs (C-136) or caps and/or plugs (C-156) on the connectors or apply tape on the end of the wires.
6. Remove the attaching hardware. If the attaching hardware is serviceable, keep it for reinstallation.
7. Remove the component.
8. Do a general visual inspection of the immediate area where the component was removed. See paragraph "4.
Miscellaneous electrical components - inspection" for the inspection requirements.
96-24-09
Rev. 1 Page 1
E-AB412-PT6T-2
3. MISCELLANEOUS ELECTRICAL COMPONENTS - INSTALLATION
1. Disconnect the battery.
2. Make sure all of the other sources of DC power are disconnected.
3. Do a general visual inspection of the immediate area where the component was removed. See paragraph "4.
Miscellaneous electrical components - inspection" for the inspection requirements.
4. Use the correct attaching hardware and install the component.
5. Remove the caps and/or plugs (C-136) caps and/or plugs (C-156) from the connectors and tape from the ends of the
wires. Use the applicable wiring diagram in Chapter 98 and attach the connectors or the wires to the proper location
or terminals.
6. Do the applicable operational check of the system.
7. Return the helicopter to the flight configuration after electrical maintenance or repairs (module 96-24-12 paragraph
"3-3. Standard practices - after electrical maintenance or repairs")
4. MISCELLANEOUS ELECTRICAL COMPONENTS - INSPECTION
NOTE
It is also recommended to do a general visual inspection in the immediate area where
the component was removed.
1. For the inspection requirements of miscellaneous electrical components, see table 1.
2. Examine the attaching hardware for cracks, wear, mechanical damage and corrosion damage. Replace as necessary.
Table 1. Electrical Wire Interconnection System (EWIS)
ITEM DEFECT, DAMAGE, FAILURE OR IRREGULARITY
Wire/wire harnesses Wire bundle/wire bundle or wire bundle/structure contact/chafing

Wire bundle sagging or improperly secured
Wires damaged (obvious damage due to mechanical impact, overheat, localized
chafing, etc.)
Lacing tape and/or ties missing/incorrectly installed
Wiring protection sheath/conduit deformity or incorrectly installed
End of sheath rubbing on end attachment device
Grommet missing or damaged
Dust and lint accumulation
Surface contamination by metal shavings/swarf
Contamination by liquids
Deterioration of previous repairs (e.g. splices)
Deterioration of production splices
Inappropriate repairs (e.g., incorrect splice)
Inappropriate attachments to or separation from fluid lines
96-24-09
Page 2 Rev. 1
E-AB412-PT6T-2
(Cont.d)
ITEM DEFECT, DAMAGE, FAILURE OR IRREGULARITY
Connectors External corrosion on receptacles

Missing/loose or damaged dust cap
Backshell tail broken
Rubber pad or packing on backshell missing
No backshell wire securing device
Fool proofing chain broken
Missing or broken safety wire
Discoloration/evidence of overheating on terminal lugs/blocks
Torque stripe misalignment
Damaged or bent contacts
Switches/switch-lights and annun- Rear protection cap damaged

ciators Corrosion
Weak detents
Ground points Corrosion and looseness
Bonding braid/bonding jumper Braid broken or disconnected

Multiple strands corroded or broken
Wiring clamps or brackets Corroded

Broken/missing
Bent or twisted
Faulty attachment (bad attachment or fastener missing)
Debonded/detached
Protection/cushion damaged
Supports (rails or tubes/conduit) Broken

Deformed
Fastener missing
Missing edge protection on rims of feed through holes
Racetrack cushion damaged
Obstructed drainage holes (in conduits)
Circuit breakers, contactors, relays, Signs of overheating

rheostats or fuses Signs of arcing
Looseness
Corrosion
96-24-09
Rev. 1 Page 3
E-AB412-PT6T-2
5. MISCELLANEOUS ELECTRICAL COMPONENTS - CLEANING
1. Remove all loose debris with a brush or clean cloth.
CAUTION
SOLVENTS CAN CAUSE DAMAGE TO SOME MATERIALS. THEY CAN

REMOVE LUBRICANTS AND SOFTEN CERTAIN MATERIALS. REFER TO
module 00-00-40 paragraph "5. The manual - consumable materials" FOR THE
APPROPRIATE SOLVENT FOR THE MATERIAL YOU ARE CLEANING.
2. Remove grease or dirt with an approved solvent depending on the material of the component.
3. Make sure the electrical component is totally dry before installation.
6. MISCELLANEOUS ELECTRICAL COMPONENTS - REPAIR
1. Tighten loose terminal connections, mountings, and attachments of electrical components.
2. Replace miscellaneous electrical components that fail to meet inspection requirements.
96-24-09
Page 4 Rev. 1
E-AB412-PT6T-2
96-24-10
ELECTRICAL SYSTEM - CONTROL PANELS
1. CONTROL PANELS - DESCRIPTION
1. Controls and control panels are mounted in the overhead console, pedestal, and instrument panel (figure 1 through
figure 5).
2. CONTROL PANELS - REMOVAL
NOTE
Removal procedure for all panels is relatively the same. A single removal procedure
may be used for any panel.
1. Remove all electrical power.
2. Disengage fasteners securing panel to mount.
3. Carefully lift panel from mount and disconnect electrical connector.
3. CONTROL PANELS - INSTALLATION
2. Position panel in mount being careful not to damage wiring.
3. Engage fasteners.
4. CONTROL PANELS - INSPECTION
1. Visually inspect for scratched, chipped, or broken edge and integrally lit panels, loose wiring connections, damaged
connector, corrosion and broken or missing mounting fasteners.
5. CONTROL PANELS - REPAIR
1. Replace items that fail to meet inspection requirements.
96-24-10
Rev. 1 Page 1
E-AB412-PT6T-2
G6AB0736A
Figure 1. Overhead console (helicopters codes [A] [B])
96-24-10
Page 2 Rev. 1
E-AB412-PT6T-2
(HELICOPTERS CODE [D])
G6AB0738A
Figure 2. Overhead console (helicopters codes [C] [D])
96-24-10
Rev. 1 Page 3
E-AB412-PT6T-2
G6AB0844A
Figure 3. Pedestal panels
96-24-10
Page 4 Rev. 1
E-AB412-PT6T-2
1. Clock (provision) 32. Fuel quantity ind. switch 62. Torquemeter indicator
2. Map light switch 33. Fuel quantity ind. *63. DME indicator (provision)
3. Lighter circuit breaker (provision) 34. Transmission oil press/temp *64. Course selector indicator (CSI)
4. Lighter (provision) indicator (provision)
5. Airspeed indicator 35. Gearbox oil press/temp indicator 65. Attitude director indicator (ADI)
*6. MB Lights (provision) 36. Dual DC ammeter 66. Horizontal situation indicator (HSI)
*7. Radar altimeter indicator (provision) 37. Fire 2 pull handle 67. HSI control switches
*8. Aux pitot static switches (Flight 38. Engine 1 out light *68. Altimeter encoder indicator
director) 39. Engine 2 out light 69. Vertical speed indicator
9. Attitude director indicator (ADI) 40. Decal (engine limits) *70. MB lights (provision)
10. Horizontal situation indicator (HSI) 41. Gas producer Tachometer (N1) *71. Radar altimeter indicator (provision)
*11. IFF Code hold switch (provision) indicator (engine 1) 72. Clock
12. Master caution light 42. Gas producer Tachometer (N1) 73. Map light switch
13. Altimeter Indicator indicator (engine 2) 74. Lighter circuit breaker (provision)
14. Vertical speed indicator 43. Inter turbine temperature (ITT) 75. Lighter (provision)
*15. Weather radar indicator (engine 1). **76. N. 3 hydraulic pressure indicator
16. RPM Warning light 44. Inter turbine temperature (ITT) **77. Decal
17. Triple tachometer indicator indicator (engine 2). **78. N. 3 hydraulic pressure indicator
18. Torquemeter indicator 45. Engine 1 oil press/temp indicator **79. Decal
*19. Tacan control panel (provision) 46. Engine 2 oil press/temp indicator **80. Decal
20. Cargo release light 47. Engine 1 fuel press. indicator 81. Copilot CYC CTR indicator light
21. Airspeed limits panel 48. Engine 2 fuel press. indicator 82. Pilot CYC CTR indicator light
22. Master caution panel 49. Dual voltmeter
*23. NAV TEST and MB control panel 50. Dual voltmeter
(provision) 51. Decal * These components are installed
*24. VOR/LOC control panel (Provision) 52. RPM warning light when the concerned kit is installed.
25. Fire 1 pull handle *53. Steering indicator (provision)
26. Baggage fire light 54. Triple tachometer indictor ** These items are installed for code
27. Baggage fire test switch *55. Windshield heater light (provision) [B].
28. Fire exiting test switch *56. Flight director light (provision)
29. Fire exiting selector switch *57. Flight director panel (provision)
30. N. 1 Hydraulic sys. 58. Master caution light
Pressure/temperature indicator 59. VG fast erect switch
31. N. 2 Hydraulic sys. 60. Decal
Pressure/temperature indicator 61. Airspeed indicator
G6AB0845B
Figure 4. Instrument panel (helicopters codes [A] [B])
96-24-10
Rev. 1 Page 5
E-AB412-PT6T-2
1. Clock (provision) 33. Fuel quantity ind. switch *61. Windshield heater light (provision)
2. Map light switch 34. Digit test switch *62. Flight director light (provision)
3. Lighter circuit breaker (provision) 35. Fuel quantity ind. *63. Flight director panel (provision)
4. Lighter (provision) 36. Dual DC ammeter 64. Pilot CYC CTR caution light
5. Airspeed indicator 37. Dual voltmeter 65. Master caution light
*6. MB Lights (provision) 38. Dual voltmeter 66. Airspeed indicator
*7. Radar altimeter indicator (provi- 39. N. 3 hydraulic system pressure 67. Torquemeter indicator
sion) indicator *68. DME indicator (provision)
*8. Aux pitot static switches (Flight 40. N. 3 hydraulic system temperature *69. Course selector indicator (CSI)
director) indicator (provision)
9. Attitude director indicator (ADI) 41. Decal 70. VG fast erect switch
10. Horizontal situation indicator (HSI) 42. Decal 71. Decal
*11. IFF Code hold switch (provision) 43. Fire 2 pull handle 72. Attitude director indicator (ADI)
12. Master caution light 44. Engine 1 out light 73. Horizontal situation indicator (HSI)
13. Copilot CYC CTR caution light 45. Engine 2 out light 74. HSI control switches
14. Altimeter Indicator 46. Gas producer tachometer (N1) 75. Altimeter indicator
15. Vertical speed indicator indicator (engine 1) *76. Altimeter-encoder-indicator (provi-
*16. Weather radar 47. Inter-turbine temperature (ITT) sion)
17. RPM Warning light indicator (engine 1) 77. Vertical speed indicator
18. Triple tachometer indicator 48. Engine 1 oil pressure/temperature *78. MB lights (provision)
19. Torquemeter indicator indicator *79. Radar altimeter indicator (provi-
*20. Tacan control panel (provision) 49. Engine 1 fuel pressure indicator sion)
21. Cargo release light 50. Gearbox oil pressure/temperature 80. Clock
22. Airspeed limits panel indicator 81. Map light switch
23. Master caution panel 51. Decal (engine limits) 82. Lighter circuit breaker (provision)
*24. NAV TEST and MB control panel 52. Gas producer tachometer (N1) 83. Lighter (provision)
(provision) indicator (engine 2)
*25. VOR/LOC control panel (Provi- 53. Inter-turbine temperature (ITT)
sion) indicator (engine 2) * These components are installed
26. Fire pull handle 54. Engine 2 oil pressure/temperature when the concerned kit is
27. Baggage fire light indicator installed.
28. Baggage fire test switch 55. Engine 2 fuel pressure indicator
29. Fire exiting test switch 56. Transmission oil pressure/temper-
30. Fire exiting selector switch ature indicator
31. Hydraulic sys. 57. Decal
Pressure/temperature indicator 58. RPM warning light
32. N. 2 Hydraulic sys. *59. Steering indicator
Pressure/temperature indicator 60. Triple tachometer indicator
G6AB0846B
Figure 5. Instrument panel (helicopters codes [C] [D])
96-24-10
Page 6 Rev. 1
E-AB412-PT6T-2
96-24-1 ELECTRICAL SYSTEM - CIRCUIT BREAKERS
96-24-11
ELECTRICAL SYSTEM - CIRCUIT BREAKERS
1. CIRCUIT BREAKERS - DESCRIPTION
There is one type of circuit breaker used on Model 412 helicopters, the fault clearing push-pull type. Circuit breakers are
mounted in the overhead console, pedestal, nose compartment, and throughout the helicopter.
Circuit breakers are electromagnetic devices that protect the electrical circuits and equipment by automatically opening the
electrical circuit when the current in the line exceeds a predetermined value.
2. CIRCUIT BREAKERS - REMOVAL
WARNING
BEFORE YOU REMOVE A CIRCUIT BREAKER ON THE HELICOPTER,

REMOVE ALL ELECTRICAL POWER AND DISCONNECT THE BATTERY. IF
NOT ACCOMPLISHED, YOU CAN CAUSE ELECTRICAL SHOCK TO
PERSONS AND/OR DAMAGE TO EQUIPMENT.
1. Remove all electrical power.
NOTE
To assist with reinstallation, it is recommended that the wires and bus bars be
identified for their installed location and orientation prior to removal.
2. Gain access to circuit breaker wiring.
3. Tag wires and disconnect.
4. Protect wires.
5. Remove screw securing circuit breaker to bus bar (if required).
6. Remove nut and washers securing circuit breaker to panel.
7. Remove circuit breaker from panel.
96-24-11
Rev. 1 Page 1
E-AB412-PT6T-2
3. CIRCUIT BREAKERS - INSTALLATION
WARNING
BEFORE YOU INSTALL A CIRCUIT BREAKER ON THE HELICOPTER,

REMOVE ALL ELECTRICAL POWER AND DISCONNECT THE BATTERY. IF
NOT ACCOMPLISHED, YOU CAN CAUSE ELECTRICAL SHOCK TO
PERSONS AND/OR DAMAGE TO EQUIPMENT.
1. Position circuit breaker on structure and secure with hardware.
2. Install screw securing circuit breaker to bus bar (if required).
3. Remove tags and install wires.
4. Perform circuit operational check.
4. CIRCUIT BREAKERS - INSPECTION
1. Inspect circuit breakers for secure mounting, corrosion, general condition, power on and off actuation, and reset
retention.
5. CIRCUIT BREAKERS - REPAIR/REPLACEMENT
1. Replace circuit breaker if inspection requirements can not be met.
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96-24-12 ELECTRICAL SYSTEM - ELECTRICAL SAFETY AND HAZARDS
96-24-12
ELECTRICAL SYSTEM - ELECTRICAL SAFETY AND HAZARDS
1. ELECTRICAL SAFETY AND HAZARDS - GENERAL
WARNING
OBEY ALL THE SAFETY PRECAUTIONS WHEN YOU DO MAINTENANCE

ON OR NEAR ELECTRICAL/ELECTRONIC EQUIPMENT.
High voltages in the electrical and electronic system are hazardous to personnel. Electrical shocks may cause serious
injuries. The generation of sparks in the presence of flammable vapors may cause explosions. Metallic objects that come in
contact with the powered electrical conductors or the components can cause injuries to personnel and damage to the
components.
2. ELECTRICAL SAFETY AND HAZARDS - SAFETY PRACTICES
WARNING
OBEY ALL THE SAFETY PRECAUTIONS WHEN YOU DO MAINTENANCE

ON OR NEAR ELECTRICAL/ELECTRONIC EQUIPMENT.
When you do any maintenance or repairs to an electrical system, or to any system that requires electrical power, follow these
precautions:
— Personnel must be trained for the specific task.
— Do not touch components that have electrical power. Direct contact with high voltage circuit, or lower voltage circuit
with a high current capability can be fatal.
— Proper tools and safety equipment must be available. use them to ensure the safety of personnel. Use them to make
sure the given task is done to the specified standards.
— Do not wear jewelry when you work on a system that is powered.
— Use recommended test equipment or their equivalents. Follow the equipment operation instructions. Additional test
equipment, lights, etc., may be used as desired, provided the purpose and intent of specified test is not compromised.
— The leads and the probes of the test equipment must be serviceable. They must be of a sufficient length to put the test
equipment at a proper location. The location of the test equipment must give a full view of the indicator. Make sure
there is no tension on the test leads or the probes.
— Give special attention to the WARNINGS, CAUTIONS and NOTES before a maintenance procedure is initiated.
Some maintenance procedures require the use of toxic chemicals, extreme temperatures, and flammable materials.
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3. ELECTRICAL SAFETY AND HAZARDS - STANDARD PRACTICES
3-1. STANDARD PRACTICES - ELECTRICAL MAINTENANCE OR REPAIRS
MATERIALS REQUIRED
NUMBER NOMENCLATURE
WARNING
UNLESS POWER IS REQUIRED FOR A MAINTENANCE PROCEDURE,

DISCONNECT THE BATTERY AND THE EXTERNAL POWER. PUT A TAG
ON THE BATTERY SWITCH TO INFORM OTHER PERSONNEL THAT
WORK IS BEING DONE.
WARNING
INFORM ALL OF THE PERSONNEL THAT WORK ON THE HELICOPTER

BEFORE YOU SUPPLY POWER TO THE ELECTRICAL SYSTEMS.
1. The procedure that follows will help to avoid injuries to personnel and damage to equipment.
a. If an electrical connector is to be left disconnected, install protective caps and plugs to protect the contacts from
shorts and prevent FOD damage. Use either C-136 caps and plugs for Electrostatic Discharge Sensitive (ESDS)
equipment, or C-156 caps and plugs for other non-ESDS equipment.
b. If a circuit breaker must remain open until a maintenance procedure is complete, install a clip or a plastic cable
strap under the circuit breaker button. Put a tag on the circuit breaker to inform other personnel not to set the
circuit breaker to the closed position.
c. If a switch must remain open or closed until a maintenance procedure is complete, put a tag on the switch to
inform other personnel not to touch the switch.
d. Inform all of the personnel that work on the helicopter before you supply power to the electrical systems.
3-2. STANDARD PRACTICES - ELECTRICAL WORK IN CONFINED SPACES
1. Some equipment installations are in confined areas and access to the test points can be difficult. When you do a test
on a powered circuit in a confined area, follow these precautions:
a. Have the applicable fire safety equipment available when you do a maintenance procedure.
b. Before you start work in a confined area, look at the wiring diagrams (Chapter 98) of the applicable electrical
systems and at the location of the equipment you will test. Make a note of the location of the high voltage areas
near the equipment you will test.
c. Be careful around any control cable or mechanism. Movement of engine or flight controls can cause movement
of cables or control rods.
d. For systems not tested, set the applicable circuit breakers to the open position.
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3-3. STANDARD PRACTICES - AFTER ELECTRICAL MAINTENANCE OR REPAIRS
1. After completing a task on any electrical system, make sure you do the steps that follow before you return the
helicopter to the flight configuration:
a. Remove all protective caps from equipment or electrical equipment.
b. Make sure all of the disconnected electrical connectors are properly re-installed.
c. After troubleshooting any electrical system, reinstall any removed control panels or electrical components such
as relays, terminal modules, switches and other miscellaneous components.
d. Remove the tags or the cable straps from the switches and the circuit breakers. Close the circuit breakers.
NOTE
As applicable, refer to the engine shutdown procedures (Flight Manual
E-AB412-PT6T-1) to determine the switch and control positions.
e. Make sure all of the switches and the controls are in the correct position. This prevents the accidental system
operation when the power is turned on.
f. If applicable, connect the battery.
g. Do an operational check on the system or systems that were repaired.
h. Install all applicable access panels and close all doors (Chapter 52).
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96-24-13 ELECTRICAL SYSTEM - SEMICONDUCTOR DEVICES
96-24-13
ELECTRICAL SYSTEM - SEMICONDUCTOR DEVICES
1. SEMICONDUCTOR DEVICES - DESCRIPTION
The semiconductor devices used are as follows:

— Standard and zener diodes
— Transient suppression diode assemblies
— Transistors
2. SEMICONDUCTOR DEVICES - MAINTENANCE PRACTICES
1. Remove the semiconductor device (module 96-24-09 paragraph "2. Miscellaneous electrical components - removal").
2. Inspect the semiconductor device ((module 96-24-09 paragraph "4. Miscellaneous electrical components -
inspection").
NOTE
When you install a semiconductor device, refer to the associated wiring diagram in
Chapter 98 to make sure of the correct orientation and wiring attachment.
3. Install the semiconductor device (module 96-24-09 paragraph "3. Miscellaneous electrical components - installation").
4. Return the helicopter to the flight configuration after electrical maintenance or repairs (module 96-24-12 paragraph
"3-3. Standard practices - after electrical maintenance or repairs").
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E-AB412-PT6T-2
96-24-14
ELECTRICAL SYSTEM - TRACK MOUNTED RELAYS
1. TRACK MOUNTED RELAYS - DESCRIPTION
Track mounted relays are electromagnetic switches that open and close under the control of other components in the
electrical circuit.
2. TRACK MOUNTED RELAYS - REMOVAL
1. Disconnect the battery and external power from the helicopter.
2. Loosen the screws (2, figure 1).
3. Carefully pull the relay (1) out from the socket base (3).
3. TRACK MOUNTED RELAYS - INSTALLATION
1. Correctly position the relay (1, figure 1) on the socket base (3) and apply finger pressure until it latches into place.
2. Tighten the screws (2).
3. Connect the battery and the external power.
4. Do the applicable operational check of the system.
4. TRACK MOUNTED RELAYS - INSPECTION
For inspection of the track mounted relay, refer to (module 96-24-09 paragraph "4. Miscellaneous electrical components -
inspection").
5. TRACK MOUNTED RELAYS - CLEANING
MATERIALS REQUIRED
NUMBER NOMENCLATURE
C-516 CLEAN CLOTH
C-552 BUTYL ACETATE
1. Clean relay pins with isopropyl alcohol (C-385) and if necessary to do a deep cleaning use butyl acetate (C-552).
2. Dry pins and surfaces with a clean cloth (C-516). Turn relay sockets down and let the solvent evaporate/dry for 20
minutes.
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1. Relay
2. Screw
3. Socket base
G6AB1023A
Figure 1. Track mounted relay - removal/installation (typical)
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E-AB412-PT6T-2
96-24-20
AC POWER SYSTEMS
1. AC POWER SYSTEM - DESCRIPTION
This system includes components of the inverter systems. Refer to Chapter 98 for applicable wiring diagrams.
See figure 1 for AC power system block diagram for helicopters codes [A] [B] and see figure 2 for helicopters codes [C] [D].
96-24-20
Page 1
E-AB412-PT6T-2
G6AB0847A
Figure 1. AC electrical power system - block diagram (helicopters codes [A] [B])
96-24-20
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E-AB412-PT6T-2
G6AB0848A
Figure 2. AC electrical power system - block diagram (helicopters codes [C] [D])
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E-AB412-PT6T-2
96-24-21
AC POWER SYSTEMS - INVERTER SYSTEMS
1. INVERTER SYSTEMS - DESCRIPTION
1-1. DESCRIPTION - HELICOPTERS CODES [A] [B]
Alternating current power control is provided by two identical 450 VA, 115/26 volt, 400 Hz, single phase, solid state
inverters 3PS1 and 3PS2. One inverter is energized by each of the two essential DC buses. Inverter 1 supplies power to the
115 and 26 Vac buses 1 and 2, and inverter No. 2 supplies power to the 115 and 26 Vac bus 3. the two inverters are completely
independent of each other. The AC power is distributed through their respective AC VOLTAGE SENSOR RELAYS, 3K1
and 3K2 and COMMON AC BUS CONTROL RELAY 3K3. Caution light segments are provided for each inverter system
and are connected to the AC voltage sensing relays.
1-2. DESCRIPTION - HELICOPTERS CODES [C] [D]
Alternating current power control is provided by two identical 450 VA, 115/26 volt, 400 Hz, single phase, solid state
inverters. One inverter is energized by each of the two essential DC buses. Inverter No. 1 (3PS1) supplies power to the 115
and 26 V AC buses 1 and 2, and inverter No. 2 (3PS2) supplies power to the 115 and 26 V AC bus 3. The two inverters are
completely independent of each other. The AC power is distributed through their respective AC voltage sensor relays (3K1
and 3 K2) inverter 2 interlock relay (3K4), and inverter 1 emergency bus relay (3K5). Caution light segments are provided
for each inverter system and are connected to the AC voltage sensor relays.
2. INVERTER SYSTEMS - OPERATIONAL CHECKS
T96 DIGITAL MULTIMETER
T97 FREQUENCY METER
2-1. OPERATIONAL CHECKS - PRELIMINARY SETUP
1. Connect external power.
2. Ensure the following circuit breakers, in the nose compartment, are closed:
— INVERTER 1 EMERG INTLK
— INVERTER 2 EMERG INTLK
3. Close the following circuit breakers:
— NO. 1 ESNTL FEEDER BUS
— NO. 2 ESNTL FEEDER BUS
96-24-21
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E-AB412-PT6T-2
— GEN 1 RESET
— GEN 2 RESET
— MASTER CAUTION
— BUS 1 VM
— BUS 2 VM
4. Set BATTERY BUS 1 and BATTERY BUS 2 switches ON.
5. Verify NO. 1 INVERTER and NO. 2 INVERTER caution lights on master caution panel are illuminated.
2-2. OPERATIONAL CHECKS - INVERTER NO. 1 CIRCUITRY
— INV 1 PWR
— 26/115 AC FEEDER BUS 1
— 26/115 EMERG BUS (helicopters codes [C] [D])
2. Set INV 1 switch to ON.
3. Verify NO. 1 INVERTER caution light is extinguished.
4. Verify both dual voltmeters indicate approximately 115 Vac.
5. Verify NO. 2 INVERTER caution light is illuminated.
6. Check for 110 - 120 Vac on 115 Vac buses No. 1, No. 2, and No. 3.
7. Check for 110 - 120 Vac on 115 VAC EMERG BUS (helicopters codes [C] [D]).
8. Check for 24,5 - 27,5 Vac on 26 Vac buses No. 1, No. 2, and No. 3.
9. Check for 24,5 - 27,5 Vac on 26 Vac EMERG BUS (helicopters codes [C] [D]).
10. Using a frequency meter, verify inverter No. 1 output frequency is 400 4 Hz.
11. Set INV 1 switch to OFF.
12. Verify NO. 1 INVERTER caution light illuminates.
13. Verify both dual voltmeters indicate zero.
2-3. OPERATIONAL CHECKS - INVERTER NO. 2 CIRCUITRY
1. Close INV 2 PWR circuit breaker.
2. Set INV 2 switch to ON.
3. Verify NO. 2 INVERTER caution light is extinguished.
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E-AB412-PT6T-2
4. Verify both dual voltmeters indicate approximately 115 Vac.
6. Check for 110 - 120 Vac on 115 Vac bus No. 1, No. 2, No. 3.
7. Check for 110 - 120 Vac on 115 VAC EMERG BUS (helicopters codes [C] [D]).
8. Check for 24,5 - 27,5 Vac on 26 Vac bus No. 1, No. 2, No. 3.
9. Check for 24,5 - 27,5 Vac on 26 VAC EMERG BUS (helicopters codes [C] [D]).
10. Using a frequency meter, verify inverter No. 2 output frequency is 400 4 Hz.
11. Set INV 2 switch to OFF.
2-4. OPERATIONAL CHECKS - INVERTER NO. 1 AND INVERTER NO. 2 CIRCUITRY [C] [D]
1. Set INV 1 and INV 2 switch to ON.
2. Verify NO. 1 INVERTER and NO. 2 INVERTER caution lights are extinguished.
3. Verify No. 1 and No. 2 bus voltmeters indicate approximately 115 Vac.
4. Set EMERG LOAD switch to EMERG LOAD.
5. Verify NO. 1 INVERTER caution light remains extinguished.
7. Verify voltage is present on 115 VAC EMERG BUS and 26 VAC EMERG BUS.
8. Verify no voltage is present on any other 115 VAC or 26 VAC BUS.
3. INVERTER SYSTEMS - INVERTER
3-1. INVERTER - DESCRIPTION
The inverters are provided to supply the alternating current power necessary for the operation of the AC apparatus installed
on the helicopter. The static-type inverters (all solid state components) are each capable of supplying one alternate current
at 115/26V, 400 Hz, single phase to a maximum of 450 VA. The electrical power for inverter operation is supplied at 28 Vdc
by the helicopter main DC system. The inverters (3PS1 and 3 PS2) are installed in the helicopter nose electrical
compartment. Inverter operation is controlled by the INVERTER No. 1 and No. 2 switches, which provide 28 Vdc electrical
power.
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E-AB412-PT6T-2
3-2. INVERTER - REMOVAL
WARNING
TO PREVENT ELECTRICAL SHOCK OR DAMAGE TO EQUIPMENT,

ENSURE EXTERNAL POWER AND BATTERY ARE DISCONNECTED.
2. Ensure all electrical power is OFF.
3. Disengage connectors and protect with cap or tape.
4. While supporting inverter, remove mounting hardware.
5. Carefully lower and remove inverter from compartment.
3-3. INVERTER - INSTALLATION
1. While supporting inverter on its mounting pad, install and secure mounting hardware.
2. Remove protective covers from connectors; engage and secure connectors.
3. Restore electrical power and perform operational check.
3-4. INVERTER - INSPECTION
1. Visually inspect inverters for following conditions.
2. Cracked or damaged cases that could impair proper operation of the inverter.
3. Proper bonding and security of mounting hardware.
4. Broken connector pins or cracked connector inserts.
3-5. INVERTER - REPAIR
1. Repair or replace damaged airframe connectors only.
2. Replace inverter if other inspection criteria is not met.
4. INVERTER SYSTEMS - BUS CONTROL RELAY [A] [B]
4-1. BUS CONTROL RELAY [A] [B] - DESCRIPTION
The bus control relay (3K3) is installed on the helicopter cabin ceiling. Relay function is to deliver the AC electrical power
from the inverter to the appropriate AC busses while the system is operating in normal conditions.
28 Vdc electrical power for relay coil operation is provided through the inverter No. 1 or No. 2 switch, while the ground
reference is provided through the contacts of No. 1 or No. 2 AC voltage sensing relay and contacts of the other AC bus
control relay. Thus, if a fault condition occurs, the feeds the ground reference to the coil of the opposite relay to prevent its
disengagement.
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E-AB412-PT6T-2
4-2. BUS CONTROL RELAY [A] [B] - REMOVAL
1. Turn off all electrical.
2. Open sound proofing on cabin ceiling.
3. Disconnect wiring.
4. Remove attaching hardware and remove relay.
4-3. BUS CONTROL RELAY [A] [B] - INSTALLATION
1. Turn off all electrical power.
2. Position relay and secure with attaching hardware.
3. Connect wiring.
4. Close sound proofing on cabin ceiling.
5. INVERTER SYSTEMS - AC VOLTAGE SENSING RELAY
5-1. AC VOLTAGE SENSING RELAY - DESCRIPTION
The AC voltage sensing relays (3K1 and 3K2) are installed in the helicopter nose electrical compartment. Relay function is
to control the operation of the AC bus control relay (3K3) and to provide the ground reference for the warning light. Relay
operation is controlled by the 115 Vac output voltage from the appropriate inverter. Thus, if an inverter fault condition
occurs, the relay will open and will redirect the electrical signals causing the AC bus control relay (3K3) to change its
contacts and the appropriate warning light to illuminate.
5-2. AC VOLTAGE SENSING RELAY - REMOVAL
2. Gain access to electrical compartment.
4. Remove attaching hardware and remove relay.
5-3. AC VOLTAGE SENSING RELAY - INSTALLATION
2. Position relay and secure with attaching hardware.
3. Connect wiring.
4. Close electrical compartment.
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E-AB412-PT6T-2
6. INVERTER SYSTEMS - TROUBLESHOOTING
Table 1. Inverter systems troubleshooting
Inverter No. 1 (3PS1) fails to operate. Open or defective INV 1 PWR or Reset or replace unit.
INV 1 CONT circuit breaker.
Defective INVERTER No. 1 Replace switch.

switch.
Defective INVERTER No. 1 Replace inverter.

(3PS1).
Ac bus overload or short circuit. Remove overload or short.
Inverter No. 2 (3PS2) fails to operate. Open or defective INV 2 PWR or Reset or replace unit.
INV 2 CONT circuit breaker.
Defective INVERTER No. 2 Replace switch.

switch.
Defective INVERTER No. 2 Replace inverter.

(3PS2).
Ac bus overload or short. Remove overload or short.
Inverter (3PS1 or 3PS2) operates but no voltage Defective INVERTER switch. Replace switch.
appears on 115 Vac buses (no ac voltage
indication on DUAL VOLTMETER). Defective AC VOLTAGE Replace relay.
SENSING RELAY (3K1 or 3K2).
Defective AC BUS CONTROL Replace relay.

REL (3K3).
Open or defective BUS 1 Reset or replace unit.

VOLTMETER or BUS 2
VOLTMETER circuit breaker.
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E-AB412-PT6T-2
(Cont.)
Improper inverter output voltage or frequency Defective DUAL VOLTMETER Replace meter.
(3PS1 or 3PS2). No. 1 or No. 2 (M21 or M22) or
(5M2 or 4M2).
Low input dc voltage. Check for proper input dc voltage

to inverter, correct low dc voltage
condition.
Faulty inverter. Replace inverter.
[A] [B] AC instrument inoperable (inverter ac AC BUS CONTROL REL (3K3) Replace relay.
voltage normal). defective.
No. 1 26 Vac or No. 2 26 Vac Reset or replace unit.

circuit breaker open or defective.
BUS 1 VOLTMETER or BUS 2 VOLTMETER AC voltmeter (M21 or M22) or Replace voltmeter.

circuit breaker will not reset. (5M2 or 4M2) shorted.
Defective BUS 1 VOLTMETER Replace unit.

or BUS 2 VOLTMETER circuit
breaker.
AC voltmeter indicates incorrectly. Defective ac voltmeter. Replace meter.
96-24-21
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E-AB412-PT6T-2
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96-24-22
AC INDICATOR SYSTEMS
1. AC INDICATOR SYSTEMS - DESCRIPTION
AC indicator systems include torque pressure, engine oil pressure, transmission oil pressure, hydraulic pressure, combining
gearbox oil pressure, fuel pressure, attitude director indicator, triple tachometer, and gas producer tachometer indicator
systems. Refer to Chapter 98 for applicable wiring diagrams.
2. AC INDICATOR SYSTEMS - TORQUE PRESSURE INDICATOR SYSTEMS [A] [B] [C]
2-1. TORQUE PRESSURE INDICATOR SYSTEMS [A] [B] [C] - DESCRIPTION
The torque pressure indicator system simultaneously displays torque output of both engines on the inner dial transmission
torque on the outer dial. Torque output of engine No. 1 is indicated by pointer No. 1, engine No. 2 is indicated by pointer
No. 2, and the resultant sum of these torques is displayed by cursor (bug). All indications are in terms of present allowable
to transmission. AC power is supplied through the TORQUE METER circuit breakers. The pilot and copilot systems are
totally independent of each other but function identically.
2-2. TORQUE PRESSURE INDICATOR SYSTEMS [A] [B] [C] - OPERATIONAL CHECK
NUMBER NOMENCLATURE
T98 PRESSURE TESTER, 0-150 PSI (0-1034 KPa)
1. Record the L.H. VALVE letter(s) and the L.H. ZERO POS or L.H. ZERO NEG value given in degrees on the engine
gearbox nameplate. This represents a positive or negative number and will be used accordingly.
2. On the ENG 1 torque pressure transmitter, remove the input-output adjustment valve cover. Place the adjustment
valve(s) designed on the gearbox to the ON position, and verify that all other adjustment valves are in the OFF position.
Replace the adjustment valve cover securely.
3. Record the XMTR ZERO value which is given in degrees on the torque transmitter. Subtract 20 degrees from this value
to obtain the adjusted zero.
4. Algebraically add the L.H. ZERO value from the engine gearbox nameplate to the adjusted zero of engine 1 pressure
torque transmitter. Divide the sum by 1.928 for helicopters code [A] [B], by 2.003 for helicopters code [C] to determine
the system zero torque pressure indication in percent.
5. Energize inverter 1. Rotate the torque transmitter zero adjustment screw and check that the pilot ENG 1 TORQUE
pointer moves through a 10% sweep. Repeat for copilot if installed.
6. Utilizing the zero adjustment screw on the engine 1 torque transmitter, set the pilot ENG 1 TORQUE pointer to the
system zero torque pressure indication calculated in step d. Repeat for copilot if installed and check that indicator is
within 1.0 percent of the pilot indicator.
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E-AB412-PT6T-2
NOTE
Each dot on the indicator is equal to 1 percent of the torque.
7. Repeat steps 1. through 6. for the R.H. (ENG 2) torque system.
NOTE
When performing the following checks, a pressure tester capable of measuring at
least 10.5 kg/cm2 (150 psig) must be used.
8. Close ENG 1 TORQUE METER and ENG 2 TORQUE METER circuit breakers. Disconnect torque pressure
transmitter from engine No. 1. Attach pressure tester to its input port and apply pressure to transmitter input, but do
not exceed 5.3 kg/cm2 (75 psig).
Check that engine No. 1 pointer on both pilot and copilot (if installed) dual torque indicator(s) reads approximately 70
percent on the inner ENGINE dial when the input pressure is 3.9 ± 0.10 kg/cm2 (55 ±1.5 psig) and the engine No. 2
pointer remains at low end of dial, and the TRANSMISSION cursor (outer dial) indicates sum of engine No. 1 and
engine No. 2 pointer indications.
9. Remove applied pressure. Check that engine No. 1 pointer and engine No. 2 pointer are at low end of the engine dial
on both pilot and copilot indicators. Also check that TRANSMISSION cursor is at low and of dial on both indicators.
10. Remove pressure tester from torque pressure No. 1 and reconnect torque transmitter to engine No. 1. Check that
connection is properly mated and is tight, and secure.
11. Repeat steps 8. through 10. for engine No. 2 (references to ENG 1 shall be ENG 2 and viceversa).
2-3. TORQUE PRESSURE INDICATOR SYSTEMS [A] [B] [C] - TROUBLESHOOTING
Table 1. Torque pressure indicator system troubleshooting
TORQUEMETER circuit breakers will not Defective TORQUEMETER Replace unit.

reset. circuit breakers.
Internal short in either torque Remove plugs from transmitters

transmitter or in either dual torque and indicators until circuit breaker
indicator. will reset. Replace defective unit.
Neither the pilot's nor copilot's dual torque Inverters de-energized. Energize inverters.
pressure indicates torque, although torque is
present. Defective TORQUEMETER Replace unit.
circuit breakers.
Both torque transmitters or both Replace defective units.

torque indicator defective.
Defective wiring Repair wiring.
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(Cont.)
Either torque pressure indicator drives down Wires reversed at pins C and D of Repair wiring.
scale. transmitter plug.
Either torque pressure indicator indicates Defective torque pressure Replace defective transmitter(s) or
incorrectly. transmitter(s) or indicator(s). indicator(s) as required.
Defective wiring Repair or replace wiring
3. AC INDICATOR SYSTEMS - ENGINE OIL PRESSURE INDICATOR SYSTEMS
3-1. ENGINE OIL PRESSURE INDICATOR SYSTEMS - DESCRIPTION
Oil pressure indicators for engine No. 1 and engine No. 2 receive signals from their respective engine oil pressure
transmitters.
3-2. ENGINE OIL PRESSURE INDICATOR SYSTEMS - OPERATIONAL CHECK
T98 PRESSURE TESTER, 0 - 150 PSI (0 - 1034 KPA)
1. Close ENG 1 OIL PRESS circuit breaker. Check engine No. 1 ENGINE OIL temperature and pressure indicator reads
0 7,5 psi.
NOTE
When performing following checks a pressure tester capable of measuring at least
150 psi (1034 kPa) must be used.
2. Disconnect pressure input line from engine 1 oil pressure transmitter on engine No. 1.
3. Attach pressure tester and apply pressure to transmitter input line, but do not exceed 110 psig (758 kPa).
4. Check ENGINE OIL indicator reads 100 psi when input pressure is 100 10 psig (689 69 kPa).
5. Disconnect pressure tester.
6. Connect pressure input line to engine 1 oil pressure transmitter.
7. Open ENG 1 OIL PRESS circuit breaker and close ENG 2 OIL PRESS circuit breaker.
8. Repeat steps 1., 2. and 3. for engine 2 oil pressure transmitter.
9. Take readings from engine No. 2 ENGINE OIL temperature and pressure indicator.
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3-3. ENGINE OIL PRESSURE INDICATOR SYSTEMS - TROUBLESHOOTING
Table 2. Engine oil pressure indicator system troubleshooting
ENG 1 OIL PRESS or ENG 2 OIL PRESS Defective circuit breakers. Replace unit.
circuit breakers will not reset.
Defective transmitter and/or Replace defective.
indicator.
Either engine oil pressure indicator fails to Inverters de-energized. Energize inverters.
respond although pressure exists.
Open or defective ENG 1 OIL Reset or replace unit.
PRESS or ENG 2 OIL PRESS
circuit breaker.
Defective transmitter and/or Replace defective unit(s).

indicator.
Either engine oil pressure indicator drives Wires reversed at pins B and C of Repair wiring.
drown scale. transmitter plugs.
4. AC INDICATOR SYSTEMS - TRANSMISSION OIL PRESSURE INDICATOR SYSTEM
4-1. TRANSMISSION OIL PRESSURE INDICATOR SYSTEM - DESCRIPTION
The transmission oil pressure transmitter sends a signal to transmission oil temperature and pressure indicator which is given
in psig.
4-2. TRANSMISSION OIL PRESSURE INDICATOR SYSTEM - OPERATIONAL CHECK
1. Close XMSN OIL PRESS circuit breaker.
2. Check XMSN OIL temperature and pressure indicator reads 0 5 psig.
NOTE
When performing following checks, a pressure tester capable of measuring at least
150 psig (1034 kPa) must be used.
3. Disconnect pressure input line from transmission oil pressure transmitter. Attach pressure tester and apply pressure to
transmitter input, but do not exceed 110 psig (758 kPa). Check XMSN OIL indicator reads 100 psig when input
pressure is 100 10 psig (689 69 kPa).
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E-AB412-PT6T-2
4. Relieve pressure and disconnect pressure tester. Reconnect pressure input line to transmission oil pressure transmitter.
4-3. TRANSMISSION OIL PRESSURE INDICATOR SYSTEM - TROUBLESHOOTING
Table 3. Transmission oil pressure indicator system troubleshooting
Transmission oil pressure indicator fails to Failure in electrical system. Check electrical system per
respond, although pressure exists. Chapter 96.
Open or defective XMSN OIL Reset or replace unit.

PRESS circuit breaker.
Defective transmitter and/or Replace defective unit.

indicator.
Transmission oil pressure indicator drives Wires reversed at pins B and C of Repair wiring.
down scale. transmitter plug.
Transmission oil pressure indicator indicates Defective transmitter and/or Replace defective unit.
incorrectly. indicator.
5. AC INDICATOR SYSTEMS - HYDRAULIC PRESSURE INDICATOR SYSTEMS
5-1. HYDRAULIC PRESSURE INDICATOR SYSTEMS - DESCRIPTION
In either hydraulic pressure indicator system, hydraulic pressure transmitter sends a signal to hydraulic pressure indicator
which is given in psig. The pressure portion is powered from the 26V AC buses 1 and 2, and registers indications received
from the hydraulic pressure transmitters.
5-2. HYDRAULIC PRESSURE INDICATOR SYSTEMS - OPERATIONAL CHECK
1. Close NO. 1 HYD PRESS circuit breaker. Apply external hydraulic pressure to No. 1 hydraulic system. Check that,
with external hydraulic pressures of 1000 psig (6895 kPa) and 1500 psig (10,342 kPa), HYDR SYS 1 hydraulic
pressure and temperature indicator reads within 50 psig of each pressure setting.
2. Repeat step 1. for the HYDR SYS 2 hydraulic pressure and temperature indicator, utilizing No. 2 HYD PRESS circuit
breaker and HYDR SYS 1 hydraulic pressure and temperature indicator.
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E-AB412-PT6T-2
5-3. HYDRAULIC PRESSURE INDICATOR SYSTEMS - TROUBLESHOOTING
Table 4. Hydraulic pressure indicator troubleshooting
Hydraulic pressure indicator fails to Defective circuit breaker. Replace defective circuit breaker.
respond when pressure exists.
Defective hydraulic pressure Replace defective unit(s).
transmitter and/or indicator.
Defective cable, loose connectors or Check cable, connectors and wiring.

defective wiring. Replace, tighten or repair as
applicable.
6. AC INDICATOR SYSTEMS - COMBINING GEARBOX (C BOX) OIL PRESSURE

INDICATOR SYSTEMS
6-1. COMBINING GEARBOX (C BOX) OIL PRESSURE INDICATOR SYSTEMS - DESCRIPTION
The C BOX oil pressure transmitter sends a signal to combining gearbox oil pressure and temperature indicator which is
given in psig.
6-2. COMBINING GEARBOX (C BOX) OIL PRESSURE INDICATOR SYSTEMS - OPERATIONAL CHECK
1. Close C BOX OIL PRESS circuit breaker. Disconnect pressure input line from pressure transmitter on the C BOX oil
pressure transmitter.
NOTE
2. Attach pressure tester and apply pressure to transmitter input, but do not exceed 100 10 psig (689 69 kPa). Check
gear box oil pressure and temperature indicator reads 100 psig when input pressure is 100 10 psig (689 69 kPa).
3. Disconnect pressure tester. Connect pressure input line to C BOX oil pressure transmitter.
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6-3. COMBINING GEARBOX (C BOX) OIL PRESSURE INDICATOR SYSTEMS - TROUBLESHOOTING
Table 5. Combining gearbox oil pressure indicator systems troubleshooting
C BOX OIL PRESS circuit breaker will not Defective C BOX OIL PRESS Replace defective unit.
reset. circuit breaker.
Defective transmitter and/or Replace defective unit(s).

indicator.
Gearbox oil pressure indicator fails to respond Inverters de-energized. Energize inverter.
when pressure exists.
Open or defective C BOX OIL Reset or replace unit.
PRESS circuit breaker.
Defective gearbox transmitter and/ Replace defective unit.

or indicator.
Gearbox oil pressure indicator pointer drives Wires reversed at pins B and C of Repair wiring.
down scale. transmitter plug.
Gearbox oil pressure indicator indicates Defective gearbox transmitter and/ Replace defective unit.
incorrectly. or indicator.
7. AC INDICATOR SYSTEMS - FUEL PRESSURE INDICATOR SYSTEMS
7-1. FUEL PRESSURE INDICATOR SYSTEMS - DESCRIPTION
In either fuel pressure indicator system, fuel pressure transmitter sends a signal to fuel pressure indicator which displays in
psig. The system is powered from the 26 V AC buses.
7-2. FUEL PRESSURE INDICATOR SYSTEMS - OPERATIONAL CHECK
1. Close ENG 1 FUEL PRESS circuit breaker. Check engine 1 FUEL PRESS indicator reads 0 3 psig.
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E-AB412-PT6T-2
NOTE
When performing the following checks a pressure tester capable of measuring at
least 150 psig (1034 kPa) must be used.
2. Disconnect pressure input line from engine 1 fuel pressure transmitter on engine No. 1. Attach pressure tester and
apply pressure to transmitter input line; do not exceed 57 psig (393 kPa). Check engine 1 FUEL PRESS indicator reads
50 psig when input pressure is 50 7 psig (345 48 kPa).
3. Disconnect pressure tester. Connect pressure line to engine 1 fuel pressure transmitter.
4. Close ENG 2 FUEL PRESS circuit breaker. Repeat steps 1., 2. and 3. for engine 2 fuel pressure transmitter on engine
No. 2.
7-3. FUEL PRESSURE INDICATOR SYSTEMS - TROUBLESHOOTING
Table 6. Fuel pressure indicator troubleshooting
FUEL PRESS circuit breaker(s) will not reset. Defective FUEL PRESS circuit Replace circuit breaker.
breaker.
Internal short in transmitter and/or Replace defective transmitter and/

indicator. or indicator.
Defective wiring. Repair or replace wiring.
Fuel pressure indicator fails to respond when Inverters deenergized. Energize inverter.
pressure exists.
Open or defective ENG 1 PRESS Reset or replace unit.
or ENG 2 FUEL PRESS circuit
breaker.
Defective fuel pressure transmitter Replace defective unit.

and/or indicator.
Fuel pressure drives down scale. Wires reversed at pins B and C of Repair wiring.
transmitter plug.
Fuel pressure indicates incorrectly. Defective fuel pressure transmitter Replace defective unit.
and/or indicator.
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8. AC INDICATOR SYSTEMS - ATTITUDE DIRECTOR INDICATOR SYSTEMS
8-1. ATTITUDE DIRECTOR INDICATOR SYSTEMS - DESCRIPTION
Attitude director indicators display flight attitude relative to the earth. Pilot and copilot attitude indicators utilize data from
respective three-axis reference sensor and rate gyro or the AHRS.
The applicable three-axis reference sensor or AHRS provide gyroscopic pitch and roll attitude data to pilot and copilot
attitude director indicator.
Pilot and copilot rate gyros or the AHRS provide data to rate-of-turn pointers which, together with inclinometers, function
as turn and slip portions of respective indicators.
The system is energized by 115V AC (attitude portion of indicators) and by 28 V DC (turn and slip portion of indicators).
It is protected by two ATTD SYSTEM circuit breakers and by TURN SLIP IND (PILOT/COPILOT) circuit breakers.
8-2. ATTITUDE DIRECTOR INDICATOR SYSTEMS - MAINTENANCE-RATE GYRO
The following maintenance procedures are applicable for pilot and copilot rate-of-turn gyros; therefore, typical procedures
are given.
8-3. ATTITUDE DIRECTOR INDICATOR SYSTEMS - REMOVAL
1. Loosen and disengage electrical connector from unit.
2. Protect ends of connector with caps or covers.
3. Remove mounting screws and washers and carefully remove unit from shelf.
8-4. ATTITUDE DIRECTOR INDICATOR SYSTEMS - INSTALLATION
1. Carefully position unit in place on shelf and install mounting screws and washers.
2. Remove protective caps or covers from ends of electrical connectors and connect to unit.
8-5. ATTITUDE DIRECTOR INDICATOR SYSTEMS - CLEANING
1. Remove grease, fungus, and ground-in dirt from case with a soft cloth dampened with approved cleaning compound.
2. Remove dirt from electrical connectors with a bristle brush and remove moisture with a dry, clean cloth.
8-6. ATTITUDE DIRECTOR INDICATOR SYSTEMS - INSPECTION
1. Inspect unit for cracked or damaged case.
2. Inspect for proper bonding and mounting.
3. Inspect for broken connector pins or cracked connector inserts.
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E-AB412-PT6T-2
8-7. ATTITUDE DIRECTOR INDICATOR SYSTEMS - REPAIR OR REPLACEMENT
1. Replace unit if case is cracked or damaged.
2. Tighten, replace, or adjust mounting hardware as necessary.
3. Repair or replace damaged airframe wiring connector.
4. Replace defective or inoperative unit.
8-8. ATTITUDE DIRECTOR INDICATOR SYSTEMS - OPERATIONAL CHECK
1. Close TURN SLIP PLT circuit breaker. Check associated rate gyro begins operating. Check RT flag, FD flag, and
horizontal and vertical command bars move out of sight and ATT flag remains in view.
2. Close PILOT ATT SYS circuit breaker. Check ATT flag moves out of view, attitude sphere erects to within 1 degree
in both pitch and roll within 3 minutes, and operation is stable.
3. Rotate roll trim knob on pilot attitude indicator to the stop in a clockwise direction. Check roll indication is 15 degrees
minimum right bank.
4. Rotate roll trim knob on pilot attitude indicator to the stop in a counterclockwise direction. Check roll indication is 15
degrees minimum left bank.
5. Rotate pitch trim knob to the stop in a clockwise direction. Check pitch indication is 10 degrees minimum dive.
6. Rotate pitch trim knob to the stop in a counterclockwise direction. Check that pitch indication is 15 degrees minimum
climb.
7. Open TURN SLIP PLT and PILOT ATT SYS circuit breaker. Check all flags come into view.
8. Repeat steps 1. through 7. for copilot attitude director indicator system.
8-9. ATTITUDE DIRECTOR INDICATOR SYSTEMS - TROUBLESHOOTING
Table 7. Attitude director indicator system troubleshooting
ATTD SYSTEM circuit breakers will not reset. Defective circuit breaker. Replace circuit breaker.
Internal short circuit in attitude Replace defective component.

indicator system.
TURN & SLIP 1 or 2 circuit breaker will not Defective circuit breaker. Replace circuit breaker.
reset.
Internal short circuit in attitude Replace defective component.
indicator system.
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(Cont.)
Attitude indicator sphere fails to operate. Defective wiring. Check connectors and circuit
continuity.Replace defective
connectors and/or repair wiring.
Indicator defective. Replace indicator.
Defective vertical displacement Replace defective component.

gyro(s).
Rate of turn pointer fails to operate. Defective wiring. Check electrical wiring and
connectors for continuity. Replace
defective connectors and/or repair
wiring.
Defective rate of turn gyro. Replace defective component.
9. AC INDICATOR SYSTEMS - TRIPLE TACHOMETER INDICATOR SYSTEMS
9-1. TRIPLE TACHOMETER INDICATOR SYSTEMS - DESCRIPTION
Each of the power turbine and rotor tach generators, sends a frequency signal, in percent of rpm, to each of the triple tach
indicators.
NOTE
Triple tachometer and gas producer tachometer indicator systems are ac self
generating and do not require ac power from helicopter inverters. In event of loss of
dc or ac electrical power from helicopter bus, ac self-generating equipment will
continue to operate.
9-2. TRIPLE TACHOMETER INDICATOR SYSTEMS - OPERATIONAL CHECK
T99 ENGINE TEST SET
1. Disconnect connector (P35/1G7P1) from main rotor tach generator and connect to matching connector on test set.
Energize tach generator in test set. Check rotor tach pointer on pilot triple tach indicator (and copilot triple tach
indicator, if installed) reads upscale and indicates approximate speed at which test set tach generator is turning.
2. Disconnect connector from test set and reconnect to rotor tach generator. Check connection is tight and properly mated.
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3. Disconnect connector (P111/1G1P1) from engine No. 1 power turbine tach generator and connect to test set. Energize
tach generator in test set. Check power turbine No. 1 pointer on pilot triple tach indicator (and on copilot indicator, if
installed) reads upscale and indicates approximate speed at which test set tach generator is turning.
4. Disconnect connector from test set and reconnect to power turbine tach generator on engine No. 1. Check connection
is tight and properly mated.
5. Disconnect connector (P112/1G2P1) from engine No. 2 power turbine tach generator and connect to test set. Energize
tach generator in test set. Check power turbine No. 2 pointer on pilot triple tach indicator (and on copilot indicator, if
installed) reads upscale and indicates approximate speed at which test set tach generator is turning.
6. Disconnect connector from test set and reconnect to engine No. 2 power turbine tach generator. Check connection is
tight and properly mated.
9-3. TRIPLE TACHOMETER INDICATOR SYSTEMS - TROUBLESHOOTING
Table 8. Triple tachometer indicator systems troubleshooting
Any one of pointers on the pilot's triple tach Corresponding tach generator Replace defective unit(s).
indicator fails to operate correctly. defective.
Defective tach indicator(s). Replace defective unit(s).
Any one of the pointers on either the pilot's or Wires reversed at pins A and B of Repair wiring.
copilot's tach indicator indicates backwards. tach generator plug(s).
Either pilot's or copilot's TRIPLE TACH Corresponding tach generator Replace defective unit.
indicator fails to operate or indicates defective.
incorrectly.
Defective tach indicator(s). Replace defective unit(s).
10. AC INDICATOR SYSTEMS - GAS PRODUCER TACHOMETER INDICATOR

SYSTEMS
10-1. GAS PRODUCER TACHOMETER INDICATOR SYSTEMS - DESCRIPTION
The gas producer tach generator on engine No. 1 sends a frequency signal to No. 1 engine gas producer indicator
proportional to engine No. 1 gas producer speed. Gas producer tach generator on engine No. 2 sends a frequency signal to
No. 2 engine gas producer indicator proportional to engine No. 2 gas producer speed. Gas producer speed indication is given
in percent of rpm.
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10-2. GAS PRODUCER TACHOMETER INDICATOR SYSTEMS - OPERATIONAL CHECK
T99 ENGINE TEST SET
1. Disconnect connector (P89/1G3P1) from engine No. 1 gas producer tach generator and connect to test set. Energize
tach generator in test set. Check engine No. 1 gas producer tach indicator reads upscale and indicates approximately
speed at which test set tach generator is turning.
2. Disconnect connector from test set and reconnect to engine No. 1 gas producer tach generator. Check connection is
3. Disconnect connector (P90/1G4P1) from engine No. 2 gas producer tach generator and connect to test set. Energize
test set tach generator. Check engine No. 2 gas producer tach indicator reads upscale and indicates approximate speed
at which test set tach generator is turning.
4. Disconnect connector from test set and reconnect to engine No. 2 gas producer tach generator. Check connection is
10-3. GAS PRODUCER TACHOMETER INDICATOR SYSTEMS - TROUBLESHOOTING
Table 9. Gas producer tachometer indicator systems troubleshooting
Either engine 1 or 2 gas producer RMP Corresponding tach generator Replace defective tach
indicator fail to operate. defective. generator(s).
Defective tach indicator(s) Replace defective tach indicator(s).
Either the engine 1 or 2 gas producer RPM Corresponding tach generator Replace defective tach
indicator indicates incorrectly. defective. generator(s).
Defective tach indicator(s). Replace defective tach indicator(s).
Either the engine 1 or 2 gas producer RPM Wires reversed at pins A and B of Remove plug(s) and reverse wires
indicator indicates backwards. tach generators. at pins A and B.
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11. AC INDICATOR SYSTEMS - FUEL QUANTITY INDICATOR SYSTEM [A] [B]
11-1. FUEL QUANTITY INDICATOR SYSTEM [A] [B] - DESCRIPTION
NOTE
Refer to module 96-24-36 paragraph "10. DC indicator systems - fuel quantity
indicator system [C] [D]" for helicopters codes [C] [D].
The fuel quantity indicator provides readings of fuel supply quantity in total pounds as determined by position of the fuel
quantity selector switch (LEFT, TOTAL or RIGHT). The system is powered from the 115 V AC bus No. 1.
AC power is supplied to the fuel quantity indicating system through the FUEL QTY circuit breaker on the overhead console.
Each fuel transmitter send a signal to the fuel quantity indicator where it is summed and displayed in total lbs. of fuel. A
switch is provided, on the pilot instrument panel, for checking fuel quantity in the left or right fuel cells.
11-2. FUEL QUANTITY INDICATOR SYSTEM [A] [B] - TROUBLESHOOTING
Table 10. Fuel quantity indicator system [A] [B] troubleshooting
FUEL QTY circuit breaker will not reset. Defective FUEL QTY circuit Replace defective unit.
breaker.
Internal short in the fuel quantity Replace defective unit(s).

system (fuel cells, or indicators).
Fuel quantity indicator fails to operate in 115 V ac BUS 1 de-energized. Energize inverter.
mode.
Open or defective FUEL QTY Reset or replace defective unit.
circuit breaker.
Defective fuel quantity indicator. Replace defective unit.
Defective selector switch. Replace switch.
Fuel quantity indicator indicates incorrectly. Defective fuel quantity indicator. Replace indicator.
Defective fuel quantity Replace defective unit(s).

transmitter(s).
Improperly adjusted. Recalibrate fuel quantity indicating

system.
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E-AB412-PT6T-2
11-3. FUEL QUANTITY INDICATOR SYSTEM [A] [B] - TESTING AND CALIBRATION
11-3-1. Testing and calibration - insulation resistance test tank unit and system wiring installation
Refer to Simmonds Precision Maintenance Manual for Installation No. 380807-001, -002, -003, Chapter 28.
11-3-2. Testing and calibration - preferred method-no fuel in tanks
T100 ENGINE TEST SET
During the following procedures, ensure the indicator remains connected.
1. Ensure helicopter is defueled.
2. Remove fuel quantity indicator from instrument panel.
3. Close FUEL QTY circuit breaker.
4. Adjust EMPTY control on back of indicator, if required, until indicator reads exactly zero.
5. Verify indicator pointer is stable (does not oscillate).
6. Open FUEL QTY circuit breaker.
7. Connect Field Calibration Unit to system using appropriate cabling (see figure 1).
8. Set FUEL QTY SEL switch to TOTAL.
9. Set tank unit capacitance decade on calibration unit for values shown in figure 1.
10. Adjust FULL control on back of indicator until indicator reads correct full indication, and is stable.
11. Disconnect Field Calibration Unit.
12. Return fuel system to its original configuration.
13. Verify all connector are secure and tight.
14. Verify indicator reads zero.
11-3-3. Testing and calibration - alternate method-fuel in tanks
Refer to Simmonds Precision Maintenance Manual for Installation No. 380807-001, -002, -003, Chapter 28.
11-3-4. Testing and calibration - maintenance fuel quantity coupler CP1/1CP1
11-3-4-1. Maintenance fuel quantity coupler CP1/1CP1 - removal
1. Disconnect and protect connectors.
2. Remove mounting hardware.
3. Remove coupler from compartment.
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11-3-4-2. Maintenance fuel quantity coupler CP1/1CP1 - installation
1. Install coupler in compartment and secure with hardware.
2. Remove protection from connectors.
3. Install connector on coupler.
11-3-4-3. Maintenance fuel quantity coupler CP1/1CP1 - inspection
1. Inspect coupler case for cracks, dents, and corrosion.
2. Inspect connector for loose, bent, or missing contacts.
3. Inspect connector for dirt, grease, or corrosion.
11-3-4-4. Maintenance fuel quantity coupler CP1/1CP1 - repair or replacement
1. Replace coupler if inspection requirements are not met.
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E-AB412-PT6T-2
G6AB0641A
Figure 1. Test setup for fuel quantity indicator calibration, dry tanks
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96-24-30 DC POWER SYSTEM
96-24-30
DC POWER SYSTEM
1. DC POWER SYSTEM - DESCRIPTION
The dc power systems include battery, external power, starter-generator, and igniter systems. Refer to Chapter 98 for wiring
diagrams.
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96-24-31
DC POWER SYSTEM - BATTERY SYSTEM
1. BATTERY SYSTEM - DESCRIPTION
The battery is provided for engine starting and as a backup source of emergency power. The battery circuit is activated by
any of the following procedures.
1. Verify NO. 1 BUS BAT and NO. 2 BUS BAT circuit breakers are closed.
2. Close both NO. 1 ESNTL BUS FEEDER and NO. 2 ESNTL BUS FEEDER circuit breakers on left overhead console
and set BATTERY BUS switch to ON.
3. Close both NO. 1 ESNTL BUS FEEDER and NO. 2 ESNTL BUS FEEDER circuit breakers on right overhead console
and set BATTERY BUS switch to ON.
SYS 1 and SYS 2 dual voltmeter will indicate battery voltage when GEN 1 RESET and GEN 2 RESET circuit breakers are
set. After the battery has been used for engine starting and the starter-generators are on line, the dual ammeter will indicate
a high current. As the state of the battery charge increases the ammeter reading will decrease until the battery is completely
charged. With the battery completely charged there will be no perceptible difference in the dual ammeter reading when the
BATTERY switch is moved from ON to OFF.
2. BATTERY SYSTEM - REMOVAL
1. Verify BATTERY BUS 1 and BATTERY BUS 2 switches are OFF and external power is not applied.
2. Open compartment door.
3. Disconnect battery cable connector by turning knob counterclockwise.
4. Disconnect battery temperature connector (if installed).
5. Disconnect vent tubes from battery case.
6. Open tiedown clamps and disengage rods from battery cover.
7. Remove battery from compartment.
8. Close compartment door.
3. BATTERY SYSTEM - INSTALLATION
2. Place battery on shelf, aligned for connections.
3. Engage tiedown rods to strap on cover.
4. Connect vent tubes to battery case.
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5. Connect battery temperature connector (if installed).
6. Connect battery cable connector by turning knob clockwise.
7. Check dual voltmeter to verify battery is charged.
4. BATTERY SYSTEM - INSPECTION
MATERIALS REQUIRED
NUMBER NOMENCLATURE
C-489 BORIC ACID SOLUTION
Inspect battery for the following conditions:
1. Loose connections at disconnect or between cells.
WARNING
THE ELECTROLYTE IS A STRONG CAUSTIC ALKALINE SOLUTION THAT

IS HARMFUL TO SKIN OR CLOTHING. USE A 3% SOLUTION OF BORIC
ACID SOLUTION (C-489) TO NEUTRALIZE SPILLED ELECTROLYTE.
FLUSH THOROUGHLY WITH WATER AND SEEK IMMEDIATE MEDICAL
AID.
CAUTION
SODIUM BICARBONATE WILL NOT NEUTRALIZE THE ELECTROLYTE

FROM A NICKEL CADMIUM BATTERY. TO PREVENT CORROSION,
NEUTRALIZE SPILLED ELECTROLYTE IN THE BATTERY COMPARTMENT
WITH A 3% SOLUTION OF BORIC ACID SOLUTION (C-489).
2. Electrolyte for proper level.
3. Clogged vent plugs or tubes.
4. Damage to individual cell cases (distortion due to overcharge, cracks, or leaks).
5. Corrosion.
NOTE
Replace battery if inspection requirements are not met. Repair of battery shall be
accomplished at an authorized battery repair station only.
5. BATTERY SYSTEM - OPERATIONAL CHECK
1. Before connecting power to battery circuitry:
a. Open all circuit breakers.
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b. Set all switches to off or normal position.
c. Verify that an open circuit exists between positive terminals of quick-disconnect and ground.
d. Check all battery circuitry connections for tightness and correct polarity.
NOTE
The following tests of battery circuitry shall be performed using installed 24 Vdc
battery as a power source, or alternatively, an external 24 Vdc power source
connected to battery connector.
2. Connect battery.
3. Close the following circuit breakers in the nose compartment:
— BUS 1 BATT
— EMERG BUS 1
4. Set BATTERY BUS 1 switch ON.
NOTE
NO. 1 MAIN DC BUS and NO. 2 MAIN DC BUS are located in the overhead
console.
5. Verify battery voltage at NO. 1 MAIN DC BUS.
6. Verify no voltage is present at NO. 2 MAIN DC BUS.
7. Close the following circuit breaker switches in the nose compartment:
— BUS 2 BATT
— EMERG BUS 2
9. Verify battery voltage is present at NO.1 and NO. 2 MAIN DC BUS.
10. Verify SYS 1 and SYS 2 dual voltmeters indicate 0 (zero) volts.
11. Close the following circuit breakers on LH overhead console:
— NO. 1 ESNTL BUS FEEDER
— GEN 1 RESET
12. Verify SYS 1 dual voltmeter indicates battery voltage.
13. Verify SYS 2 dual voltmeter indicates 0 (zero) voltage.
14. Repeat steps 11. through 13. with NO. 1 ESNTL BUS FEEDER circuit breaker open on LH overhead console and
closed on RH overhead console.
15. Open NO. 1 ESNTL BUS FEEDER circuit breaker.
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16. Close the following circuit breakers on LH overhead console:
— GEN 2 RESET
17. Verify SYS 2 dual voltmeter indicates battery voltage.
18. Verify SYS 1 dual voltmeter indicates 0 (zero) voltage.
19. Repeat steps 16. through 18. with NO. 2 ESNTL BUS FEEDER circuit breaker open on LH overhead console and
closed on RH overhead console.
20. Place NON-ESNTL BUS switch to NORMAL and close NON ESS BUS circuit breaker.
21. Close all NO. 1 ESNTL BUS FEEDER circuit breakers.
22. Verify no voltage is present on NON-ESSENTIAL BUS.
24. Verify battery voltage is present on NON-ESSENTIAL BUS.
25. Set BATTERY BUS 1 switch OFF.
30. Close MASTER CAUTION circuit breaker.
31. Set EMERG LOAD switch to EMERG LOAD.
32. Verify BATTERY caution light is illuminated.
33. Switch BATTERY BUS 2 switch ON then OFF.
34. Verify BATTERY caution light remains illuminated.
35. Set BATTERY BUS NO. 1 switch OFF.
36. Verify BATTERY caution light remains illuminated.
37. Set EMERG LOAD switch NORMAL.
42. Verify BATTERY caution light is extinguished.
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46. Verify BATTERY caution light is extinguished.
6. BATTERY SYSTEM - MAINTENANCE
Nickel-cadmium batteries shall not be serviced while installed in helicopter. Batteries shall be removed and serviced every
100 hours by authorized battery shop personnel only. For additional information refer to vendors manual.
7. BATTERY SYSTEM - SERVICE
MATERIALS REQUIRED
NUMBER NOMENCLATURE
C-237 VARNISH
C-489 BORIC ACID SOLUTION
NOTE
Nickel-cadmium batteries shall not be serviced while installed in helicopter.
Batteries shall be removed and serviced every 100 hours by authorized battery shop
personnel only.
Clean battery and battery compartment as follows:
CAUTION
TO PREVENT CONTAMINATION, DO NOT USE EQUIPMENT THAT HAS

BEEN USED ON LEAD ACID BATTERIES.
TO PREVENT THE POSSIBILITY OF SHORTING THE INDIVIDUAL CELLS,

DO NOT USE A WIRE BRUSH TO CLEAN THE BATTERY AND ENSURE THE
VENT PLUGS ARE CLOSED BEFORE STARTING TO CLEAN BATTERY.
ENSURE OUTSIDE OF BATTERY IS COMPLETELY DRY BEFORE
RETURNING TO USE.
1. Disconnect and remove battery.
2. Clean battery with a dry stiff fiber brush or wash with water.
3. Verify battery compartment is clean and free of alkaline deposits.
4. Check for corrosion; if present, remove with boric acid solution (C-489).
5. Retouch varnished surfaces with varnish (C-237) (as required).
6. Install and connect battery.
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NOTE
With the battery completely charged there will be no perceptible difference in the
dual ammeter reading when the BATTERY switch is moved from ON to OFF.
7. Ensure battery is fully charged.
8. BATTERY SYSTEM - TROUBLESHOOTING
Table 1. Battery system troubleshooting
No battery voltage is indicated on either No. Open or defective BATTERY BUS Close or replace switch.
1 or No. 2 DC VOLTS meters. 2 (or BATTERY BUS 1) switch.
Open or defective BUS 2 BAT SW Close or replace circuit breakers.

(or BUS 1 BAT SW) circuit
breaker.
Defective No. 2 (or No. 1) BUS Replace replay.

BATTERY relay.
Severely discharged or defective Charge or replace battery.

battery.
All No. 1 and No. 2 ESSENTIAL Close all ESSENTIAL BUS

BUS FEEDERS circuit breakers FEEDERS circuit breakers.
open.
Both GEN RESET circuit breakers Close or replace circuit breakers.

are open or defective.
No battery voltage is indicated on No. 1 DC Defective No. 1 GEN RESET Replace circuit breaker.
VOLTS meter. Normal battery voltage is circuit breaker.
indicated on No. 2 DC VOLTS meters.
Defective No. 1 DC VOLTS meter. Replace meter.
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E-AB412-PT6T-2
(Cont.d)
If BATTERY BUS 2 switch is used

to place battery on buses. (Normal
operation condition):
Defective diodes in No. 1 essential Replaces diodes.

bus feeder circuit.
Defective No. 1 ESSENTIAL BUS Replace circuit breakers.

FEEDERS circuit breakers in right
hand overhead console.
If BATTERY BUS 1 switch is used,

(alternate condition):
Defective diodes in No. 1 essential Replace diodes.

bus feeder circuit.

circuit breakers in left-hand
overhead console.
No battery voltage is indicated on No. 2 DC Defective No. 2 GEN RESET Replace circuit breaker.
VOLTS meter. Normal battery voltage is circuit breaker.
indicated on No. 1 DC VOLTS meter.
Defective No. 2 DC VOLTS meter. Replace meter.

to place battery on buses. (Normal
operation condition):
Defective diodes in No. 2 essential Replaces diodes.

bus feeder circuit.

FEEDERS circuit breakers in right
hand overhead console.
96-24-31
Rev. 3 Page 7
E-AB412-PT6T-2
(Cont.d)

(alternate condition):
Defective diodes in No. 2 essential Replace diodes.

bus feeder circuit.

FEEDERS circuit breakers in
left-hand overhead console.
Battery does not provide power to Defective NON ESS BUS switch. Replace switch.
non-essential busses with NON ESS BUS
switch set to MANUAL position. Defective non-essential bus relay Replace defective relay.
No. 1 or No. 2.
Defective wiring. Replace wiring.
DC VOLTS meter indicates less than 19 volts Defective or discharged battery. Replace or recharge battery.
dc.
Defective voltmeter. Replace voltmeter.
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E-AB412-PT6T-2
96-24-32
DC POWER SYSTEM - EXTERNAL POWER SYSTEM
1. EXTERNAL POWER SYSTEM - DESCRIPTION
CAUTION
ELECTRICAL/ELECTRONIC SYSTEMS ARE NOT PROTECTED FROM AN

OVERVOLTAGE CONDITION WHEN OPERATING ON EXTERNAL POWER.
TO PREVENT DAMAGE TO ELECTRICAL/ELECTRONIC SYSTEMS,
ENSURE THE EXTERNAL POWER SOURCE IS EQUIPPED WITH AN
OVERVOLTAGE PROTECTION CIRCUIT.
External power is connected to the helicopter electrical systems through the external power receptacle. No special action or
switching are required to connect external power. If external power connections are of proper polarity, the external power
relay closes automatically and connects ground unit to main dc bus 2. If the connections are not of proper polarity, no action
occurs.
For helicopters codes [A] [B], No. 1 and No. 2 dc essential buses may be energized by closing GEN 1 RESET, GEN 2
RESET, and all ESNTL BUS FEEDER circuit breakers. The nonessential bus may be energized by setting NON-ESNTL
BUS switch to MANUAL. This allows complete checkout of all equipment or other ground operations to be performed.
For helicopters codes [C] [D], No. 1 and No. 2 dc essential buses and No. 1 and No. 2 emergency buses are energized, when
all ESNTL BUS FEEDER circuit breakers are closed. With battery installed, nonessential bus No. 1 and No. 2 may be
energized by placing the NON-ESNTL BUS switch to MANUAL. This allows accomplishment of operational checks and
other ground operations.
2. EXTERNAL POWER SYSTEM - RECEPTACLE
2-1. RECEPTACLE - REMOVAL
1. Ensure electrical power is off.
2. Remove nuts and washers from terminal post of receptacle.
3. Identify and remove conductors from receptacle.
4. Protect conductor ends with electrical tape.
5. Remove mounting screws and lift receptacle from bracket.
2-2. RECEPTACLE - INSTALLATION
1. Position receptacle on bracket and secure with mounting screws.
2. Remove electrical tape from conductors and position on terminals.
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E-AB412-PT6T-2
3. Secure conductors to terminals with existing hardware.
2-3. RECEPTACLE - INSPECTION
1. Visually check contact pins in receptacle for corrosion and looseness.
2. Check wiring and terminals for evidence of overheating.
2-4. RECEPTACLE - REPAIR
1. Replace external power receptacle if inspection requirements are not met.
3. EXTERNAL POWER SYSTEM - OPERATIONAL CHECK
Before connecting external power:
1. All switches are set to off or normal position.
2. Visually check external power receptacle wiring for correct polarity and terminations.
3. Apply 28 Vdc reverse polarity power between small pin in external power receptacle and helicopter structure (positive
to helicopter structure and negative to small pin in external power receptacle).
4. Verify external power relay (K1/2K1) does not close.
5. Remove 28 Vdc reverse polarity power.
6. Connect dc power source to external power receptacle and energize.
7. Adjust external power source to 28 0,5 Vdc.
8. Verify 28 0,5 Vdc is present on No.2 MAIN DC BUS and zero Vdc is present on No.1 MAIN DC BUS.
— GEN 1 RESET
— GEN 2 RESET
— For helicopters codes [C] [D] close also MAIN DC No. 1 circuit breaker.
10. Verify both dual volt meters indicate 28 0,5 Vdc.
11. Deenergize external power source.
12. Verify dual voltmeter indicates zero Vdc.
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E-AB412-PT6T-2
4. EXTERNAL POWER SYSTEM - TROUBLESHOOTING
Table 1. External power system troubleshooting
Unable to obtain external power for electrical Defective EXP PWR DIODE. Replace diode.
system when external power source plug in
inserted into external power receptacle. Defective EXP PWR REL (K1). Replace relay.
Voltage from external source too Increase voltage output of external

low. (Less than 28 Vdc). power source.
Reverse polarity in plug. Check connectors at attachment

points on APU for proper
connection.
External power relay (K1) is energized with Defective diode. Replace diode.
reverse polarity voltage applied to EXT PWR
receptacle (J3). Defective wiring. Repair wiring.
No power available on non-essential bus. NON-ESS BUS switch in Place NON-ESS BUS switch in
External power applied, and both DC VOLTS NORMAL position. MANUAL position to energize
meters indicate normal voltage. non-essential bus when generators
are not operating.
Defective No. 1 or No. 2 Replace overload sensor.

non-essential bus overload sensor.
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E-AB412-PT6T-2
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Page 4
E-AB412-PT6T-2
96-24-33
DC POWER SYSTEM - GENERATOR SYSTEM
1. GENERATOR SYSTEM - DESCRIPTION
The primary 28 Vdc power system consists of two starter-generator systems, designed to work independently of each other,
or in conjunction with each other to produce a composite dual generator system. The two generating systems normally
operate in parallel and equally share total load on dc buses. In event of failure of one generator, remaining generator is
capable of supplying essential loads on helicopter bus. Maintenance of the starter-generators is covered in chapter 71 of this
manual.
2. GENERATOR SYSTEM - OPERATIONAL CHECK
2-1. OPERATIONAL CHECK - GENERATOR NO. 1 SYSTEM
1. Remove lower nose access panel located underneath nose of helicopter.
2. Remove voltage setting protective cover from No. 1 DC CONTROL PANEL.
3. Set GEN 1, GEN 2, BATTERY BUS 1, and BATTERY BUS 2 switches to OFF positions.
4. Remove all electrical power from helicopter buses.
5. Connect one end of a 3-ft. length of helicopter wire to load side of a 5 ampere circuit breaker.
6. Connect bus side of circuit breaker to terminal A1 (generator side) of bus NO. 1 BUS/BAT CONTROL RELAY.
7. Leave other end of wire disconnected, but protect it from accidental short to ground or to other circuitry.
8. Ensure 5 ampere circuit breaker is open.
NOTE
Either the helicopter battery or an external 28 Vdc power source may be used for
starting power.
9. Make a normal start of No. 1 engine.
10. Bring engine 1 starter-generator to normal operating speed but do not close GEN 1 switch.
11. Energize only minimum electrical equipment necessary for normal starting and ground run.
12. Insert voltmeter probes into test jacks on No. 1 DC CONTROL PANEL observing correct polarity.
13. Verify voltmeter indicates normal generator voltage (27 to 28 Vdc).
14. Close 5 ampere circuit breaker and place GEN 1 switch to ON.
15. Momentarily short loose end of wire on the 5 ampere circuit breaker to ground.
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E-AB412-PT6T-2
16. Remove short and check voltmeter reading is approximately zero volts.
17. Set GEN 1 switch to RESET and then OFF.
18. Verify voltmeter indicates normal generator voltage.
19. Set GEN 1 switch to ON.
20. Verify ENG 1 DC GENERATOR caution light on master caution panel extinguishes and both dual voltmeters indicate
normal generator voltage.
21. Momentarily energize a load supplied by essential dc bus No. 1, such as landing light.
22. Verify No. 1 ammeter reads upscale.
23. Set GEN 1 switch to OFF.
24. Verify ENG 1 DC GENERATOR caution light on master caution panel illuminates.
25. Shut down No. 1 engine.
26. Remove electrical power from helicopter buses.
27. Remove voltmeter probes from test jacks of No. 1 DC CONTROL PANEL.
28. Install voltage setting protective cover on No. 1 DC CONTROL PANEL.
29. Remove wire and 5 ampere circuit breaker.
30. Install lower nose access panel.
2-2. OPERATIONAL CHECK - GENERATOR NO. 2 SYSTEM
1. Remove lower nose access panel, located underneath nose of helicopter.
2. Remove voltage setting protective cover from No. 2 DC CONTROL PANEL.
3. Set GEN 1, GEN 2, BATTERY BUS 1, and BATTERY BUS 2 switches to OFF.
4. Connect one end of a 3-ft. length of helicopter wire to load side of a 5 ampere circuit breaker.
5. Connect bus side of circuit breaker to terminal A2 (generator side) of No. 2 BUS/BAT CONTROL RELAY.
6. Leave other end of wire disconnected, but protect it from accidental short to ground or to other circuitry.
7. Verify 5 ampere circuit breaker is open.
NOTE
Either the helicopter battery or an external 28 Vdc power source may be used for
starting power.
8. Make a normal start of No. 2 engine.
9. Bring engine 2 starter-generator to normal operating speed but do not close GEN 2 switch.
10. Energize only minimum electrical equipment necessary for normal starting and ground run.
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E-AB412-PT6T-2
11. Insert voltmeter probes into test jacks on No. 2 DC CONTROL PANEL observing correct polarity.
12. Verify voltmeter indicates normal generator voltage (27 to 28 Vdc).
13. Close 5 ampere circuit breaker and set GEN 2 switch to ON.
14. Momentarily short to ground the loose end of wire on 5 ampere circuit breaker.
15. Remove short and check voltmeter reading is approximately zero volts.
16. Set GEN 2 switch to RESET and then OFF.
17. Verify voltmeter indicates generator output voltage.
18. Set GEN 2 switch to ON.
19. Verify ENG 2 DC GENERATOR caution light on master caution panel extinguishes and both dual voltmeters indicate
generator voltage.
20. Momentarily energize a load supplied by essential dc bus No. 2 such as landing light.
21. Verify No. 2 ammeter reads upscale.
23. Verify ENG 2 DC GENERATOR caution light on master caution panel illuminates.
24. Shut down No. 2 engine.
26. Remove voltmeter probes from test jacks of No. 2 DC CONTROL PANEL.
27. Install voltage setting protective cover on No. 2 DC CONTROL PANEL.
28. Remove wire and 5 ampere circuit breaker.
2-3. OPERATIONAL CHECK - GENERATOR NO. 1 AND GENERATOR NO. 2 SYSTEM
1. Remove lower nose access panel located underneath nose of helicopter.
2. Operate both engines at flight idle speed in accordance with normal ground run operations.
3. Ensure both BATTERY switches are ON.
4. Verify battery voltage is present on both buses, indicating the two primary dc buses are connected.
CAUTION
IF RESULTS DESCRIBED IN STEPS 5. OR 6. ARE NOT OBTAINED,

IMMEDIATELY SET BATTERY SWITCHES AND BOTH GEN SWITCHES TO
OFF. THIS WILL PREVENT DAMAGE TO STARTER-GENERATORS IF
EITHER OR BOTH DC CONTROL UNITS SHOULD BECOME DEFECTIVE.
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E-AB412-PT6T-2
5. Set GEN 1 and GEN 2 switches to ON. Verify both dual voltmeters indicate approximately 27 to 28 Vdc.
6. Connect voltmeter to generator circuitry terminal of No. 2 START-GEN RELAY. Verify voltmeter indicates generator
voltage.
7. Simulate an engine failure by shutting off No. 2 engine fuel supply.
8. While monitoring helicopter dual voltmeter:
a. Verify ENG 2 DC GENERATOR caution light on master caution panel illuminates.
b. Verify Engine 2 starter-generator loses speed.
c. Verify No. 2 generator voltage decreases.
d. Verify both dual voltmeters indicate previous values.
9. Disconnect voltmeter from No. 2 START-GEN RELAY.
10. Connect voltmeter to generator circuitry terminal of engine 1 starter-generator.
11. Simulate a second engine failure by shutting off No. 1 engine fuel supply.
12. While monitoring both dual voltmeters:
a. Verify ENG 1 DC GENERATOR caution light on master caution panel illuminates.
b. Verify Engine 1 starter-generator loses speed.
c. Verify No. 1 generator voltage decreases.
d. Verify both dual voltmeter indications drop to and remain at battery potential.
13. Set BATTERY switches to OFF.
14. Verify both dual voltmeters indicate zero voltage.
15. Set all switches to off or normal position.
16. Remove voltmeter.
17. Close lower nose access panel.
2-4. OPERATIONAL CHECK - VOLTAGE CONTROL PARALLELING ADJUSTMENT
NOTE
Perform equalization adjustment only after completing operational check of
generator No. 1 and No. 2 systems (paragraph "2-3. Operational check - generator
No. 1 and generator No. 2 system").
1. Remove lower nose access panel.
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E-AB412-PT6T-2
CAUTION
DO NOT DISCONNECT OR RECONNECT CABLE TO CONTROL UNIT

WHEN GENERATORS ARE ROTATING, AS THIS MAY CAUSE DAMAGE TO
CONTROL UNIT.
2. Close circuit breakers required for engine starting and ground run.
3. Start both engines.
NOTE
Do not set generator switches ON until specified in following steps.
4. Increase and maintain engine speed to indicate 71 percent N1 or greater.
5. Set GEN 1 switch to RESET and then to OFF.
6. Set GEN 2 switch to RESET and then to OFF.
7. Measure voltage at No. 1 DC CONTROL UNIT test jacks with a digital voltmeter (figure 1). If necessary, adjust the
No. 1 DC CONTROL UNIT for the required voltage as follows:
SEASONAL TEMPERATURE VOLTAGE SETTING
Maximum daily ambient temperature does not exceed 58F (14,4C) 28,0 ± 0,1 volts dc
Maximum daily ambient temperature exceeds 58F (14,4C) 27,0 0,1 volts dc
8. Measure voltage at No. 2 DC CONTROL UNIT test jacks with a digital voltmeter (figure 1). If necessary, adjust the
No. 2 DC CONTROL UNIT until the voltage is ± 0,1 VDC of that voltage set for No. 1 GENERATOR.
9. Connect digital voltmeter positive lead to positive test jack of No. 1 DC CONTROL UNIT and connect negative lead
to positive test jack of No. 2 DC CONTROL UNIT (figure 1).
10. Verify that meter reads 0,00 ± 0,1 VDC.
11. If necessary, adjust only one of the DC CONTROL UNITS until voltmeter indicates 0,1 VDC or less.
12. Set GEN 1 and GEN 2 switches to ON.
NOTE
Battery BUS 1 switch automatically switched to OFF in previous step.
13. Set BATTERY BUS 2 switch to OFF.
14. Continue parallel operation (both generators operating) for 5 minutes. During this time, observe dual ammeter and
verify that the differential between the two generators does not exceed 20 amperes.
15. Shut down both engines.
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E-AB412-PT6T-2
2-5. OPERATIONAL CHECK - NONESSENTIAL BUS SYSTEM
Operational check of nonessential bus system should be performed immediately after completing equalization adjustment
with both generators operating and parallel.
1. Close NON ESNTL BUS circuit breaker.
2. Place NON-ESNTL BUS switch to MANUAL.
3. Check for 28 Vdc on nonessential bus in overhead console.
4. Set NON-ESNTL BUS switch to NORMAL. Check for 28 Vdc on nonessential bus in overhead console.
6. Verify ENG 2 DC GENERATOR caution light on MASTER CAUTION PANEL is illuminated.
7. Check for zero volts on nonessential bus.
9. Check for 28 Vdc on nonessential bus.
10. Set GEN 2 switch to ON and GEN 1 switch to OFF.
11. Check for 28 Vdc on nonessential bus.
3. GENERATOR SYSTEM - TROUBLESHOOTING
Table 1. Generator system troubleshooting
ENG 1 DC GENERATOR caution light fails to Defective caution light. Replace caution light.
illuminate when No. 1 generator is off. (GEN
No. 1 switch in OFF position). Defective DC CONT UNIT. Replace unit.
Defective GEN No. 1 switch. Replace switch.
Defective No. 1 GEN RELAY. Replace relay.
ENG 1 DC GENERATOR caution light Defective caution light. Replace caution panel.
remains illuminated when No. 1 generator is
energized. Defective DC CONT UNIT. Replace unit.
Defective START CONT RELAY Replace relay.

No. 1.
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E-AB412-PT6T-2
(Cont.)
ENG 2 DC GENERATOR caution light fails to Defective caution light. Replace caution light.
illuminated when No. 2 generator is off (GEN
No. 2 switch in OFF position). Defective DC CONT UNIT. Replace unit.
ENG 2 DC GENERATOR caution light Defective caution light. Replace caution panel.
remains illuminated when No. 2 generator is
energized. Defective DC CONT UNIT. Replace unit.

No. 2 (K8).
DC VOLTS meter No. 1 dc voltage varies with Defective DC CONT UNIT. Replace unit.
No. 1 engine RPM.
Defective starter generator. Replace unit.
DC VOLTS meter No. 1 dc voltage low. Defective DC CONT UNIT. Replace unit and/or adjust
voltage.
Defective diodes. Replace diode(s).
Defective voltmeter. Repair meter.
Defective circuit breakers. Replace unit(s).
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E-AB412-PT6T-2
(Cont.)
DC VOLTS meter No. 1 dc voltage high. Defective DC CONT UNIT. Replace unit and/or adjust
voltage.
DC VOLTS meter No. 2 dc voltage varies with Defective DC CONT UNIT. Replace unit.
No. 2 engine RPM.
DC VOLTS meter No. 2 dc voltage low. Defective DC CONT UNIT. Replace unit and/or adjust
voltage.
Defective diodes. Replace diodes.
Defective voltmeter. Repair meter.
Defective circuit breakers. Replace units.
DC VOLTS meter No. 2 dc voltage high. Defective DC CONT UNIT. Replace unit and/or adjust
voltage.
AMMETER does not indicate proper load Defective DUAL AMMETER. Replace meter.
current for No. 1 generator.
Defective SHUNT GEN 1. Replace shunt.
AMMETER does not indicate proper load Defective DUAL AMMETER. Replace meter.
current for No. 2 generator.
No. 1 generator must frequently be RESET Defective DC CONT UNIT. Replace unit and/or adjust No. 1
without an overvoltage condition existing generator voltage for zero
under normal operating conditions. differential voltage.
No. 2 generator must frequently be RESET Defective DC CONT UNIT. Replace unit and/or adjust No. 2
without an overvoltage condition existing generator voltage for zero
under normal operating conditions. differential voltage.
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E-AB412-PT6T-2
(Cont.)
Non-essential dc bus will not energize with Defective NON-ESS switch. Replace switch.
both starter, generators operating (NON-ESS
switch in MAN position). Defective NON-ESS BUS Replace relay.
RELAY No. 1.
Defective NON-ESS BUS Replace relay.

RELAY No. 2.
Defective FEEDER SENSOR. Replace sensor.
Defective FEEDER SENSOR Replace sensor.

(S186).
Defective circuit breaker. Replace circuit breaker.
Non-essential dc bus will not energize with In addition to above: In addition to above:
both starter generators operating (NON-ESS Defective NON-ESS BUS Replace relay.
switch in NOR position). RELAY.
Defective NON-ESS BUS Replace relay.

RELAY.
Conditions normal. DC VOLTS meter DC Regulators No. 1 and No. 2 Adjust DC regulators No. 1 and/or
indications do not agree. out of adjustment. No. 2.
NOTE
If adjustment settings do not
correct the cause, replace DC
regulators.
AMPS meter does not indicate approximately Open circuit between pin K of Repair wire connecting pin K of
equal load on each generator. connector on Control Unit No. 1 Control Unit No. 1 to pin K of
and pin K of connector on Control Control Unit No. 2.
Unit No. 2.
Improper voltage adjustment of Shut down generators one at a

one control unit. time and adjust for proper voltage
on each. Voltage should be equal
when independently measured.
96-24-33
Page 9
E-AB412-PT6T-2
G6AB0744A
Figure 1. Voltage control paralleling adjustment
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Page 10
E-AB412-PT6T-2
96-24-34
DC POWER SYSTEM - STARTER AND IGNITER SYSTEMS
1. STARTER AND IGNITER SYSTEMS - DESCRIPTION
One starter-generator is mounted on each of the two engines. If electrical power is supplied to the series (or starter) winding,
the starter-generator will produce a rotational torque for starting the engine. Electrical power may be from the battery or
from an external source of 28 Vdc power. Starting of engine No. 1 is accomplished by closing ENGINE NO. 1 IGN circuit
breaker and ENGINE NO. 1 START RLY circuit breaker. Set ENGINE 1 FUEL switch to ON and START switch (on pilot
collective switch) to ENG 1 position. This energizes No. 1 start control relay and No. 1 starter-generator relay which
energizes No. 1 generator relay, and also energizes engine No. 1 ignition unit. Current now flows through contacts of No. 1
generator relay and No. 1 starter-generator relay to the series (starter) winding of the starter-generator No. 1. Starting of
engine No. 2 is accomplished by the above described procedure utilizing control items of engine No. 2 system in lieu of
engine No. 1 system items. Maintenance of the starter-generators is covered in chapter 71 of this manual.
2. STARTER AND IGNITER SYSTEMS - OPERATIONAL CHECK
2-1. OPERATIONAL CHECK - STARTERS
2-1-1. Starters - starter No. 1 circuitry
NOTE
Disconnect wire in following step only if starter fails to rotate.
1. Disconnect wire P95A1 from terminal C on engine 1 starter-generator and isolate from helicopter structure.
2. Close ENGINE NO. 1 START RLY, NO. 1 ESNTL BUS FEEDER(S), GEN 1 RESET and NO. 1 BUS BAT switch
circuit breakers.
3. Set BATTERY BUS 1 switch to ON.
4. Position START switch on the pilot collective stick to ENG 1.
5. Verify battery voltage is present on disconnected end of wire P95A1 and zero voltage is present at terminal B (wire
P72A1) of starter-generator.
6. Verify battery voltage is present on No. 1 dual voltmeter.
WARNING
DUE TO HIGH ELECTRICAL SHOCK HAZARD, DO NOT RECONNECT

STARTER - GENERATOR WIRE IF AN OPERATIONAL CHECK OF THE
ENGINE IGNITION IS TO BE PERFORMED.
7. Set START switch to OFF.
8. Verify zero voltage is present on disconnected wire P95A1.
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E-AB412-PT6T-2
9. Turn off electrical power and connect wire P95A1.
2-1-2. Starters - starter No. 2 circuitry
NOTE
Disconnect wire in following step only if starter fails to rotate.
2. Disconnect wire P98A1 from terminal C on engine 2 starter-generator and isolate from helicopter structure.
3. Connect dc external power source to external power receptacle and energize.
4. Close ENGINE NO. 2 START RLY, GEN 2 RESET and NO. 2 ESNTL BUS FEEDER circuit breakers.
5. Set START switch on pilot collective stick to ENG 2.
6. Verify external power source voltage is present on disconnected wire P98A1 and zero voltage is present at terminal B
(wire P85A1) of engine 2 starter-generator.
WARNING
DUE TO HIGH ELECTRICAL SHOCK HAZARD, DO NOT RECONNECT

STARTER - GENERATOR WIRE IF AN OPERATIONAL CHECK OF THE
ENGINE IGNITION IS TO BE PERFORMED.
7. Set START switch to OFF.
8. Verify zero voltage is present on disconnected wire P98A1.
9. Turn off electrical power and connect wire P98A1.
2-2. OPERATIONAL CHECK - IGNITERS
NOTE
This check must be accomplished on battery power.
2-2-1. Igniters - engine ignition unit No. 1
1. Close ENGINE NO. 1 IGN and ENGINE NO. 1 START RLY circuit breakers.
2. Set ENGINE 1 FUEL switch to ON.
5. Position START switch on pilot collective stick to ENG 1.
6. Verify igniters can be heard arcing.
7. Release START switch.
8. Open ENGINE NO. 1 IGN and ENGINE NO. 1 START RLY circuit breakers.
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E-AB412-PT6T-2
9. Set ENGINE 1 FUEL switch to OFF.
10. If igniters were heard, proceed to engine no. 2. If not accomplish the following steps.
11. Disconnect engine 1 ignition unit connector (1Z9P1) from engine 1 ignition unit.
14. Verify zero voltage is present between pin A and pin B (ground) of engine 1 ignition unit connector.
16. Verify battery voltage is present between pin A and pin B of engine 1 ignition unit connector.
19. Reconnect engine 1 ignition unit connector to engine 1 ignition unit.
20. Verify connector is properly mated, tight, and secure.
2-2-2. Igniters - engine ignition unit No. 2
NOTE
This check must be accomplished on battery power.
6. Verify igniters can be heard arcing.
7. Release START switch.
8. Open ENGINE NO. 2 IGN and ENGINE NO. 2 START RLY circuit breakers.
10. If igniters were heard, check is complete, secure helicopter. If not, accomplish the following steps.
11. Disconnect connector (1Z10P1) from engine 2 ignition unit.
13. Set START switch on pilot collective stick to ENG 2.
14. Check zero voltage is present between pin A and pin B (ground) of connector.
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E-AB412-PT6T-2
16. Check battery voltage is present between pin A and pin B of engine 2 ignition unit connector.
19. Reconnect connector to the ignition unit.
20. Check connector is properly mated, tight and secure.
3. STARTER AND IGNITER SYSTEMS - TROUBLESHOOTING
Table 1. Starter and igniter systems troubleshooting
STARTER SYSTEMS
Starter No. 1 fails to operate when START Defective START switch. Replace switch.
switch is positioned to No. 1 position (START
ENG 1 circuit breaker closed and FUEL Defective START ENG 1 circuit Replace unit.
SWITCH No. 1 in ON position). breaker.
Replace START CONT RELAY Replace relay.

No. 1.
Defective # 1 START RELAY. Replace relay.
Defective No. 1 STR-GEN Replace unit.

RELAY.
Defective starter-generator No. 1. Replace unit.
Defective SHUNT GEN 1 Replace shunt.

Repair wiring.
Defective wiring.
START switch is not maintained in No. 1 Defective diode. Replace diode.

position.
Defective holding coil on START Replace switch.
switch.
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E-AB412-PT6T-2
(Cont.)
START switch is not maintained in No. 2 Defective diode. Replace diode.

position.
Defective holding coil on START Replace switch.
switch.
Starter No. 1 fails to produce sufficient RPM Defective No. 1 starter-generator. Replace unit.
during start cycle.
Battery in low state of charge. Charge or replace battery.
Starter No. 2 fails to operate when START Defective START switch. Replace switch.
switch is positioned to No. 2 position (START
ENG 2 circuit breaker closed and FUEL Defective START ENG 2 circuit Replace unit.
SWITCH No. 2 in ON position). breaker.

CONT RELAY No. 2.
Defective #2 START RELAY. Replace relay.
Defective No. 2 STR-GEN Replace relay.

RELAY.
Defective starter-generator No. 2. Replace unit.
Starter No. 2 fails to produce sufficient RPM Defective No. 2 starter-generator. Replace unit.
during start cycle.
Battery in low state of charge. Charge or replace battery.
IGNITER SYSTEMS
No. 1 igniter fails to operate when START Defective IGNITION UNIT. Replace unit.
switch is set to position 1 (FUEL SWITCH No.
1) in ON position and IGN SYS #1 circuit Defective START CONT RELAY Replace relay.
breaker. No. 1.
Defective FUEL SWITCH No. 1. Replace switch.
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E-AB412-PT6T-2
(Cont.)
Defective IGN SYS No. 1 circuit Replace unit.

breaker.
No. 2 igniter fails to operate when START Defective IGNITION UNIT. Replace unit.
switch is set to position 2 (FUEL SWITCH No.
2 in ON position and IGN SYS ±# 2 circuit Defective START CONT RELAY Replace relay.
breaker closed). No. 2 (K8).
Defective FUEL SWITCH No. 2. Replace switch.
Defective IGN SYS No. 2 circuit Replace unit.

breaker.
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E-AB412-PT6T-2
96-24-35
DC POWER SYSTEM - POWER DIODES
1. POWER DIODES - DESCRIPTION
Refer to figure 1 or figure 2 for electrical wiring and figure 3 or figure 4 for functional checkout.
2. POWER DIODES - REMOVAL
3. Remove attaching hardware from defective diode.
4. Remove diode.
3. POWER DIODES - INSTALLATION
MATERIALS REQUIRED
NUMBER NOMENCLATURE
C-041 HEATSINK COMPOUND
1. Apply silicone heatsink compound (C-041) between diode and heatsink.
2. Install mounting hardware.
NOTE
Threads of diode stud should be dry. Assure no silicone heatsink compound is on
threads of diode stud.
3. Torque diode stud fixing nut 20 to 30 in-lbs (2,26 to 3,39 Nm).
4. Perform functional checkout of replaced diode.
4. POWER DIODES - INSPECTION
1. Visually inspect diodes for the following:
a. Charred/discolored insulation.
b. Proper bonding and security of mounting hardware.
c. Cleanliness and corrosion.
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E-AB412-PT6T-2
5. POWER DIODES - FUNCTIONAL CHECKOUT
C-T96 DIGITAL MULTIMETER
2. Open copilot NO. 1 ESNTL BUS FEEDERS circuit breakers and NO. 2 ESNTL BUS FEEDERS circuit breakers.
3. Open pilot NO. 1 ESNTL BUS FEEDERS circuit breakers and NO. 2 ESNTL BUS FEEDERS circuit breakers.
4. Loosen fasteners and lower cockpit overhead circuit breaker panels.
NOTE
Refer to figure 1 (helicopters codes [A] [B]) or figure 2 (helicopters codes [C] [D])
for simplified electrical bus wiring.
Refer to figure 3 (helicopters codes [A] [B]) or figure 4 (helicopters codes [C] [D])
as a guide to power source, circuit breaker, and switch positions for testing various
diodes.
5. Set digital multimeter (DMM) to DIODE TEST setting.
6. Connect positive lead of DMM to wire terminal (anode) of diode and negative lead to the heat sink (cathode) to forward
bias the diode.
NOTE
Replace diodes that fail either step 7., 9. or 11.
7. Verify a DMM reading of 0,25 to 1,15 V.
8. Connect negative lead of DMM to wire terminal (anode) of diode and positive lead to the heat sink (cathode) to reverse
bias the diode.
9. Verify that the DMM reads OPEN (high resistance).
10. Apply sideway pressure with multimeter leads while monitoring meter.
11. Check for intermittent short circuit.
12. Close copilot NO.1 ESNTL BUS FEEDERS circuit breakers and NO. 2 ESNTL BUS FEEDERS circuit breakers.
13. Close pilot NO.1 ESNTL BUS FEEDERS circuit breakers and NO. 2 ESNTL BUS FEEDERS circuit breakers.
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E-AB412-PT6T-2
G6AB0745A
Figure 1. Simplified electrical bus wiring (helicopters codes [A] [B])
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E-AB412-PT6T-2
G6AB0746B
Figure 2. Simplified electrical bus wiring (helicopters codes [C] [D])
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E-AB412-PT6T-2
96-24-35
G6AB0747B
Figure 3. Power diode functional checkout (helicopters codes [A] [B]) (sheet 1 of 2)
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E-AB412-PT6T-2
G6AB0748B
Figure 3. Power diode functional checkout (helicopters codes [A] [B]) (sheet 2 of 2)
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E-AB412-PT6T-2
G6AB0749B
Figure 4. Power diode functional checkout (helicopters codes [C] [D]) (sheet 1 of 2)
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E-AB412-PT6T-2
G6AB0750A
Figure 4. Power diode functional checkout (helicopters codes [C] [D]) (sheet 2 of 2)
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E-AB412-PT6T-2
96-24-36
DC INDICATOR SYSTEMS
1. DC INDICATOR SYSTEMS - DESCRIPTION
The dc indicator systems include mast torque measurement system (helicopters code [D]), standby attitude indicator, engine
oil temperature indicator, transmission oil temperature indicator, combining gearbox oil temperature indicator, engine
hourmeter, turn and slip indicator, interturbine temperature indicator, hydraulic oil temperature indicator systems and fuel
quantity indicator system. Refer to Chapter 98 for appropriate system wiring diagram.
2. DC INDICATOR SYSTEMS - MAST TORQUE MEASUREMENT SYSTEM [D]
2-1. MAST TORQUE MEASUREMENT SYSTEM [D] - DESCRIPTION
Mast torque measurement is accomplished by a sensor located on the bottom of the transmission and extending up into the
bottom of the mast. The sensor consists of two monopole pickups. These pickups are located inside two sets of mast splines
to detect the torsional displacement between them. The bottom sensor is solid in the mast and is the reference sensor. The
upper pickup is located on the lower end of the torque tube and is the signal sensor. The signal sensor is connected to the top
of the mast and is displaced in relation to the reference sensor when the mast is under a torque condition. During manufacture
of the mast, the twist rate of the mast is determined, and the mast data plate is stamped with a letter from A to R indicating
the stiffness of the mast. The electrical signals from the reference and signal pickups are in phase at zero torque and 145.4°
degrees out of phase at 100% torque, which corresponds to 4.8 degree of mechanical twist for an "H" graded mast. The
torque signal conditioner has a cover plate on one end covering a 15 position switch marked A through R. This switch must
be set to the letter corresponding to the letter on the mast data plate. The mast torque signal conditioner then provides an
output to the triple torque indicators. All torque is indicated in percentages. Engine 1 and engine 2 torque is indicate by
separate meter movements on right side of indicator and mast torque is indicated on the left side.
OVER TORQ warning lights for the pilot and copilot are mounted on the instrumental panel. A self-test function is initiated
by pressing pilot or copilot OVER TORQ warning light or selecting BITE on the signal conditioner (figure 1). The self-test
function will cause the mast torque output signals to be 105 ±1.0% (as indicated on the triple torque indicators) and over
torque output signal to illuminate the OVER TORQ warning lights.
A latching over torque indicator is provided to indicate when the output torque exceeds a preset torque level. The indicator
trips within 0,5 seconds of the over torque occurrence. The indicator, located beneath the cover plate, is reset mechanically.
Trip point is 108 ±0.5% for -105. and 110 ±-0.5% for -107 and -109. The indicator is visible through the cover plate.
A test function is provided to determine the phase difference during a zero torque calibration procedure. The function is
initiated by selecting PHASE on the switch on the signal conditioner control panel. A DC voltage (phase voltage) is
measurable between the +DVM and -DVM terminals.
A temperature sensor mounted on the transmission top case provides temperature compensation above and below 77°F
(25°C) for change in mast elasticity.
2-2. MAST TORQUE MEASUREMENT SYSTEM [D] - MAST TORQUE INDICATION CHECK
1. Open MAST TORQUE circuit breaker (1CB50).
2. Disconnect connector (1A7P1) from signal conditioner (1A7).
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NOTE
Resistance measurement in the following step depends on ambient air temperature.
For a temperature of 77F (25C), resistance should be 99 2 ohms.
3. Select the 200 ohm resistance scale on multimeter.
4. Connect leads to pins F and G of connector (1A7P1).
5. Multimeter should indicate 80 to 110 ohms for ambient temperature of –22F to 131F (–30C to 55C). Refer to
table 1 for additional values.
6. Connect connector (1A7P1) to signal conditioner (1A7).
7. Close MAST TORQUE circuit breaker (1CB50).
Table 1. Mast torque temperature sensor resistance values
TEMPERATURE (°C) RESISTANCE (OHMS)
-40 77.39 ± 0.40
-30 80.56 ± 0.40
-20 83.77 ± 0.40
-10 87.04 ± 0.40
0 90.38 ± 0.40
10 93.80 ± 0.40
20 97.31 ± 0.40
30 100.91 ± 0.40
40 104.60 ± 0.40
50 108.39 ± 0.40
2-3. MAST TORQUE MEASUREMENT SYSTEM [D] - OPERATIONAL CHECK
Test mast torque system as follows:
1. Press pilot OVER TORQ warning light and hold for approximately 10 seconds to initiate mast torque systems
built-in-test (BIT) function.
NOTE
Mast torque overtorque indicator will trip if torque indicates in excess of 110% 
0.5% for 0.5 second.
2. Verify pilot and copilot torque indicators read 105 1%.
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E-AB412-PT6T-2
3. Verify pilots and copilots OVER TORQ warning lights illuminate.
4. Repeat steps 1. through 3. except press copilot OVER TORQ warning light.
2-4. MAST TORQUE MEASUREMENT SYSTEM [D] - ZERO TORQUE CALIBRATION
1. Remove blades from main rotor hub (Chapter 62).
2. Remove cover plate from signal conditioner control panel (figure 1).
3. Connect digital multimeter to signal conditioner terminals marked + DVM and – DVM.
4. Select a scale on digital multimeter of approximately 20 VDC.
5. Ensure GAIN adjustment rotary switch on signal conditioner is set to letter which corresponds to the torsional stiffness
code letter stamped on the plate located on the mast.
6. Start either engine in accordance with appropriate 412 Flight Manual.
CAUTION
WITHOUT MAIN ROTOR BLADES INSTALLED, THE ENGINE WILL REACT

QUICKER TO THROTTLE MOVEMENTS. TO AVOID POSSIBLE
OVERSPEED, SET RPM INCR/DECR SWITCH TO FULL DECR PRIOR TO
INCREASING RPM AND MOVE THROTTLES SLOWLY.
7. Run engine at 95 to 100% NR.
8. Verify standpipe alignment at zero torque as follows:
NOTE
Steps a. through e. do not apply to -105 signal conditioners.
a. Rotate coarse adjustment multiposition switch to the full clockwise position.
b. Hold toggle switch to PHASE position.
c. Measure and record the voltage between –DVM and +DVM terminals.
d. Release the toggle switch from the PHASE position.
e. Verify the voltage is between –2.43 and –3.68 VDC.
f. If voltage is not within range, standpipe requires realignment.
9. Calibrate signal conditioner to obtain proper signal at zero torque (0.000 ± 0.008 volts across –DVM and +DVM) as
follows:
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E-AB412-PT6T-2
CAUTION
EXCESSIVE PRESSURE ON POTENTIOMETER ADJUST SHAFTS WILL

CAUSE DAMAGE.
a. Make sure the CRS ADJ switch is still in the fully clockwise position and then move two position
counterclockwise.
b. Measure and record the voltage between –DVM and +DVM terminals.
NOTE
If the voltage does not change when the coarse adjustment switch is repositioned,
then stop the calibration and correct the wiring or the failed system component.
c. The voltage between – DVM and + DVM terminal should be -0,6 VDC to +0,6 VDC. Move the CRS ADJ switch
clockwise or counterclockwise as needed to get the required voltage.
d. Rotate the MED ADJ counterclockwise or clockwise until the voltage between – DVM and + DVM 0,000 
0,030 volts.
e. Rotate the FINE ADJ counterclockwise or clockwise until the voltage between – DVM and + DVM 0,000 
0,008 volts.
NOTE
Better accuracy can be maintained by selecting a lower DC voltage range on the
DVM after the signal has been reduced below 0,1 VDC.
It is normal for voltage at the DVM terminals to oscillate by as much as  0,008

VDC. The average should be set as close to zero as possible.
f. If zero cannot be achieved, reposition the MED ADJ and FINE ADJ potentiometer at center of rotation range by:
(1) Rotate both potentiometer shafts 30 turns counterclockwise.
(2) Rotate both potentiometer shafts 12 turns clockwise.
g. Repeat steps b. through f. as many times as required to get the results in step e. Each time, reposition either the
CRS ADJ switch one position either clockwise or counterclockwise from the previous position.
CAUTION
DO NOT ENGAGE ROTOR BRAKE WITHOUT MAIN ROTOR BLADES

INSTALLED.
10. Shut down engine.
11. Reset overtorque indicator, if required.
12. Install cover plate on signal conditioner.
13. Install blades on main rotor hub (Chapter 62).
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2-5. MAST TORQUE MEASUREMENT SYSTEM [D] - MAST TORQUE SYSTEM FLIGHT CHECK
1. Load helicopter as near to maximum gross weight as practical in a symmetrical manner which assures a centered CG.
2. Perform a ground run torque check as follows:
a. Start both engines in accordance with appropriate flight manual.
b. Set NR to 100%.
c. Center cyclic and directional controls.
d. Set collective control so rotor is at flat pitch.
e. Pilot and copilot torque indicators should each indicate approximately 10% engine torque and 20% mast torque.
3. Perform normal take off and power climb within the following conditions:
a. Less than 8000 feet altitude.
b. Straight attitude (cyclic centered) with no directional pedal movement and autopilot off.
c. Speed of 85 to 90 knots.
d. Pull sufficient collective to obtain engine torque readings greater than 45%.
4. Record engines and mast torques indicated on pilot and copilot torque indicators.
5. Readings from pilot and copilot torque indicators should be within 1% of each other.
6. Sum of engine No. 1 and engine No. 2 torque readings should be 2 to 9% higher than mast torque reading.
2-6. MAST TORQUE MEASUREMENT SYSTEM [D] - CALIBRATION CHECK
CAUTION
A MAST TORQUE SYSTEM ZERO CALIBRATION (PARAGRAPH "2-4. Mast

torque measurement system [D] - zero torque calibration") IS REQUIRED FOR
THE FOLLOWING EVENTS:
REPLACEMENT OF THE MONOPOLE TORQUE SENSOR.
REPLACEMENT OF THE MAST TORQUE SIGNAL CONDITIONER.
REPLACEMENT OF THE MAST TORQUE FILTER.
REPLACEMENT OF THE MAST ASSEMBLY OR MAST TORQUE TUBE

ASSEMBLY.
ALIGNMENT OF MAST TORQUE TUBE ASSEMBLY TO MAST ASSEMBLY

HAS CHANGED.
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2-7. MAST TORQUE MEASUREMENT SYSTEM [D] - ENGINE TORQUE PRESSURE INDICATING
SYSTEM
The engine torque pressure indicator system simultaneously displays torque output of both engines on the right side of the
pilot and copilot (if installed) triple torque indicator. Pointer No. 1 indicates engine No. 1 torque pressure transmitter output
and pointer No. 2 indicates engine No. 2 torque pressure transmitter output. Mast torque is indicated on the left side.
Indications are in percent. DC power is supplied through the ENGINE NO 1 TORQUE and ENGINE NO 2 TORQUE circuit
breakers. The pilot and copilot indicators are independent but function identically.
G6AB0849A
Figure 1. Signal conditioner control panel
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E-AB412-PT6T-2
2-7-1. Engine torque pressure indicating system - operational check
MATERIALS REQUIRED.
NUMBER NOMENCLATURE
C-405 LOCKWIRE
1. Open engine cowling and reduction gearbox access doors.
2. Locate combining gearbox data plate. Record L.H. valves letter code and L.H. alpha value given in degrees celsius on
the data plate (figure 2).
3. Remove cap from slope adjustment port of torque transducer (figure 3).
4. Use following table, ensure rotary switch is set to position associated with letter code on combining gearbox data plate.
Adjust rotary switch if necessary. Install cap in slope adjustment port.
Gearbox Data Plate Slope Setting Transducer Slope Switch Setting
NIL 1
A 2
B 3
AB 4
D 5
AD 6
BD 7
ABD 8
BCD 9
ALL 10
5. Close INV 1 PWR, ENG 1 TORQUEMETER and ENG 2 TORQUEMETER circuit breakers.
6. Disconnect hose at engine No. 1 torque transducer (1MT1) from engine No. 1 (figure 3).
NOTE
During the following steps, the pressure tester must remain level with the transducer
part.
7. Attach pressure tester to torque transducer pressure port. Apply a test pressure of 35.4 ± 1.7 kPa) to transducer input.
Record reading on pilot engine No. 1 torque indicator.
8. Calculate engine torque percent corresponding to test pressure of 35.4 psig (244 kPa) using following equation.
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E-AB412-PT6T-2
EQUATION:
Alpha value recorded in step 2.  2 = Engine torque percent.
EXAMPLE CALCULATION:
Engine No. 1 alpha value of 86.9  2 = 43.45 which rounds off to 43.5 engine torque percent.
Engine No. 2 alpha value of 85.4  2 = 42.7 engine torque percent.
9. Pilot engine No. 1 torque indicator should match engine torque percent calculated in step h. If torque percent does not
match, adjust as follows:
a. Remove cap from zero adjustment port of torque transducer (view A, figure 3).
b. Rotate zero adjustment screw until pilot engine No. 1 torque indicator reads calculated torque percent.
c. Copilot torque indicator should read within 1% of pilot torque indicator. Engine No. 2 torque indicator for both
pilot and copilot should indicate zero torque.
d. Install cap in zero adjustment port. Secure caps in zero adjustment port and slope adjustment port with lockwire
(C-405).
10. Connect hose to engine No. 1 torque transmitter pressure port.
11. Repeat steps 3. through 10. for engine No. 2, except references to engine No. 1 should be replaced with engine No. 2
and references to L.H. should be replaced with R.H.
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E-AB412-PT6T-2
G6AB0644A
Figure 2. Engine combining gearbox data plate
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E-AB412-PT6T-2
G6AB0645A
Figure 3. Torque transmitter
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E-AB412-PT6T-2
3. DC INDICATOR SYSTEMS - ENGINE OIL TEMPERATURE INDICATOR SYSTEM
3-1. ENGINE OIL TEMPERATURE INDICATOR SYSTEM - DESCRIPTION
Dc power is supplied through ENGINE NO. 1 OIL TEMP circuit breaker and ENGINE NO. 2 OIL TEMP circuit breaker.
Engine 1 oil temperature bulb controls engine No. 1 ENGINE OIL temperature and pressure indicator. Engine 2 oil
temperature bulb controls engine No. 2 ENGINE OIL temperature and pressure indicator. Each indicator also displays its
respective engine oil pressure.
3-2. ENGINE OIL TEMPERATURE INDICATOR SYSTEM - OPERATIONAL CHECK
NOTE
Ambient temperature checks are not valid when ambient air is below minus 5.0C.
1. Close ENGINE NO. 1 OIL TEMP circuit breaker.
2. Check engine No. 1 ENGINE OIL temperature and pressure indicator indicates approximate ambient temperature with
engine cooled to ambient temperature.
3. Close ENGINE NO. 2 OIL TEMP circuit breaker.
4. Verify engine No. 2 ENGINE OIL temperature and pressure indicator indicates approximate ambient temperature with
engine cooled to ambient temperature.
3-3. ENGINE OIL TEMPERATURE INDICATOR SYSTEM - TROUBLESHOOTING
Table 2. Engine oil temperature indicator system troubleshooting
ENG 1 OIL TEMP or ENG 2 OIL TEMP Defective ENG 1 OIL TEMP or Replace unit.
circuit breaker will not reset. ENG 2 OIL TEMP circuit breaker.
Internal short in temperature bulb(s) Replace defective unit(s).

or indicator(s).
One of engine oil temperature indicators 28 V dc bus de-energized. Energize 28 V dc bus.

fails to operate.
Open or defective ENG 1 OIL Reset or replace unit.
TEMP or ENG 2 OIL TEMP circuit
breaker.
One of the engine oil temperature indicators Defective temperature bulb or Replace defective unit.
indicates incorrectly. indicator.
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E-AB412-PT6T-2
(Cont.d)
Either engine oil temperature indicator Wires reversed at pins B and C on Repair wiring.
indicates backwards. indicator plug.
4. DC INDICATOR SYSTEMS - TRANSMISSION OIL TEMPERATURE INDICATOR

SYSTEM
4-1. TRANSMISSION OIL TEMPERATURE INDICATOR SYSTEM - DESCRIPTION
Dc power is supplied through XMSN OIL TEMP circuit breaker. The transmission oil temperature and pressure bulb
controls transmission oil temperature indicator. The indicator also displays its respective transmission oil pressure.
4-2. TRANSMISSION OIL TEMPERATURE INDICATOR SYSTEM - OPERATIONAL CHECK
NOTE
1. Close XMSN OIL TEMP circuit breaker.
2. Verify XMSN OIL temperature and pressure indicator indicates approximately ambient temperature with transmission
cooled to ambient temperature.
4-3. TRANSMISSION OIL TEMPERATURE INDICATOR SYSTEM - TROUBLESHOOTING
Table 3. Transmission oil temperature indicator system troubleshooting
XMSN OIL TEMP circuit breaker will not Defective XMSN OIL TEMP Replace unit.
Internal short in bulb or indicator. Replace defective unit(s).
Transmission oil temperature indicator fails 28 V dc bus de-energized. Energize DC bus.

to operate.
Open or defective XMSN OIL Reset or replace unit.
TEMP circuit breaker.
Defective temperature bulb or Replace defective unit(s).

indicator.
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Page 12 Rev. 2
E-AB412-PT6T-2
(Cont.d)
Transmission oil temperature indicator Defective temperature bulb or Replace defective unit.
indicates incorrectly. indicator.
Transmission oil temperature indicator Wires reversed at pins B and C of Repair wiring.
indicates backwards. indicator plug.
5. DC INDICATOR SYSTEMS - COMBINING GEARBOX (C BOX) OIL TEMPERATURE

INDICATOR SYSTEM
5-1. COMBINING GEARBOX (C BOX) OIL TEMPERATURE INDICATOR SYSTEM - DESCRIPTION
DC power is supplied through the C BOX OIL TEMP circuit breaker. Combining gearbox oil temperature bulb controls the
combining gearbox oil temperature and pressure indicator. Indicator also displays its respective gearbox oil pressure.
5-2. COMBINING GEARBOX (C BOX) OIL TEMPERATURE INDICATOR SYSTEM - OPERATIONAL

CHECK
NOTE
1. Close C BOX OIL TEMP circuit breaker.
2. Verify GEAR BOX oil temperature and pressure indicator indicates approximate ambient temperature with combining
gearbox cooled to ambient temperature.
5-3. COMBINING GEARBOX (C BOX) OIL TEMPERATURE INDICATOR SYSTEM -

TROUBLESHOOTING
Table 4. Combining gearbox oil temperature troubleshooting
Gearbox oil temperature indicator indicates Defective temperature bulb or Replace defective unit.
C. BOX OIL TEMP circuit breaker will not Defective C BOX OIL TEMP Replace unit.
Internal short in temperature bulb Replace defective unit.

and/or indicator.
Gearbox oil temperature indicator fails to 28 V dc us de-energized. Energize bus.

operate.
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E-AB412-PT6T-2
(Cont.d)
Open or defective C BOX OIL Reset or replace unit.

TEMP circuit breaker.
Defective temperature bulb and/or Replace defective unit.

indicator.
6. DC INDICATOR SYSTEMS - ENGINE HOURMETER SYSTEM
6-1. ENGINE HOURMETER SYSTEM - DESCRIPTION
With HOURMETER and ENG 1 RPM and ENG 2 RPM circuit breakers closed (rotor rpm indicator above 92.6 2%), the
hourmeter starts registering by receiving 28 Vdc power from dc bus through HOURMETER circuit breaker, deenergized
hourmeter relay, C BOX oil pressure switch, engine No. 2 aft compartment connector, and to ground. When engine speed
decreases (rotor rpm below 92%), hourmeter relay receives 28 Vdc signal from RPM limit detector thus energizing relay
and stopping hourmeter.
6-2. ENGINE HOURMETER SYSTEM - OPERATIONAL CHECK
1. Disconnect connector (8S8P1) from C box oil pressure switch.
2. Open ROTOR RPM circuit breaker.
3. Install a temporary short between pins B and C of connector (8S8P1).
4. Close HOURMETER circuit breaker.
5. Verify hourmeter operates.
6. Open HOURMETER circuit breaker.
7. Remove temporary short installed in step 3.
8. Reconnect connector (8S8P1) to C box oil pressure switch.
9. Verify connector is tight and properly mated.
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Page 14 Rev. 2
E-AB412-PT6T-2
6-3. ENGINE HOURMETER SYSTEM - TROUBLESHOOTING
Table 5. Engine hourmeter system troubleshooting
HOURMETER circuit breaker will not reset. Circuit breaker defective. Replace circuit breaker.
Electrical wiring defective Repair or replace electrical wiring.
With 28 V BUS DC energized Defective relay. Replace relay.

HOURMETER and RPM WARM circuit
breakers close and engines shut down. Defective pressure switch. Replace switch.
Hourmeter registers.
No. 28 V dc signal from Pin. No. 28 V dc signal from Pin F of Refer to module 96-31-54
RPM Warning Box. "CAUTION AND WARNING
SYSTEM - RPM LIMIT
WARNING SYSTEMS"
Condition same as above except: engines are Defective relay. Replace relay.
running and the rotor RPM is more than 96%.
Hourmeter does not register. Defective pressure switch. Replace switch.
28 V dc signal present at Pin F or Refer to module 96-31-54

RPM Warning Box. "CAUTION AND WARNING
SYSTEM - RPM LIMIT
WARNING SYSTEMS"
7. DC INDICATOR SYSTEMS - TURN AND SLIP (PART OF ATTITUDE DIRECTOR

INDICATOR)
7-1. TURN AND SLIP (PART OF ATTITUDE DIRECTOR INDICATOR) - DESCRIPTION
The turn and slip indicator and rate gyro are dc powered. Pilot and copilot rate gyros and AHRS provide data to rate-of-turn
pointers which, together with the inclinometers, function as turn and slip portions of respective ADI's.
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E-AB412-PT6T-2
7-2. TURN AND SLIP (PART OF ATTITUDE DIRECTOR INDICATOR) - OPERATIONAL CHECK
For operational check of turn and slip function of ADI, refer to module 96-24-22 paragraph "8-8. Attitude director indicator
systems - operational check".
8. DC INDICATOR SYSTEMS - INTERTURBINE TEMPERATURE (ITT) INDICATOR

SYSTEMS
8-1. INTERTURBINE TEMPERATURE (ITT) INDICATOR SYSTEMS - DESCRIPTION
Voltage generated by thermocouples located in interturbine area of engine No. 1 is transmitted through internal engine
harness, bias compensator, to engine No. 1 ITT indicator. Engine No. 2 interturbine temperature voltage signal is transmitted
through internal engine harness, bias compensator, to engine No. 2 ITT indicator.
8-2. INTERTURBINE TEMPERATURE (ITT) INDICATOR SYSTEMS - OPERATIONAL CHECK
T98 TURBINE TEMPERATURE INDICATING TEST SET
NOTE
Tolerances stated do not include test equipment tolerances.
1. Disconnect connector (1Z11P1/1Z12P1) from ITT compensator unit for engine 1/engine 2.
2. Disconnect alumel and chromel leads from terminals on gas generator case of each engine.
NOTE
Smaller diameter lead of gas generator is chromel, and larger diameter lead is
alumel.
3. Connect turbine temperature test set to leads disconnected from terminals on gas generator case on engine 1/engine 2.
4. Check connections for proper polarity.
5. Close ENGINE NO 1 and/or ENGINE NO 2 ITT COMP circuit breakers.
6. Adjust test set for an input of 810C and verify ITT indicator reads 810°C 2.5C.
7. Record ITT TRIM value given in degrees Celsius from PERFORMANCE REFERENCE DATA plate on power
section of engine.
8. Subtract trim value from 810C.
9. Connect ITT compensator 1/2 unit connector depending on engine being tested.
10. Verify connection is tight and secure.
11. Verify ITT indicator indication is within ±5C of value calculated in steps 7. and 8.. Refer to Chapter 76 for adjustment
procedure.
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12. Check insulation resistance of internal thermocouple harness with the test set.
13. Resistance to ground from either chromel or alumel terminal shall be not less than 5,000 ohms.
14. Measure loop resistance between chromel and alumel terminals on the terminal block.
15. Resistance shall be not less than 1,8 ohms nor more than 2.6 ohms.
16. Connect chromel and alumel leads to gas generator case terminals.
17. Repeat steps 2. through 16. for engine 2 (references to engine No. 1 shall become references to engine No. 2).
8-3. INTERTURBINE TEMPERATURE (ITT) INDICATOR SYSTEMS - TROUBLESHOOTING
Table 6. Interturbine temperature (ITT) indicator system troubleshooting
ITT indicator(s) fail to operate. Wiring and/or connectors open or Correct or replace wiring and/or
misaligned. connectors.
Defective indicator(s). Replace defective indicator.
Open thermocouple lead. Repair thermocouple wiring.
ITT indicator(s) indicate incorrectly. Indicator not properly adjusted. Re-calibrate and adjust turbine inlet
temperature indicator system.
(Code A). Resistance spool(s) not (Code A). Adjust resistance spool(s)
properly adjusted. in accordance with calibration
procedure.
Wiring and/or correctors incorrectly Repair wiring and/or connectors.

wired or misaligned.
Defective indicator. Replace indicator and calibrate and

adjust turbine inlet temperature
indicator system.
Defective thermocouple. Replace defective thermocouple and

re-calibrate system.
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E-AB412-PT6T-2
9. DC INDICATOR SYSTEMS - HYDRAULIC OIL TEMPERATURE INDICATOR

SYSTEM
9-1. HYDRAULIC OIL TEMPERATURE INDICATOR SYSTEM - DESCRIPTION
Dc power is supplied from dc bus No. 1 and dc bus No. 2 through hydraulic temperature circuit breakers to respective dual
hydraulic pressure/temperature indicator. Ac power is used in pressure indicating portion of indicator. Hydraulic temperature
bulbs control indicators which display fluid temperature in degrees Celsius.
9-2. HYDRAULIC OIL TEMPERATURE INDICATOR SYSTEM - OPERATIONAL CHECK
NOTE
Check No. 1 System as follows.
1. Close HYD NO 1 TEMP circuit breaker.
2. Check HYDR SYS 1 indicator indicates approximately ambient temperature with engine cooled to ambient
temperature.
Check No. 2 System as follows.
1. Close HYD NO 2 TEMP circuit breaker.
2. Check HYDR SYS 2 indicator indicates approximately ambient temperature with engine cooled to ambient
temperature.
9-3. HYDRAULIC OIL TEMPERATURE INDICATOR SYSTEM - TROUBLESHOOTING
Table 7. Hydraulic oil temperature indicator system troubleshooting
Hydraulic indicator inoperative. Defective circuit breaker. Replace defective circuit breaker.
Defective temperature bulb and/or Replace defective unit(s).

indicator.
Defective cable, loose connectors or Check cable, connectors and wiring.

defective wiring. Replace, tighten or repair as
applicable.
Hydraulic temperature indicator indicates Defective temperature bulb and/or Replace defective unit(s).
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E-AB412-PT6T-2
10. DC INDICATOR SYSTEMS - FUEL QUANTITY INDICATOR SYSTEM [C] [D]
Fuel quantity indicator system is a capacitance type system consisting chiefly of eight fuel quantity probes, two signal
conditioners and a dual pointer fuel quantity indicator with digital totalizer.
It is a 28 Vdc system powered by both emergency buses through ENGINE NO 1 FUEL QTY and ENGINE NO 2 FUEL
QTY circuit breakers.
Each cell, except upper center cells, contains a fuel quantity probe. Quantities sensed by probes are summed by signal
conditioners No. 1 (left) and signal conditioner No. 2 (right) and transmitted to FUEL QTY indicator for display. Fuel
quantity select switch mounted on instrument panel to left of indicator, enables lower forward and lower middle cell
quantities to be displayed separately. DIGITS TEST switch adjacent to fuel quantity select switch enables indicator digital
totalizer to be tested.
10-1. FUEL QUANTITY INDICATOR SYSTEM [C] [D] - TESTING AND CALIBRATION
NOTE
This is the preferred testing and calibration method based on empty fuel tanks and
dry probes.
Refer to appropriate test equipment manual for alternate procedure when it is
required to perform calibration procedure with fuel in the tanks.
T70 FUEL QUANTITY TEST SET
T103 412 SP ADAPTER MODULE
T105 FUEL QUANTITY TEST SET
NOTE
The following test procedures are applicable to system 1 (left fuel quantity pointer
and totalizer, signal conditioner No. 1, and fuel cells and their components on left
side of helicopter) and to signal conditioner no. 2 (same as above except for right
side). To test left side (system 1), connect test set to signal conditioner No. 1 and
read and interpret results for outputs applicable to system 1. To test right side
(system 2), connect test set to signal conditioner No. 2 and read and interpret results
for outputs applicable to system 2.
1. Remove connectors (1A5P1/1A6P1) from signal conditioner No. 1 and No. 2.
2. Connect fuel quantity test set in a tee connection with respective signal conditioner and connectors.
3. Close ENGINE NO 1 FUEL QTY, ENGINE NO 2 FUEL QTY, ENGINE NO 1 FUEL TRANS, and ENGINE NO 2
FUEL TRANS circuit breakers.
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Rev. 2 Page 19
E-AB412-PT6T-2
4. Position following helicopter switches to positions indicated below:
BATTERY BUS 1 (2S3) ON
BATTERY BUS 2 (2S4) ON
NON-ESNTL BUS (2S7) MANUAL
5. On test set:
a. TEST FUNCTION switch to PROBE.
b. RANGE switch to 200 pF.
c. ON/OFF switch to ON.
d. ADAPTER FUNCTION switch to MEAS.
e. MONITOR switch to IND-VDC.
f. TANK PROBE switch to UPPER OUTBD.
6. Press PRESS-TO-READ-CAP switch.
7. Read and record test set digital display.
8. Indication shall be 0,0 0,5 pF.
9. With PRESS-TO-READ-CAP switch pressed, set TANK PROBE switch to FWD, AFT, MID and AUX positions.
10. Read and record digital display at each position.
11. Indication shall be 0,0 0,5 pF.
12. Disconnect connector from fuel quantity indicator.
13. Set ADAPTER FUNCTION switch to CAL and TEST FUNCTION switch to CAP-SIM-CAL.
14. Press PRESS-TO-READ-CAP switch, and with test set CAP SIM (pF) control, set digital display to indicate total
probe value recorded in steps 8. and 11.
15. Set TEST FUNCTION switch to IND AMP.
16. Adjust E adjustment on respective signal conditioner for an indication of –0,03 Vdc on digital display.
17. Set TEST FUNCTION switch to CAP-SIM-CAL.
18. Press PRESS-TO-READ-CAP switch, and with CAP SIM control, set digital display to indicate 99.9 pF.
19. Set TEST FUNCTION switch to IND AMP.
20. Adjust F adjustment on respective signal conditioner for an indication of 7.50 Vdc on digital display.
21. Set TEST FUNCTION switch to CAP-SIM-CAL.
22. Press PRESS-TO-READ-CAP switch and with CAP SIM control, set digital display to read 54.3 pF.
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E-AB412-PT6T-2
23. Connect connector to fuel quantity indicator and set TEST FUNCTION switch to IND AMP.
24. Digital display shall indicate 4.09 0,02 Vdc, and fuel quantity indicator shall indicate 1200 40 pounds (both pointer
and digital displays).
25. On test set, set LIQUID LEVEL switch to NORM and TANK SIM switches 1, 2, and 6 to DRY.
26. Verify FUEL LOW caution panel segment on master caution panel illuminates.
27. Set LIQUID LEVEL switch to SIM.
28. FUEL LOW caution panel segment shall remain illuminated.
29. Set TANK SIM 6 switch to WET.
30. FUEL LOW caution panel segment shall extinguish.
31. Set TANK SIM 2 switch to WET.
32. Respective FUEL TRANS caution panel segment on master caution panel shall illuminate.
33. Set TANK SIM 1 switch to WET and TANK SIM 2 switch to DRY.
34. Respective FUEL TRANS caution panel segment shall remain illuminated.
35. On engine and fuel control panel (1A1), set respective FUEL TRANS switch to ON.
36. Verify proper pump operation.
37. On test set, set TANK SIM 1 switch to DRY and record the time it takes for transfer pump to deenergize.
38. Time shall be 30 10 seconds.
39. On engine and fuel control panel (1A1), set the respective FUEL TRANS switch to OFF.
40. Pull ENGINE 1 FUEL QTY (or ENGINE 2 FUEL QTY) circuit breaker. Observe respective FUEL TRANS caution
light illuminates.
41. Push circuit breaker back in.
42. Set LIQUID LEVEL switch to NORM.
43. Set MONITOR switch to THERM 1, 2, and 6.
44. Read and record digital display voltage indications.
45. Indications shall be 1,8 0,3 Vdc at 25C.
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10-2. FUEL QUANTITY INDICATOR SYSTEM [C] [D] - THERMISTOR CHECK
NOTE
The following is provided as an aid to troubleshooting when a thermistor problem is
suspected.
1. Set ohmmeter to RX100.
NOTE
Not all probes have thermistors.
2. Connect red lead to pin 4 of probe and black lead to pin 6 of probe. The resistance should be 1000 ohms 20 ohms at
25C.
3. Move black lead to pin 5 of probe. Resistance should be 400 ohms ± 20 ohms at 25°C.
10-3. FUEL QUANTITY INDICATOR SYSTEM [C] [D] - TROUBLESHOOTING
Table 8. Fuel quantity indicator system [C] [D] troubleshooting
FUEL QTY circuit breaker will not reset. Defective FUEL QTY ENGINE Replace defective unit.
1 or 2 circuit breaker.
Internal short in the fuel quantity Replace defective unit(s).

system (fuel cells, or signal
conditions).
Fuel quantity indicator fails to operate in 115 V ac BUS 1 de-energized. Energize inverter.
mode.
Open or defective FUEL QTY Reset or replace defective unit.
ENGINE 1 or 2 circuit breaker.
Defective fuel quantity indicator. Replace defective unit.
Defective selector switch. Replace switch.
Fuel quantity indicator indicates Defective fuel quantity indicator. Replace indicator.
incorrectly.
Defective on signal conditions. Replace defective unit(s).
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11. DC INDICATOR SYSTEMS - UTILITY (NO. 3) HYDRAULIC PRESSURE AND

TEMPERATURE INDICATOR SYSTEM [B] [C]
11-1. UTILITY (NO. 3) HYDRAULIC PRESSURE AND TEMPERATURE INDICATOR SYSTEM [B] [C] -
DESCRIPTION
The utility hydraulic pressure and temperature indicators are dual type indicators registering hydraulic oil temperature in
degree celsius and hydraulic pressure in psi.
The pressure indicator is installed on the top part of the instrument panel and electrically connected to the transmitter ad
consists of a synchro energized by 26 Volt AC 400 Hz and connected to a synchro movement causes the pointer to move.
The system is protected by the UTILITY HYDR, circuit breaker. The indicator scale is graduate from 0 to 5.000 psi.
The temperature indicator is installed on the instrument panel and connected to a transmitter installed on the return line
adjacent on the reservoir. The temperature transmitter consists of a temperature sensitive variable resistor.
The indicator consists of a bridge resistor whose unbalanced condition causes the pointer to move.
The indicator scale is graduated from -50° to +150°C.

The system is energized by 28 Volt DC and protected by the No. 1 HYDR TEMP circuit breaker.
11-2. UTILITY (NO. 3) HYDRAULIC PRESSURE AND TEMPERATURE INDICATOR SYSTEM [B] [C] -
OPERATIONAL CHECK
1. Close UTILITY HYD circuit breaker.
2. Apply external hydraulic pressure and pressurize system.
3. Raise pressure to 3.000 psi and check that indicator reads correctly.
4. Release pressure and disconnect test bench.
5. Close No. 1 HYDR TEMP circuit breaker and check that utility hydraulic system fluid temperature indicator reads
approximate ambient temperature.
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E-AB412-PT6T-2
96-24-51 DC ELECTRICAL SYSTEM EQUIPMENT - BATTERY
96-24-51
DC ELECTRICAL SYSTEM EQUIPMENT - BATTERY
1. BATTERY - DESCRIPTION
The helicopter is equipped with a 24 volt, 34 ampere hour, nickel-cadmium battery, located in the nose compartment. Battery
power is used for limited ground operation or for engine starting when no dc external power is available or as an emergency
source of power in the event of failure of both generators. The batteries of the sintered-plate type employing nickel-cadmium
plates and electrolyte of potassium hydroxide, housed in steel case, with single cells interconnected by terminal links.
Damaged individual cells of the battery may be replaced. The negative terminal of the battery is grounded to the helicopter
structure and the positive terminal is connected to the main DC system. Connection between battery and helicopter cabling
is obtained by a quick disconnected plug. Two tubes are connected to the battery case: one for ventilation and one for
breathing.
2. BATTERY - REMOVAL
1. Check that BATTERY switch as are OFF, and external power is not applied. Open compartment door.
2. Disconnect battery cable connector by turning knob counterclockwise.
3. Disconnect two vent tubes from battery case.
4. Open tie-down clamps and disengage rods from battery cover. Lift battery from compartment.
5. Close compartment door.
NOTE
Replace battery (BT1) or (2BT1) if inspection requirements are not met. Repair of
battery should be accomplished in an authorized battery repair station.
3. BATTERY - INSTALLATION
2. Place battery on shelf, aligned for connections. Engage tie-down rods to strap on cover. Secure and lockwire.
3. Connect vent tubes to battery case and tighten clamps.
4. Insert cable connector in battery receptacle and secure by turning knob clockwise.
5. Check that voltmeter will show indication when BATTERY BUS 1 or BATTERY BUS 2 switch is ON. Return switch
to OFF after test. Close compartment door.
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4. BATTERY - INSPECTION
Inspect battery for the following conditions.
1. Loose connections at disconnect or between cells.
WARNING
THE ELECTROLYTE IS A STRONG ALKALINE SOLUTION THAT IS

HARMFUL TO THE HANDS OR CLOTHING. USE A 3 PERCENT SOLUTION
OF BORIC ACID, TO NEUTRALIZE SPILLED ELECTROLYTE. FLUSH
THOROUGHLY WITH WATER.
CAUTION
DO NOT USE SODIUM BICARBONATE TO NEUTRALIZE THE

ELECTROLYTE SPILLED IN BATTERY COMPARTMENT FROM A NICKEL
CADMIUM BATTERY.
2. Electrolyte for proper level.
3. Clogged vent plug or vent tubes.
4. Damage to individual cell cases (distortion due to overcharge, cracks, or leaks).
5. BATTERY - SERVICE
1. Clean battery and battery compartment as follows:
CAUTION
DO NOT USE WIRE BRUSH. CHECK THAT VENT PLUGS ARE CLOSED
BEFORE CLEANING AND THAT BATTERY IS COMPLETELY DRY BEFORE
RETURNING TO USE.
CAUTION
DO NOT USE EQUIPMENT THAT HAS BEEN USED ON LEAD ACID

BATTERIES.
a. Disconnect and remove battery. Clean battery with a dry, stiff fiber brush or wash with water.
b. Check that battery compartment is clean and free from alkaline deposits. If corrosion is present, remove with
diluted boric acid solution. Retouch varnished surfaces. If necessary, with alkali-resistant varnish (C15-3).
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2. Install and connect battery. Ensure that battery is charged. A fully charged battery can be determined by moving the
battery BATTERY BUS 1 or BUS 2 switch from ON to OFF and observing the effect on the generator ammeter. If the
change in indication is less than 5 amperes, the battery is fully charged. No other maintenance, servicing, or inspection
of the battery is authorized.
NOTE
Nickel-cadmium batteries shall not be serviced while installed in the helicopter. The
battery shall be removed and serviced every 100 hours by authorized battery shop
personnel only.
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96-24-52 DC ELECTRICAL SYSTEM EQUIPMENT - EXTERNAL POWER RECEPTACLE
96-24-52
DC ELECTRICAL SYSTEM EQUIPMENT - EXTERNAL POWER
RECEPTACLE
1. EXTERNAL POWER RECEPTACLE - DESCRIPTION
1-1. DESCRIPTION - HELICOPTERS CODES [A] [B]
The dc external power receptacle (J3), located on the right side of the helicopter nose, permits dc power from the auxiliary
power unit to be applied to the helicopter electrical system during ground operations. Receptacle J3 contains a high-current
common ground pin and a high-current positive polarity pin for the application of power and an additional low-current pin
to provide dc control voltage for relay excitation when the dc auxiliary power unit is connected with correct polarity. A
microswitch actuated by the dc external door, controls the illumination of the external power light on the caution panel.
1-2. DESCRIPTION - HELICOPTERS CODE [C]
External power may be connected to the helicopter electrical systems through the external power receptacle (2J1). No special
action or switching is necessary to connect external power. If external power connections are of the correct polarity, the
external power relay (2K1) closes automatically and connects the ground unit to the main dc bus 1 and 2. If connections are
not of correct polarity, no action occurs. No. 1 and No. 2 dc essential buses may be energized by closing GEN 1 RESET,
GEN 2 RESET and all MAIN DC ESNTL BUS FEEDER circuit breakers). The nonessential bus may be energized by
placing NON-ESNTL BUS switch to MANUAL. This allows complete checkout or all equipment or other ground
operations to be performed. Electrical equipment will not be protected from overvoltage conditions when operating on
external power unless the external power source used provides this protection.
2. EXTERNAL POWER RECEPTACLE - REMOVAL
1. Be sure electrical power is off.
2. Remove nuts and washers from terminal post of receptacle, identify and remove conductors from receptacle.
3. Protect removed conductor ends with electrical tape.
4. Remove mounting screws and lift receptacle from bracket.
3. EXTERNAL POWER RECEPTACLE - INSTALLATION
1. Position receptacle on bracket and install mounting screws.
2. Remove protective cover from conductors and connect same to respective receptacle terminals, using existing
hardware.
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4. EXTERNAL POWER RECEPTACLE - INSPECTION
1. Visually check contact pins in receptacle for corrosion and looseness.
2. Check condition of wiring and terminals for overheading.
5. EXTERNAL POWER RECEPTACLE - REPAIR
Replace (J3) or (2J-1) if inspection requirements are not met.
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96-24-53 DC ELECTRICAL SYSTEM EQUIPMENT - STARTER GENERATOR
96-24-53
DC ELECTRICAL SYSTEM EQUIPMENT - STARTER GENERATOR
1. STARTER GENERATOR - DESCRIPTION
Two starter-generators, are installed on the forward side of the accessory gearbox, on the section which extends above the
cabin ceiling, below the engine air intake ducts. The starter generators, one for each engine, are a combination electric
motor-generator type and have dual functions. As dc motors energized by the battery or by an external power source, they
provide the power required to start the helicopter engines. After engine start the starter-generators operate as dc generators
with a power output of 6 KW and a voltage output regulated at 28 volts. Generator operation is controlled by 2 dc control
boxes. The starter generators are of the self-excited type incorporating 4 main poles and 4 interpoles with a series winding
for engine starting. An integral fan, keyed to the rotor shaft, permits self-cooled operation. The fan is protected by a cover.
The cooling air is obtained through an air intake on the engine cowling and is directed into the cover by a flexible duct. The
starter generators are mounted on the helicopter power plant via mounting flanges and clamps.
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96-24-54 DC ELECTRICAL SYSTEM EQUIPMENT - DC CONTROL BOX
96-24-54
DC ELECTRICAL SYSTEM EQUIPMENT - DC CONTROL BOX
1. DC CONTROL BOX - DESCRIPTION
Two dc control boxes (Z22 and Z23) (2Z2 and 2Z3), manufactured by Lear-Siegler are located in the helicopter nose
electrical compartment. The dc control boxes are static type, and therefore do not contain any moving parts.
Each box incorporates 3 printed circuit boards. The top board contains the paralleling and the voltage regulator. The middle
board contains the line contactor relays and the reverse current controls. The bottom board contains the ground fault
protection and the overvoltage circuits.
Thus, the dc control box, when in operation, maintains generator output voltage within calibrated limits by varying generator
excitation, and, at the same time, protects the dc system against overvoltage, ground faults and reverse by de-energizing the
generator. Following temporary de-energization, the generator can be reset via the control box, by setting the GEN switch
to RESET and then back to ON.
2. DC CONTROL BOX - REMOVAL
2. Disconnect plug from dc control box.
3. Remove screws and washers and remove dc control box.
3. DC CONTROL BOX - INSTALLATION
2. Hold dc control box in place and secure with 4 screws and washers.
3. Connect plug to dc control box.
4. If necessary, carry out dc generator voltage regulation
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96-24-5 DC ELECTRICAL SYSTEM EQUIPMENT - CURRENT TRANSFORMER
96-24-55
DC ELECTRICAL SYSTEM EQUIPMENT - CURRENT TRANSFORMER
1. CURRENT TRANSFORMER - DESCRIPTION
The dc electrical system is equipped with current transformers to prevent damage or unbalanced conditions in the system.
Six current transformers are provided and are installed two in the helicopter nose lower compartment roof and four in the
overhead roof.
The current transformers are composed of a magnetic iron core on which is wound a coil operating as a secondary. The
primary is the helicopter cabling passing through the magnetic iron core. When current flows in the primary, a proportional
output is induced in the secondary winding.
The current transformers are connected in series and to the dc control box. During normal operation the total secondary
winding output is equal to zero and the dc electrical system is balanced.
In the event of malfunction, an unbalance is produced and sensed by the relative dc control box which causes the
disconnection of the relative generator.
2. CURRENT TRANSFORMER - REMOVAL
2. Gain access to helicopter nose electrical compartment.
3. Remove nuts, washers and wiring from current transformer and battery cable from battery bus bar.
4. Remove nuts on relay and slide battery bus bar away from current transformer.
5. Remove screws and washers and remove current transformer.
7. Remove nuts and washers and wiring from transformers.
8. Disconnect wiring passing through current transformer at nearest disconnect point.
9. Remove screws and washers and slide current transformer off cabling.
3. CURRENT TRANSFORMER - INSTALLATION
2. Hold current transformer in position and secure with screws and washers.
3. Slide battery bus through transformer and secure to relays with nuts.
4. Connect wiring and resistor to current transformer. Connect battery cable to battery bus using bolt, nut and washers.
Close helicopter nose electrical compartment.
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E-AB412-PT6T-2
5. Slide current transformer over cabling.
6. Hold current transformer in position and secure with screws and washers.
7. Connect wiring (primary winding) to disconnect point.
8. Connect wiring and resistor to current transformer and secure with nuts and washers.
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96-24-56 DC ELECTRICAL SYSTEM EQUIPMENT - INGNITION EXCITER
96-24-56
DC ELECTRICAL SYSTEM EQUIPMENT - INGNITION EXCITER
1. IGNITION EXCITER - DESCRIPTION
Two ignition exciters (Z9 and Z10) or (2Z9 and 1Z10) are installed one on each engine. They provide high voltage to the
ignition spark igniter during the start cycle. Power to the ignition exciters is controlled by the START switch through the
start control relay (K7 and K8) or (1K1 and 1K2 and the FUEL switch on the engine control panel.
NOTE
For further information refer to engine technical manual.
2. IGNITION EXCITER - REMOVAL
Refer to engine technical manual.
3. IGNITION EXCITER - INSTALLATION
Refer to engine technical manual.
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96-24-57 DC ELECTRICAL SYSTEM EQUIPMENT - DC EXTERNAL POWER RELAY
96-24-57
DC ELECTRICAL SYSTEM EQUIPMENT - DC EXTERNAL POWER RELAY
1. DC EXTERNAL POWER RELAY - DESCRIPTION
The dc external power relay (K1) or (2K1), located in the helicopter nose electrical equipment compartment, applies 28 Vdc
power from the external dc power receptacle (J3) or (2J1) to the helicopter dc power system. With dc external power
connected to (J3) or (2J1) the path from the low current pin of (J3) or (2J1) through the diode is completed and the relay is
energized. With the relay energized, dc power from the high current pint of (J3) or (2J1) if fed through the closed contacts
of the relay to the helicopter electrical system.
2. DC EXTERNAL POWER RELAY - REMOVAL
2. Remove nuts, washers and disconnect wiring.
3. Remove bolts and washers and relay.
3. DC EXTERNAL POWER RELAY - INSTALLATION
2. Position relay on helicopter and secure with bolts and washers.
3. Connect wiring and secure with nuts and washers.
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96-24-57
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96-24-58 DC ELECTRICAL SYSTEM EQUIPMENT - START RELAY
96-24-58
DC ELECTRICAL SYSTEM EQUIPMENT - START RELAY
1. START RELAY - DESCRIPTION
No. 1 (K5) or (2K5) and No. 2 (K6) or (2K6) start relays, are installed on the cabin ceiling, right and left sides. Both relays
are main power contacts and auxiliary contact type. Relay function is to select start and dc generator circuits in the starter
generator.
Relay operation is controlled by the START switch. When the relay is de-energized, the generating circuit contacts are
closed: when the relay is energized, the start circuit contacts are closed.
2. START RELAY - REMOVAL
3. Slide back terminal covers from terminals.
4. Remove nuts and washers, disconnect wiring and bus bar.
5. Remove screws and remove relay.
3. START RELAY - INSTALLATION
2. Position relay and secure with screws.
3. Install bus bar between terminal A1 and B1 connect wiring and secure with nuts and washers. Slide terminal covers
over terminals.
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96-24-59 DC ELECTRICAL SYSTEM EQUIPMENT - START CONTROL RELAY
96-24-59
DC ELECTRICAL SYSTEM EQUIPMENT - START CONTROL RELAY
1. START CONTROL RELAY - DESCRIPTION
No. 1 (K7) or (1K1) and No. 2 (K8) or (1K2) start control relays are installed in the helicopter nose electrical equipment
compartment. Relay operation is controlled by the START switch. During the start cycle the relays are energized and through
their contacts provide dc control voltage to Ng (K3) or (2K3) and Nf (K4) (or (2K4) generator relays, to the ignition boxes
(Z9 and Z10) or (2Z9 and 2Z10) and short starter-generator parallel excitation.
2. START CONTROL RELAY - REMOVAL
3. Remove screws and washers and remove relay.
3. START CONTROL RELAY - INSTALLATION
2. Position relay on bracket and secure with screws and washers.
3. Connect wiring.
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96-24-59
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96-24-60 DC ELECTRICAL SYSTEM EQUIPMENT - NO. 1 AND NO. 2 DC GENERATOR RELAY
96-24-60
DC ELECTRICAL SYSTEM EQUIPMENT - NO. 1 AND NO. 2 DC
GENERATOR RELAY
1. NO.1 AND NO. 2 DC GENERATOR RELAY - DESCRIPTION
The No. 1 (K3) or (2K3) and No. 2 (K4) or (2K4) dc generator relays, are installed on the cabin roof. Both relays are main
power contact and auxiliary contact type. Each relay provides connection between the dc starter-generator circuit and the
battery. DC external power, and dc distribution circuits. During the start cycle, relay operation is controlled by the START
switch through the start control relays (K7 or K8) or (1K1 or 1K2).
During normal operation, relay operation is controlled by the control boxes (Z22 and Z23) or (2Z2 and 2Z3) through the
start relays (K5 and K6) or (2K5 and 2K6) and the start control relays (K7 and K8) or (1K1 and 1K2).
2. NO.1 AND NO. 2 DC GENERATOR RELAY - REMOVAL
3. Slide back terminal covers, remove nuts and disconnect wiring.
4. Remove screws and washers, and remove relay.
3. NO.1 AND NO. 2 DC GENERATOR RELAY - INSTALLATION
2. Position relay on cabin ceiling and secure with screws and washers. Four washers must be installed between relay and
bracket.
3. Connect wiring and secure with nuts and washers.
4. Slide terminal covers over terminals.
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96-24-61 DC ELECTRICAL SYSTEM EQUIPMENT - NON ESSENTIAL BUS RELAY
96-24-61
DC ELECTRICAL SYSTEM EQUIPMENT - NON ESSENTIAL BUS RELAY
1. NON ESSENTIAL BUS RELAY - DESCRIPTION
The non-essential bus relays No. 1 (K39) or (2K11) and No. 2 (K2), are installed on the cabin ceiling. Relay function is to
connect the non-essential busses to the main dc system.
The relays are controlled by the NON ESS BUS switch. When the switch is set to MANUAL, with dc power on, the 2 relays
are excited and connect the non-essential busses to the main dc system. When the switch is set to NORMAL, the 2
non-essential bus control relays No. 1 (K33) or (2K9) and No. 2 (K34) or (2K10) and are excited only when both generators
are opening and connected to the main dc system.
2. NON ESSENTIAL BUS RELAY - REMOVAL
3. Slide back terminal covers, remove nuts and washers and wiring from relay.
3. NON ESSENTIAL BUS RELAY - INSTALLATION
2. Hold relay in position and secure with screws and washers.
3. Connect wiring to relay and secure with screws and washers. Slide terminal covers over terminals.
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96-24-62 DC ELECTRICAL SYSTEM EQUIPMENT - NON ESSENTIAL BUS CONTROL RELAY
96-24-62
DC ELECTRICAL SYSTEM EQUIPMENT - NON ESSENTIAL BUS CONTROL
RELAY
1. NON ESSENTIAL BUS CONTROL RELAY - DESCRIPTION
The non-essential bus control relays No. 1 (K33) or (2K9) and No. 2 (K34) or (2K10) are installed in the helicopter nose
electrical equipment compartment. They are controlled by the dc control boxes through the series of auxiliary contacts on
the dc generator relays (K3 and K4) or (2K5 or 2K6) and the starter relays (K5 and K6). When both relays are excited, they
control the automatic connection of the non-essential bus system to the main dc system. They also control battery interlock
relay (K57) or (2K12) operation.
2. NON ESSENTIAL BUS CONTROL RELAY - REMOVAL
3. NON ESSENTIAL BUS CONTROL RELAY - INSTALLATION
2. Position relay on bracket and secure with screws and washers.
3. Connect wiring.
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96-24-63 DC ELECTRICAL SYSTEM EQUIPMENT - NO. 1 AND NO. 2 BATTERY BUS RELAY
96-24-63
DC ELECTRICAL SYSTEM EQUIPMENT - NO. 1 AND NO. 2 BATTERY BUS
RELAY
1. NO. 1 AND NO. 2 BATTERY BUS RELAY - DESCRIPTION
Both No. 1 (K9) or (2K7) and No. 2 (K10) or (2K8) battery equipment compartment. Both relays are line contactor relays
with main power contacts and double-trow auxiliary contacts that caution the BATTERY caution light located on the caution
panel. The No. 2 (K10) or (2K8) battery bus relay connects the battery bus to external dc power bus and to the No. 2 dc
Generation and distribution system. The No. 1 (K9) or (2K7) battery bus relay connects the battery bus to the dc generation
and distribution system. No. 2 battery bus relay operation is controlled by the BATTERY BUS 2 switch. The switch is of
the retaining coil type. The retaining circuit of the switch is controlled by the No. 2 dc control box (Z22) or (2Z1).
The No. 1 battery bus relay operation is controlled by the BATTERY BUS 1. The switch is of the retaining coil type. The
retaining circuit of the switch is controlled not only by the No. 1 dc control box, but also by the battery interlock relay (K57)
or (2K12) and by 2 non-essential bus relay (K33 and K34) or (2K9 and 2K10). This control system prevents the No. 1 battery
bus relay (K9) or (2K7) being energized during normal system operation with both dc generators operating and BATTERY
BUS 2 set to ON.
2. NO. 1 AND NO. 2 BATTERY BUS RELAY - REMOVAL
1. Disconnect quick-disconnect plug from battery.
2. Remove nuts, washers and wiring from relay.
3. Remove bolts and washers and remove relay.
3. NO. 1 AND NO. 2 BATTERY BUS RELAY - INSTALLATION
2. Position relay on helicopter and secure with two bolts and washers.
3. Connect wiring to relay terminals and secure with washers and nuts.
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96-24-64 DC ELECTRICAL SYSTEM EQUIPMENT - BATTERY INTERLOCK RELAY
96-24-64
DC ELECTRICAL SYSTEM EQUIPMENT - BATTERY INTERLOCK RELAY
1. BATTERY INTERLOCK RELAY - DESCRIPTION
The battery interlock relay (K57) or (2K12) is located in the helicopter nose electrical equipment compartment. The relay
controls the automatic dropping of the Ng dc generating and distribution system from the battery bus during normal
operation of the electrical system.
2. BATTERY INTERLOCK RELAY - REMOVAL
2. Remove wiring from relay.
3. Remove two nuts, washers and two bolts.
NOTE
Operations at steps b. and e. allow removal of battery interlock relay and
non-essential bus relay (K33) or (2K9).
3. BATTERY INTERLOCK RELAY - INSTALLATION
2. Position two relay on bolts with spacers.
3. Fit relay to helicopter structure with washers and nuts.
4. Connect wiring to relay terminals.
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96-24-65 DC ELECTRICAL SYSTEM EQUIPMENT - NON ESSENTIAL BUS SENSOR
96-24-65
DC ELECTRICAL SYSTEM EQUIPMENT - NON ESSENTIAL BUS SENSOR
1. NON ESSENTIAL BUS SENSOR - DESCRIPTION
Two non-essential bus sensors (S185 and S186) or (2S5 and 2S6) are installed on the cabin ceiling. The sensors are
connected in series on the non-essential bus supply line. An overload on the line causes the sensor to open its contacts and
cuts-off power to the corresponding non-essential bus relay (K39 or K2) or (2K11) and causes the NON ESS BUS circuit
breaker to pop, shorting the circuit to ground. The circuit breaker cannot be reset until the cause of the overload condition
has been eliminated.
2. NON ESSENTIAL BUS SENSOR - REMOVAL
3. Remove sensor cover.
4. Remove screws and washers and wiring.
5. Remove screws and washers and remove sensor.
3. NON ESSENTIAL BUS SENSOR - INSTALLATION
2. Hold sensor in position and secure with screws and washers.
3. Connect wiring and secure with screws and washers.
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96-24-65
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96-25-01 POWERED PASSENGER STEP SYSTEM (KIT)
96-25-01
POWERED PASSENGER STEP SYSTEM (KIT)
1. POWERED PASSENGER STEP SYSTEM (KIT) - DESCRIPTION
The powered passenger step system is powered by 28 Vdc from bus No. 2 through the STEP circuit breaker, STEP switch
and right and left step actuators. When the STEP switch is set to RAISE, the actuator attached to the respective step retracts
to raise the step and then stops. When the STEP switch is set to STOW, the actuator attached to the respective step extends
to lower the step and then stops.
2. POWERED PASSENGER STEP SYSTEM (KIT) - OPERATIONAL CHECK
CAUTION
TO PREVENT DAMAGE TO ACTUATOR MOTORS, NEVER REPEAT STEPS 1

TO 6 MORE THAN ONE TIME IN SUCCESSION.
1. Ensure 28 Vdc power is applied to helicopter.
2. Close STEP circuit breaker.
3. Set STEP switch to RAISE.
4. Verify both steps raise freely (without binding) and stop when fully extended.
5. Set STEP switch to STOW.
6. Verify both steps lower freely (without binding) to each skid gear.
7. Set STEP switch to OFF.
8. Verify steps remain stowed.
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96-25-02 EMERGENCY FLOATS SYSTEM
96-25-02
EMERGENCY FLOATS SYSTEM
1. EMERGENCY FLOATS SYSTEM - DESCRIPTION
Emergency floats inflation is controlled by an electrical circuit powered directly from the battery. The electrical circuit is
divided into four sections: one section for control, two section for explosive cartridge power supply and one for test.
The four sections of the circuit breakers, labelled EMERGENCY FLOATES CIRCUIT BREAKERS, located on RH side of
the pedestal.
The circuit is controlled by a control panel which incorporates a preset switch fitted with a protection guard labelled
FLOATS INFLATE/ARM-SAFETY and by a switch labelled MANUAL FLOAT which be operated if floats inflation will
not occur at the time of contact with water.
Carrying out the float infiltration procedure will excite the inflation relay which though its contacts closes the power circuit
of the explosive cartridge.
A test box inserted in the float infiltration circuit allows a quick functional check of helicopter electrical and cartridge
explosive circuits. The test box mounted in the nose of helicopter contains the inflation relay, test relay, fire test lights and
the NORM TEST switch which when operated during ground test causes the illumination of the EMER FLOAT light on the
advisory panel. See Chapter 98 for wiring diagram.
2. EMERGENCY FLOATS SYSTEM - OPERATIONAL CHECK
Refer to Chapter 25.
3. EMERGENCY FLOATS SYSTEM - TROUBLESHOOTING
Refer to Chapter 25.
4. EMERGENCY FLOATS SYSTEM - MAINTENANCE
CAUTION
THE CONNECTION ON CIRCUIT BREAKERS, CONTROL SWITCHES AND

RELAYS ARE PROTECTED WITH BONDING COMPOUND. ONLY REMOVE
THESE COMPONENTS WHEN DEFECTIVE. AFTER CHANGING
DEFECTIVE COMPONENTS APPLY BONDING COMPONENT AS
FOLLOWS.
1. The two compounds solidify when exposed to air, use necessary precaution to prevent the compounds becoming
unusable.
2. Clean the surface to be treated.
3. Apply a coat of compound without submerging.
4. Air dry for one hour.
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5. Using a brush entirely cover all connections with a coat of compound to obtain a good waterproofing effect. Air dry
for two hours. After application of bounding compound functionally check circuit and check insulation resistance.
5. EMERGENCY FLOATS SYSTEM - TEXT BOX
5-1. TEXT BOX - DESCRIPTION
The test box is mounted in the helicopter nose electrical compartment. The box contains the float control relay, test light
control relay, test switch and lights.
5-2. TEXT BOX - REMOVAL
1. Remove quick release connection from battery.
2. Disconnect electrical connector from box.
3. Remove necessary securing hardware and remove the box.
5-3. TEXT BOX - INSTALLATION
1. Position the box on support and fix securing hardware.
2. Connect the electrical connector to the box.
3. Carry out electrical test of circuit.
5-4. TEXT BOX - DISASSEMBLY
CAUTION
THE BOX IS WATERPROOFED. THE CONNECTOR, FIVE LIGHTS AND

SWITCH MUST HAVE BONDING COMPOUND APPLIED.
1. Remove the box from the helicopter.
2. Remove securing screw, cover and seal from the box.
3. Disconnect the electrical cable, securing hardware and remove the two relays.
4. Disconnect the electrical cable, remove securing hardware and remove the connector, lighters and switch.
5-5. TEXT BOX - ASSEMBLY
1. Install connector, switch and five lights on the box connect the electrical cable, install two relays in the box and connect
up electrical cable.
2. Seal all parts (including screws) with compound in accordance with instructions on the containers.
3. Replace the seal and install the cover on the box, ensure cover is heretically sealed.
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6. EMERGENCY FLOATS SYSTEM - CONTROL PANEL
6-1. CONTROL PANEL - DESCRIPTION
The control panel is located on the central pedestal. The control panel front plate contains to light and two switch both
protected with a guard cover. The two switches are labelled FLOATS INFLATION/ARM-SAFETY and MANUAL
FLOATS. The first switch is used as a preset switch when in ARM position and to prevent accidental inflation when in
SAFETY position. The second switch is used for manual inflation in case the float switches, on lower side of helicopter, will
not cause automatic inflation at the time of helicopter contact with water.
6-2. CONTROL PANEL - REMOVAL
1. Loosen fasteners securing control panel and lift panel out of pedestal.
2. Disconnect electrical connector from rear of panel and remove it from helicopter.
6-3. CONTROL PANEL - INSTALLATION
1. Connect electrical connector to control panel.
2. Position control panel on control pedestal and secure in position by tightening fasteners.
6-4. CONTROL PANEL - INSPECTION
1. Inspect from panel and case for general condition.
2. Check lights for damage or burned lamps.
3. Check switches for proper operation.
4. Inspect connector for corrosion, damaged threads, bent or broken pins.
6-5. CONTROL PANEL - REPAIR OR REPLACEMENT
Replace control panel if inspection criteria are not met.
7. EMERGENCY FLOATS SYSTEM - FLOAT SWITCHES
7-1. FLOAT SWITCHES - DESCRIPTION
The float switches are installed as a pair, two forward and two aft underside the helicopter.
7-2. FLOAT SWITCHES - REMOVAL
1. Gain access to float switches support, (forward or aft as required).
2. Disconnect electrical wiring from float switches and remove nut securing switch to support.
3. From underside the helicopter, unscrew hardware securing shield and remove shield from helicopter.
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E-AB412-PT6T-2
4. Pull to remove switch from helicopter; remove grommet, if necessary.
7-3. FLOAT SWITCHES - INSTALLATION
1. Install grommet, if removed, and insert float switch.
2. Gain access to float switch support and secure switch end to support by installing and tightening nuts.
3. Connect electrical wiring to float switch.
4. Position shield on float switch and secure it to helicopter by tightening securing screws.
7-4. FLOAT SWITCHES - INSPECTION
Inspect float switch for general condition.
7-5. FLOAT SWITCHES - REPAIR OR REPLACEMENT
Replace float switch if inspection criteria are not met.
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96-25-03
CARGO HOOK CONTROL CIRCUIT
1. CARGO HOOK CONTROL CIRCUIT - DESCRIPTION
The circuit supplies power to the electro-mechanical device that controls hook opening. The circuit is powered by 28 Vdc
and is protected by the CARGO HOOK REL circuit breaker. When the CARGO REL switch (located on upper control
panel) is set to ARM, the two switches, located on the cyclic stick, are energized. When the pilot depress the relative switch,
electrical power is supplied, through a relay, to the solenoid controlling hook opening. When the circuit is energized, the
CARGO HOOK segment on the advisory panel, located on the instrument panel in front of the pilot, will illuminate.
2. CARGO HOOK CONTROL CIRCUIT - OPERATIONAL CHECK
1. Close CARGO HOOK circuit breaker. Place CARGO REL switch to ARM and check that CARGO HOOK ARMED
caution light is illuminated.
2. Operate release switch, located on pilot's cyclic stick. Check that solenoid is energized and hook opens.
3. Repeat step 2. operating copilot's switch.
3. CARGO HOOK CONTROL CIRCUIT - TROUBLESHOOTING
Table 1. Cargo hook control circuit troubleshooting
Caution light extinguishes when the system is Defective caution light. Replace lamp.
ready to operate.
Incorrect connections in supply Check connections and repair as
line. required.
Electrical release fails. Incorrect release relay connection. Check connections and repair as
required.
Defective release relay. Replace relay.
Defective switches on cyclic sticks. Replace switches.
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96-26-01
ENGINE FIRE EXTINGUISHER SYSTEMS
1. ENGINE FIRE EXTINGUISHER SYSTEMS - DESCRIPTION
When a fire occurs in engine compartment No. 1, No. 1 control fire detector element and fire detector amplifier causes FIRE
1 PULL handle switch to illuminated. In event fire extinguishing action is required, actuating FIRE 1 PULL handle switch
will arm main and reserve fire extinguisher circuit for engine 1. The pull handle will also close particle separator door, shut
off fuel to engine 1, and deenergize both engine 1 and engine 2 bleed air valves. Actuating FIRE EXT switch to MAIN will
discharge main fire extinguisher bottle into engine 1. If above action does not extinguish fire, reserve fire extinguisher bottle
can be discharged into engine compartment No. 1 by placing FIRE EXT switch to RESERVE. When fire occurs in engine
compartment No. 2, No. 2 fire detector element and fire detector amplifier, causes FIRE 2 PULL handle switch to
illuminated. In event fire extinguishing action is required, actuating FIRE 2 PULL handle switch will arm main and reserve
fire extinguisher circuit for engine 2. The pull handle will also close particle separator door, shut off fuel to engine 2, and
deenergize both engine 2 and engine 1 bleed air valves. Actuating FIRE EXT switch to MAIN will discharge main fire
extinguisher bottle into engine 2. If above action does not extinguish fire, reserve fire extinguisher bottle can be discharge
into engine compartment No. 2 by placing FIRE EXT switch to RESERVE.
2. ENGINE FIRE EXTINGUISHER SYSTEMS - OPERATIONAL CHECK
WARNING
SQUIB CARTRIDGES ARE PYROTECHNIC DEVICES. INADVERTENT

D E T O N AT I O N C A N R E S U LT I N S E R I O U S I N J U RY. P R I O R T O
ACCOMPLISHING ANY OPERATIONAL CHECK, THE SQUIB ELECTRICAL
TERMINALS "ACTUATE CONNECTION" AND "GROUND CONNECTION"
ON EACH OF THE FOUR SQUIBS MUST BE SHORTED TOGETHER.
CAUTION
DO NOT USE A BATTERY POWERED CONTINUITY LIGHT, OR ANY

SIMILAR DEVICE IN AN ATTEMPT TO TEST SQUIB ASSEMBLY. USE OF
TEST DEVICES OR OHMETER WHICH PASS MORE THAN 30 MA MIGHT
DETONATE SQUIB ASSEMBLY AND CAN AFFECT ITS USEFUL LIFE.
1. Ensure external power is removed and BATTERY BUS 1 and BUS 2 switches are set to OFF.
2. Open the following circuit breakers:
— ENG 1 FIRE DET
— ENG 2 FIRE DET
— INST PILOT
— MAIN FIRE EXT
— RES FIRE EXT
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E-AB412-PT6T-2
3. Gain access to fire extinguisher bottles by removing access plates on right and left engine cowl.
4. Remove all actuating and ground wires from both main and reserve fire extinguisher bottles.
5. Restrain loose wires from contact with airframe and remaining wires.
6. Install a shorting device (wire) between actuate and ground connection of each squib (figure 1).
7. Apply electrical power to helicopter buses.
8. Close MAIN FIRE EXT circuit breaker.
9. Pull FIRE 1 PULL handle.
10. Set FIRE EXT selector switch to MAIN.
11. Check squib firing voltage (28 Vdc) is present at wire W3D20.
12. Check no squib firing voltage on remaining fire extinguisher wires.
13. Set FIRE EXT selector switch to RESERVE.
14. Check for zero voltage on all disconnected wires.
15. Set FIRE EXT selector switch to OFF.
17. Reset FIRE 1 PULL handle.
19. Position FIRE EXT selector switch to MAIN.
20. Check squib firing voltage is present at end of wire W6D20.
21. Check no squib firing voltage on remaining fire extinguisher wires.
24. Set FIRE EXT selector switch to OFF.
27. Open MAIN FIRE EXT circuit breaker.
28. Close RES FIRE EXT circuit breaker.
30. Set FIRE EXT selector switch to MAIN.
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G6AB0757A
33. Check squib firing voltage is present on wire W2C20.
34. Check no squib firing voltage on all remaining fire extinguisher wires.
35. Set FIRE EXT switch to OFF.
38. Pull FIRE 2 PULL handle switch.
39. Set FIRE EXT switch to MAIN.
41. Set FIRE EXT switch to RESERVE.
42. Check squib firing voltage is present on wire W5C20.
43. Check no squib firing voltage on all remaining fire extinguisher wires.
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44. Set FIRE EXT switch to OFF.
48. Open RES FIRE EXTG circuit breaker.
50. Hold FIRE EXT PRESS TO TEST switch in TEST position.
51. Check FIRE 1 PULL handle switch illuminates.
52. Close ENG 2 FIRE DETR circuit breaker.
53. Hold FIRE EXT PRESS TO TEST switch in test position.
54. Check FIRE 2 PULL handle switch illuminates.
55. Open ENG 1 FIRE DET and ENG 2 FIRE DETR circuit breakers.
57. Set BATTERY BUS 1 and BUS 2 switches OFF.
58. Remove shorting device on squibs (figure 1).
WARNING
FAILURE TO PROPERLY CONNECT WIRING MAY RESULT IN FIRE

EXTINGUISHING SYSTEM FAILURE OR DISCHARGE OF WRONG FIRE
EXTINGUISHER BOTTLE.
59. Connect wires to fire extinguisher bottles.
60. Check connections are properly mated, tight, and secure.
— ENG 1 FIRE DET
— ENG 2 FIRE DETR
— INST PILOT
— MAIN FIRE EXT
— RES FIRE EXTG
62. Install access plates on right and left engine cowl.
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96-30-01 WINDSHIELD WIPER SYSTEMS
96-30-01
WINDSHIELD WIPER SYSTEMS
1. WINDSHIELD WIPER SYSTEMS - DESCRIPTION
Windshield wipers may be operated individually by positioning pilot or copilot switch to low, medium, high, and
deenergized in off and park position. Park position is a spring-loaded position (returns to OFF) for stowing wiper blades to
a location where vision is not obstructed.
2. WINDSHIELD WIPER SYSTEMS - OPERATIONAL CHECK
CAUTION
DO NOT OPERATE WIPERS ON DRY WINDSHIELD. SUITABLY PROTECT

WINDSHIELD AGAINST SCRATCHING BY WIPER BLADES.
1. Close WIND SHIELD WIPER PILOT and CPLT circuit breakers.
2. Set WIPERS PILOT switch to LO, MED, HI, OFF and PK positions respectively.
3. Check only pilot wiper operates in accordance with WIPERS PILOT switch position.
4. Set WIPERS COPILOT switch to LO, MED, HI, OFF and PK positions respectively.
5. Check only copilot wiper operates in accordance with WIPERS COPILOT switch position.
6. Open WIND SHIELD WIPER PILOT and CPLT circuit breakers.
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96-31-30
96-31-30
VOICE/FLIGHT DATA RECORDER SYSTEM (P/N 412-705-001-101 AND 103)
1. VOICE/FLIGHT DATA RECORDER SYSTEM
The voice and flight data recorder system consist of a flight data recorder, a cockpit voice recorder, and their associated
hardware and wiring. Refer to module 96-24-00 ELECTRICAL SYSTEM for equipment location and chapter 98 for
applicable wiring diagrams.
2. FLIGHT DATA RECORDER SYSTEM - DESCRIPTION
This system (figure 1) consists of a flight data acquisition unit (FDAU), a flight data recorder (FDR), an accelerometer, an
air data computer (ADC), and a system fail relay.
The flight data acquisition unit gathers data from the air data computer and various instruments and sensors. It also passes
data to the flight data recorder and clock signals to the cockpit voice recorder (CVR). Dc power is required flight data
acquisition unit and both ac and dc power are required for the flight data recorder unit. FDR SYS FAIL caution light on the
master caution panel illuminates with a FDAU failure, FDR failure, loss of power to either unit, or if either unit is not
installed. In addition, the flight data acquisition unit contains two light emitting diodes (LED) on its front cover, which are
independently activated by a fault signal for either the flight data acquisition unit or flight data recorder.
The FDR SYS FAIL caution light and flight data recorder (LED) extinguish automatically once the fault is cleared. But, in
order to extinguish the LED caution indicator on the flight data acquisition unit, activated by a FDAU fault, the fault must
first be cleared, and then the FDAU circuit breaker must be reset.
3. FLIGHT DATA RECORDER SYSTEM - REMOVAL PROCEDURES
3-1. REMOVAL PROCEDURES - FLIGHT DATA RECORDER (FDR)
WARNING
1. Ensure FDR circuit breaker is open.
2. Loosen the two fasteners on front of flight data recorder (2, figure 2) far enough to free the two hook supports.
3. Remove flight data recorder (2) by pulling straight out of mounting tray (7).
3-2. REMOVAL PROCEDURES - AIR DATA COMPUTER (ADC)
WARNING
96-31-30
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E-AB412-PT6T-2
1. Ensure FDAU circuit breaker is open.
2. Remove pitot and static lines.
3. Disconnect connector.
4. Remove and retain screws and washers that secure air data computer (5) and retain all hardware for reinstallation.
5. Remove air data computer (5) from mounting tray (6).
3-3. REMOVAL PROCEDURES - FLIGHT DATA ACQUISITION UNIT (FDAU)
WARNING
2. Loosen the two fasteners on front of flight data acquisition unit (3) far enough to free the two hook supports.
3. Remove flight data acquisition unit (3) by pulling straight out of mounting tray (4).
3-4. REMOVAL PROCEDURES - ACCELEROMETER
WARNING
2. Disconnect connector.
3. Remove and retain screws and washers that secure accelerometer (1) and retain all hardware for reinstallation.
4. Remove accelerometer (1).
4. FLIGHT DATA RECORDER SYSTEM - INSTALLATION PROCEDURES
4-1. INSTALLATION PROCEDURES - FLIGHT DATA RECORDER (FDR)
1. Ensure FDR circuit breaker is open.
2. Position flight data recorder (2, figure 2) on mounting tray (7) and push carefully into place.
3. Place the two tray-locking mechanism over flight data recorder (2) crow feet. Secure by turning locking mechanism
hand tight.
4. Verify that the flight data recorder (2) is securely mounted to the mounting tray (7) and no looseness is evident.
5. Close FDR circuit breaker .
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6. Verify that the FDR SYS FAIL caution light is extinguished.
4-2. INSTALLATION PROCEDURES - AIR DATA COMPUTER (ADC)
2. Connect connector.
3. Position air data computer (5) on mounting tray (6) and secure with four screws and washers.
CAUTION
TORQUE ALL PLASTIC FITTINGS TO 15 ± 5 IN-LBS (1.695 ±0.56 NM).
4. Install pitot and static lines.
NOTE
Ensure all lines and fittings to be installed are free of water traps; use drain caps to
meet these requirements.
5. Close FDAU circuit breaker.
6. Perform a pitot-static leak test check. (Refer to module 95-34-10 FLIGHT INSTRUMENTS - PITOT-STATIC
SYSTEM).
4-3. INSTALLATION PROCEDURES - FLIGHT DATA ACQUISITION UNIT (FDAU)
2. Position flight data acquisition unit (3) on mounting tray (4) and push it carefully into place.
3. Place the two tray-locking mechanisms over flight data acquisition unit (3) crow feet and secure by turning locking
mechanism until hand tight.
5. Perform a functional test procedure of the flight data recorder system (Refer to paragraph "8. Flight data recorder
system - functional test").
4-4. INSTALLATION PROCEDURES - ACCELEROMETER
2. Install accelerometer (1) and connect connector.
5. FLIGHT DATA RECORDER SYSTEM - INSPECTION PROCEDURES
1. Visually inspect components for general condition or damage.
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2. Visually inspect air data computer and accelerometer for damage to case.
3. Visually inspect accelerometer for oil damage.
4. Visually inspect condition of pitot and static line connectors for damaged threads or cracking.
5. Visually inspect electrical connector for damaged/ bent pins, corrosion, or cracks.
6. Visually inspect condition of all mounting hardware for corrosion or wear.
7. Inspect stenciled markings for legibility.
6. FLIGHT DATA RECORDER SYSTEM - CLEANING PROCEDURES
MATERIALS REQUIRED
NUMBER NOMENCLATURE
C-533 TRICHLOROTRIFLOROETHANE
1. Clean chassis surfaces with paper towel or soft clean cloth moistened in mild detergent, then dry thoroughly.
2. Remove detergent residue with paper towel or soft clean cloth.
3. Remove stubborn dirt/grease from chassis using a lint-free cloth or a soft-bristle brush moistened with isopropyl
alcohol (C-385).
4. Thoroughly dry surfaces.
5. Clean connector contacts using a soft-bristled brush moistened with isopropyl alcohol (C-385).
7. Remove debris and clean static line ports/connectors using a lint-free cloth moistened with isopropyl alcohol (C-385).
9. Remove stubborn dirt/grease from accelerometer chassis using a soft-bristle brush moistened in Freon compound
(C-533).
10. Dry clean with paper towel or soft clean cloth.
7. FLIGHT DATA RECORDER SYSTEM - REPAIR OR REPLACEMENT
1. Replace defective or inoperative units.
NOTE
ULB battery can be locally replaced. Contact vendor for appropriate procedures.
2. Further repairs, other than removal or replacement, must be conducted by an authorized repair facility.
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8. FLIGHT DATA RECORDER SYSTEM - FUNCTIONAL TEST
T122 ROSE ANALYSIS UNIT (RAU)
--- TILT TABLE (PLUS & MINUS 45°)
--- INCLINOMETER
--- PITOT/STATIC TESTER
T123 TEST CABLE
--- HYDRAULIC TEST SET
--- EXTENDER CABLE
1. Visually inspect each component to ensure that it is properly installed, and electrical connectors are properly mated
and tight.
2. Connect test cable to flight data recorder (FDR).
3. Connect external power.
4. Connect and apply hydraulic power to helicopter.
5. Air data parameters (using the pitot/static tester connected to the copilot’s system and the AUX PITOT STATIC
switches set to NORM).
a. Check altitude as follows:
(1) Simulate the altitudes below with the airspeed set to 0 kts and verify that the RAU readout is within
acceptable limits. Record the values:
APPLIED COPILOT’S RAU READING

ALTITUDE ALTIMETER (Feet)
(Feet) (Feet) Min Max
-500 --- -600 -400
0 --- -100 100
500 --- 400 600
5000 --- 4850 5150
10000 --- 9850 10150
b. Check vertical speed as follows:
(1) Simulate the vertical speed (VS) below and verify that the RAU readout is within acceptable limits. Record
the values:
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E-AB412-PT6T-2

ALTITUDE RATE VERTICAL SPEED (fpm)
(Feet per min) (Feet per min) Min Max
0 --- -250 250
500 --- 250 750
2000 --- 1750 2250
-500 --- -750 -250
-2000 --- -2250 -1750
c. Check airspeed as follows:
(1) Simulate the airspeeds below with the altitude set to 0 ft and verify that the RAU readout is within
acceptable limits. Record the values:

AIRSPEED INDICATED AIRSPEED (kts)
(knots) (knots) Min Max
20 --- 10 30
50 --- 40 60
100 --- 90 110
140 --- 130 150
6. Outside air temperature.
a. Check outside air temperature as follows:
(1) Verify that the RAU readout is within plus or minus 2° C compared to the real date. Record the value:
OAT INDICATED RAU READING

(degrees C) (degrees C)
--- ---
7. Accelerations.
a. Check vertical acceleration as follows:
(1) Detach the accelerometer from its mounting and hold in its normal orientation and verify that the RAU
reading shows between 0.8 and 1.2 G. Record the value.
(2) Rotate the accelerometer forward 90° and verify that the RAU reading shows between -0.2 and 0.2 G.
Record the value.
(3) Rotate the accelerometer a further 90° until it is fully inverted from its normal installed position and verify
that the RAU shows between -1.2 and -0.8 G. Record the values:
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E-AB412-PT6T-2
ACCELEROMETER RAU READING

POSITION (G)
Min Max
Normal 0.8 1.2
90° fwd -0.2 0.2
180° fwd -1.2 -0.8
b. Check longitudinal acceleration as follows:
(1) Hold the accelerometer in its normal orientation and verify that the RAU reading shows between -0.03 and
0.03 G. Record the value.
(2) Rotate the accelerometer 90° forward and verify that the RAU readout shows between -1.03 and -0.97 G.
Record the value.
(3) Return the accelerometer to normal orientation and then rotate it aft through 90°. Verify that the RAU
readout shows between 0.97 and 1.03 G. Record the value:
ACCELEROMETER RAU READING

POSITION (G)
Min Max
Normal -0.03 0.03
90° fwd -1.03 -0.97
90° aft 0.97 1.03
8. Heading.
a. Check heading as follows:
(1) Switch the pilot’s compass MAG/DG switch to DG. Slew the compass card to the headings below and
verify that the RAU readings are within ± 5°. Record the values:
PILOT COMPASS HEADING RAU READING

(degrees) (degrees)
Min Max
0 -5 5
90 85 95
240 235 245
9. Hydraulic system (using the external hydraulic power source).
a. Check collective as follows:
(1) With the hydraulic system operational, lower the collective stick to its lowest position. Verify that the RAU
readout shows between -3 and 3%. Record the value.
(2) Raise the collective stick to its highest position and verify that the RAU readout shows between 97 and
103%. Record the value:
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E-AB412-PT6T-2
COLLECTIVE POSITION RAU READING

(%)
Min Max
Fully down -3 3
Fully up 97 103
b. Check yaw pedals as follows:
(1) With the hydraulic system operational, apply full left pedal. Verify that the RAU readout shows between
-106 and -94%. Record the value.
(2) Apply full right pedal and verify that the RAU shows between 94 and 106%. Record the value:
PEDAL RAU READING

POSITION (%)
Min Max
Fully left -106 -94
Fully right 94 106
c. Check longitudinal cyclic as follows:
(1) With the hydraulic system operational, apply full forward cyclic stick. Verify that the RAU readout shows
between -106 and -94%. Record the value.
(2) Apply full aft cyclic and verify that the RAU readout shows between 94 and 106%. Record the value:
CYCLIC STICK RAU READING

POSITION (%)
Min Max
Fully fwd -106 -94
Fully aft 94 106
d. Check lateral cyclic as follows:
(1) With the hydraulic system operational, apply full left stick. Verify that the RAU readout shows between
-106 and -94%. Record the values.
(2) Apply full right stick and verify that the RAU readout shows between -94 and 106%. Record the value:
CYCLIC STICK RAU READING

POSITION (%)
Min Max
Fully left -106 -94
Fully right 94 106
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E-AB412-PT6T-2
e. Check hydraulic system pressure discretes as follows:
(1) With both primary and secondary hydraulic systems operational, select HYDRAULIC SYSTEM NO. 1 to
OFF and then back to ON. Verify that the HYDRAULIC warning light on the caution panel illuminates
and, on the RAU the PRIM HYD LOW indicator changes from NORM to LOW before the HYDRAULIC
warning extinguishes and the RAU indicator returns to NORM.
CAUTION
THE HYDRAULIC SYSTEM SHOULD NOT BE KEPT SWITCHED OFF FOR

MORE THAN APPROXIMATELY 10 SECONDS DUE TO THE
CHARACTERISTICS OF THE SYSTEM WHEN DRIVEN BY EXTERNAL
HYDRAULIC POWER.
(2) Select HYDRAULIC SYSTEM NO. 2 to OFF and then back to ON. Verify that the HYDRAULIC warning
on the caution panel illuminates and, on the RAU the SEC HYD LOW indicator changes from NORM to
LOW before the HYDRAULIC warning extinguishes and the RAU indicator returns to NORM.
10. Autopilot discretes.
a. Check autopilot discretes as follows:
(1) With both hydraulic systems and all electrical and instrument systems operational, verify that the NO. 1
AUTOPILOT and NO. 2 AUTOPILOT warning lights on the caution panel are illuminated.
(2) Verify on the RAU that the SAS FLT shows FLT, HP1 shows OFF and HP2, shows OFF.
(3) Sequentially select AP1 and AP2. Verify that on the RAU, HP1 and HP2 change to ON respectively and
when both are ON, SAS FLT shows OK and the NO. 1 AUTOPILOT and NO. 2 AUTOPILOT lights are
extinguished.
(4) Deselect AP1 an AP2 and note that the reverse occurs.
11. Attitude.
a. Check attitude as follows:
(1) Remove the pilot's Tarsyn 3-axis gyro and install it on the tilt table using the extender cable. Use the
inclinometer to measure the angle of the gyro and cross check with the pilot’s attitude indicator. Record
the values:
PITCH RAU READING

(degrees)
Min Max
45° nose up +43 +47
0° nose -02 +02
45° nose down -47 -43
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E-AB412-PT6T-2
ROLL RAU READING

(degrees)
Min Max
45° right +43 +47
0° -02 +02
45° left -47 -43
(2) Disconnect the extender cable and reinstall the gyro in the helicopter.
12. Rotor brake.
a. Check rotor brake as follows:
(1) Apply the ROTOR BRAKE. On the RAU, verify that the ROTOR BRAKE No. 1 and ROTOR BRAKE
No. 2 indicators change from OFF to ON in agreement with the ROTOR BRAKE caution lights.
13. VHF keylines.
a. Check VHF keylines as follows:
(1) With the pilot and copilot ICS, apply key COMM1 and then COMM2. On the RAU, verify that the VHF
Key No. 1 and VHF Key No. 2 indicators change from NOKEY to KEY respectively.
14. Engine fire warnings.
a. Check engine fire warnings as follows:
CAUTION
DO NOT PULL THESE HANDLES.
(1) Depress the PRESS TO TEST engine fire detector test switch. On the RAU, verify that the FIRE1 and
FIRE2 indicators change from NONE to FIRE in agreement with the warning lights in the left and right
emergency handles.
15. Baggage fire warnings.
a. Check baggage fire warnings as follows:
NOTE
This warning pulses; therefore, close attention must be paid to note the RAU
indication.
(1) Depress the BAGGAGE FIRE TEST switch. On the RAU, verify that the BAG FIRE indicator changes
from NONE to FIRE in agreement with the BAGGAGE FIRE warning light.
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E-AB412-PT6T-2
9. VOICE/FLIGHT DATA RECORDER SYSTEM - RETRIEVAL OF DATA
T124 PORTABLE ANALYSIS UNIT (PAU)
T125 PORTABLE PRINTER UNIT (PPU)
The portable analysis unit and the portable printer unit are used to extract, analyze, monitor or copy recorded data from the
flight data recorder. For additional information refer to LORAL component Maintenance Manual, Publication No.
165-E0514-00.
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E-AB412-PT6T-2
(FDR)
(FDAU)
(ADC)
G6AB1070A
Figure 1. Simplified block diagram flight data recorder system
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E-AB412-PT6T-2
A 1. Accelerometer
2. Flight data recorder (FDR)
3. Flight data acquisition unit (FDAU)
4. Mounting tray
5. Air data computer (ADC)
6. Mounting tray
7. Mounting tray
A 8. Control panel
7 6 5
G6AB1071A
Figure 2. Flight data recorder system equipment location
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E-AB412-PT6T-2
10. COCKPIT VOICE RECORDER SYSTEM - DESCRIPTION
The system (figure 3) consists a cockpit voice recorder (CVR), a recorder control unit (RCU) and an impact switch.
This system is dc powered and protected by the CVR circuit breaker. The CVR, via the ICS panels, records the microphone
signals, keyed and unkeyed, and the headphone audio. It also records the audio signals from the area microphone, and time
correlation signals from the flight data acquisition unit. The record time is a minimum of 30 minutes on a 1/4 in.
preconditioned continuous loop magnetic tape. In the event of a crash, the inertia switch disables power to the CVR to
prevent erasure of audio data.
11. COCKPIT VOICE RECORDER SYSTEM - REMOVAL PROCEDURES
WARNING
11-1. REMOVAL PROCEDURES - COCKPIT VOICE RECORDER (CVR)
1. Ensure CVR system circuit breaker is open.
2. Loosen the two fasteners on front of cockpit voice recorder (6, figure 4) far enough to free the two hook supports.
3. Remove cockpit voice recorder (6) by pulling straight out of mounting tray (7).
11-2. REMOVAL PROCEDURES - RECORDER CONTROL UNIT (RCU)
2. Loosen spring-lock fasteners that secure recorder control unit (5) to pedestal.
3. Lift recorder control unit (5) far enough out of pedestal to permit access to electrical connector at back of unit.
4. Disconnect electrical connector at rear of unit. Lift clear.
11-3. REMOVAL PROCEDURES - IMPACT SWITCH
1. Remove and retain screw (1) and washer (2) that secures bonding strap (3) to the impact switch (4).
2. Remove and retain screws (9) and washers (8) that secure the impact switch (4) to mounting location.
3. Disconnect electrical connector at back of unit.
4. Remove impact switch (4).
11-4. REMOVAL PROCEDURES - MOUNTING TRAY
1. Remove and retain screws that secure mounting tray (7) and spacer, retain all hardware for reinstallation.
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E-AB412-PT6T-2
12. COCKPIT VOICE RECORDER SYSTEM - INSTALLATION PROCEDURES
WARNING
12-1. INSTALLATION PROCEDURES - COCKPIT VOICE RECORDER (CVR)
2. Position cockpit voice recorder (6, figure 4) on mounting tray (7) and push carefully into place.
3. Place the two tray-locking mechanisms over cockpit voice recorder crow feet secure by turning locking mechanism
handtight.
4. Verify that the cockpit voice recorder (6) is securely mounted to the mounting tray (7) and no looseness is evident.
12-2. INSTALLATION PROCEDURES - RECORDER CONTROL UNIT (RCU)
1. Ensure that CVR system circuit breaker is open.
2. Connect electrical connector to back of control panel.
3. Position recorder control unit (5) in pedestal and secure with spring lock fasteners.
12-3. INSTALLATION PROCEDURES - IMPACT SWITCH
1. Position impact switch (4) in place and secure with mounting screws (9) and washers (8).
2. Connect electrical connector to back of the impact switch (4).
3. Install bonding strap (3) to impact switch (4) and secure with screw (1) and washer (2). Measure the resistance of
electrical bond; verify bonding is less than 10 milliohms.
12-4. INSTALLATION PROCEDURES - MOUNTING TRAY
1. Position mounting tray (7) and spacer, secure with mounting screws.
2. Verify bonding for mounting tray is less than 2.5 milliohms.
13. COCKPIT VOICE RECORDER SYSTEM - INSPECTION PROCEDURES
1. Inspect cockpit voice recorder as follows:
a. Visually inspect components for general condition or damage.
b. Visually inspect electrical connector for damaged/ bent pins, corrosion or cracks.
c. Visually inspect condition of all mounting hardware for corrosion or wear.
d. Verify that the cockpit voice recorder is securely mounted to the mounting tray and no looseness is evident.
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E-AB412-PT6T-2
2. Inspect recorder control unit as follows:
a. Visually inspect recorder control unit exterior surfaces for damage or missing attaching screws and turn lock
fasteners.
b. Visually inspect front panel nomenclatures and markings for legibility.
c. Visually inspect indicator for cracks, damaged lenses, etc.
d. Visually inspect area microphone for dust or dirt accumulation or other visible contamination or damage.
e. Visually inspect condition of all mounting hardware for corrosion or wear.
f. Visually inspect switches for damage and security.
14. COCKPIT VOICE RECORDER SYSTEM - CLEANING PROCEDURES
MATERIALS REQUIRED
Refer to BHT-ALL-SPM for specifications and source.
NUMBER NOMENCLATURE
CAUTION
EXERCISE CARE WHEN CLEANING THE INDICATING PANEL TO

PREVENT SCRATCHING THE SURFACE COATING. SCRATCHES IN THE
SURFACE COATING MAY NOT BE EVIDENT UNTIL THE DISPLAY IS
OPERATED.
1. Remove moisture and loose dirt with a soft clean cloth.
2. Remove dust and dirt from panel control with a soft clean cloth. To remove fingerprints or difficult dirt, use a cloth
moistened with water; if necessary, a mild detergent may be used to remove grease or other substances not effectively
cleaned with water only.
4. Clean connector contacts using a soft-bristled brush moistened with isopropyl alcohol (C-385).
5. Clean the switch end of the beacon with water, mild detergent and a soft cloth, then dry thoroughly with a clean cloth.
Clean the switch end insulator to prevent leakage currents from occurring across the switch. This will affect battery
life. The water switch should be cleaned when dirt or dust becomes apparent.
15. COCKPIT VOICE RECORDER SYSTEM - REPAIR OR REPLACEMENT
1. Replace defective or inoperative units.
2. Further repairs, other than removal or replacement, must be conducted by an authorized repair facility
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E-AB412-PT6T-2
16. COCKPIT VOICE RECORDER SYSTEM - FUNCTIONAL CHECK
NOTE
The CVR has a TEST interlock through the pilot and copilot intercommunication
system (ICS) control units to ensure 212-077-200-105 ICS control units are
installed. If the meter fails to indicate during the test, an earlier model (lower dash
number) ICS control unit may have been installed.
1. Close CVR circuit breaker.
2. Press test button on CVR control panel, and hold for 3 seconds.
3. Verify meter indication reads GOOD.
NOTE
The meter needle will normally oscillate slightly. A channel failure will result in the
needle dropping from the green section of the meter scale or returning to zero, either
of which indicate a definite NO GO condition.
4. Cover area microphone.
NOTE
The CVR control panel requires a 600 ohm headset with a standard phone plug to
monitor CVR audio.
5. Monitor CVR audio.
6. Using pilot microphones announce date, time, and helicopter serial number.
7. Verify CVR audio is clear, intelligible, and delayed approximately 0,5 seconds.
NOTE
A continual BEEP from the FDAU is normal.
8. Repeat steps 4 through 7 using copilot microphone.
9. Set ICS volume control to midrange and cover area microphone.
11. Using pilot microphones key and announce date, time, and helicopter serial number.
14. Using copilot microphones key and announce date, time, and helicopter serial number.
16. Uncover area microphone.
17. Disconnect pilot and copilot headsets.
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E-AB412-PT6T-2
19. From the pilot or copilot seat, announce date, time, and helicopter serial number.
21. Remove all power from the CVR system.
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E-AB412-PT6T-2
G6AB1072A
Figure 3. Simplified block diagram cockpit voice recorder system
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E-AB412-PT6T-2
1
2
A
3
9
8 4
1. Screw
2. Washer
3. Bonding strap
4. Impact switch
5. Recorder control unit (RCU) B
6. Cockpit voice recorder (CVR)
7. Mounting tray
8. Washer
9. Screw
G6AB1073A
Figure 4. Cockpit voice recorder system equipment location
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E-AB412-PT6T-2
96-31-50
CAUTION AND WARNING SYSTEM
1. CAUTION AND WARNING SYSTEM - DESCRIPTION
Caution and warning system includes master caution panel, pilot MASTER CAUTION light, copilot MASTER CAUTION
light, pilot RPM warning light, copilot RPM warning light, ENG 1 OUT light, ENG 2 OUT light, switches, diodes, relays,
and interconnected wiring.
The master caution panel (figure 1, figure 2) is a multi capsulated (each capsule includes an indicator light) panel which is
protected by MASTER CAUTION circuit breaker. Each indicator light is in series with a respective caution light system
containing switches and associated components. MASTER CAUTION lights mounted on instrument panel illuminate
simultaneously when one or more capsule indicator(s) illuminates. Caution light and warning circuits include items as listed
in this section. Refer to Chapter 98 for appropriate system wiring diagram.
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E-AB412-PT6T-2
G6AB0751A
Figure 1. Master caution panel (helicopters codes [A] [B])
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E-AB412-PT6T-2
G6AB0752A
Figure 2. Master caution panel (helicopters codes [C] [D])
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E-AB412-PT6T-2
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96-31-51
CAUTION AND WARNING SYSTEM - OPERATION
1. OPERATION - DESCRIPTION
MASTER CAUTION lights on pilot and copilot instrument panel illuminate in conjunction with one or more indicator panel
lights to announce a fault or malfunction in a monitored system. MASTER CAUTION lights can be reset in readiness for
next fault by momentarily depressing TEST-RESET switch to RESET. Individual indicator lights on caution panels will
remain illuminated as long as fault condition exists. Momentarily pressing TEST switch will illuminate all indicator lights
on master caution panel, MASTER CAUTION lights, the RPM warning lights, ENG 1 OUT light, and ENG 2 OUT light.
Caution and warning lights are so designed that after each initial application of power, all indicator lights will illuminate
bright. Manual selection of a bright or dimmed condition is provided by a BRIGHT-DIM switch on master caution panel.
Momentarily placing BRIGHT-DIM switch to DIM will momentarily dim master caution panel indicator lights, MASTER
CAUTION light, RPM ENG 1 OUT, and ENG 2 OUT. Lights will dim and remain dim if pilot INSTR LTS rheostat (R1/
8R1) is rotated clockwise from OFF. Lights can be reset to bright by momentarily placing BRIGHT-DIM switch to BRIGHT
or by rotating pilot INSTR LTS rheostat counterclockwise to OFF.
2. OPERATION - OPERATIONAL TEST
2-1. OPERATIONAL TEST - MASTER CAUTION LIGHT SYSTEM
During system operational checks, MASTER CAUTION lights on pilot instrument panel should illuminate each time a
caution panel segment illuminates, and shall be reset each time in readiness for another fault indication.
1. Close MASTER CAUTION and CAUTION FAIL circuit breakers.
2. Check MASTER CAUTION lights illuminate and each caution light illuminates in accordance with following listing.
3. Reset MASTER CAUTION lights by placing RESET/TEST switch to RESET and releasing.
4. Check MASTER CAUTION lights extinguish and individual caution lights remain either on or off in accordance with
the following lists.
Helicopters codes [A] [B]:
CAUTION LIGHTS ON/OFF CONDITION
ENG 1 DC GENERATOR ON
ENG 1 OIL PRESSURE ON
ENGINE 1 PART SEP ON
96-31-51
Page 1
E-AB412-PT6T-2
(Cont.)
ENG 2 PART SEP ON
ENG 1 FUEL BOOST ON
ENG 2 FUEL BOOST ON
ENG 1 FUEL FILTER OFF
ENG 2 FUEL FILTER OFF
ENG 1 FUEL LOW ON 1
ENG 2 FUEL LOW ON 1
ENG 1 GOV MANUAL OFF
ENG 1 CHIP OFF
ENG 2 CHIP OFF
ENG 1 FUEL VALVE OFF
ENG 1 GEN OVHT OFF
ENG 2 GEN OVHT OFF
CAUTION PANEL OFF
HYDRAULIC ON
XMSN OIL ON
PRESSURE CHIP C BOX ON
C BOX OIL PRESS ON
INVERTER #1 ON
CHIP XMSN OFF
INVERTER #2 ON
XMSN OIL TEMP OFF
C BOX OIL TEMP OFF
EXTERNAL POWER ON
CHIP 42/90 BOX OFF
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Page 2
E-AB412-PT6T-2
(Cont.)
FUEL XFEED OFF
DOOR LOCK ON
HEATER AIR LINE OFF
BATTERY ON
AFCS OFF
BATTERY TEMP OFF
NOTES:
1 Light in ON state only when fuel quantity is less than 10%

of tank capacity. Quantity is less than 10% of tank capacity.
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E-AB412-PT6T-2
Helicopters codes [C] [D]:
ENG 1 PART SEP OFF ON
ENG 2 PART SEP OFF ON
ENG 1 ENGINE CHIP OFF
ENG 2 ENGINE CHIP OFF
NO. 1 FUEL BOOST ON
NO. 1 GEN OVHT OFF
NO. 2 GEN OVHT OFF
NO. 2 FUEL BOOST ON
NO. 1 FUEL TRANS ON
AFCS ON
C’BOX OIL PRESSURE ON
XMSN OIL PRESSURE ON
NO. 2 FUEL TRANS ON
BATTERY TEMP OFF
ROTOR BRAKE OFF
C’BOX OIL TEMP OFF
XMSN OIL TEMP OFF
ROTOR BRAKE OFF
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Page 4
E-AB412-PT6T-2
(Cont.)
BATTERY ON
NO. 1 FUEL FILTER ON/OFF
C’BOX CHIP OFF
XMSN CHIP OFF
CAUTION PANEL OFF 2
NO. 2 FUEL FILTER OFF
FUEL LOW ON OR OFF 1
NO. 1 INVERTER ON
NO. 1 HYDRAULIC ON
NO. 2 HYDRAULIC ON
NO. 2 INVERTER ON
FUEL INTCON OFF
HEATER AIR LINE OFF
EXTERNAL POWER ON
42/90 BOX CHIP OFF
DOOR LOCK ON
FUEL XFEED OFF
FDR SYS FAIL OFF
AUTOTRIM OFF
NOTES:
1 Light in ON state only when fuel quantity is less than

10% of tank capacity.
2 Dimming not required.
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Page 5
E-AB412-PT6T-2
3. OPERATION - OPERATIONAL CHECK
3-1. OPERATIONAL CHECK - CAUTION PANEL LIGHT SYSTEM
1. Test caution lights by setting TEST PNL/LT switch to TEST and releasing.
2. Check MASTER CAUTION lights momentarily illuminate brightly and then extinguish.
3. Check all caution lights momentarily illuminate brightly and return to former condition.
4. Set BRT/DIM switch to DIM and release.
5. Check caution lights do not dim.
6. Rotate PILOT INSTR LT rheostat, clockwise from OFF.
7. Actuate BRT/DIM switch again.
8. Check lights dim and hold.
9. Rotate PILOT INSTR LT rheostat counterclockwise to OFF and check lights return to bright.
10. Ensure that ENGINE 1 GOV and ENGINE 2 GOV switches are not set to MANUAL position.
11. Check the following occurs while TEST switch on master caution panel is set to PNL.
a. CAUTION PANEL segment illuminates in bright mode.
b. All other segments are extinguished.
c. ENG 1 OUT, ENG 2 OUT lights are illuminated in bright mode.
d. MASTER CAUTION light(s) are illuminated in bright mode.
4. OPERATION - ADVISORY PANEL
4-1. ADVISORY PANEL - DESCRIPTION
The ADVISORY PANEL installed in the pedestal incorporates a series of advisory lights. The advisory light remains
illuminated as long as the condition, causing illumination, exists. An ADVISORY PNL TEST push-button type switch is
located above the ADVISORY PANEL and allows testing all advisory lights by illumination.
When the ADVISY PNL BRIGHT-DIM switch is placed to BRIGHT, the advisory lights will illuminate brightly. Light
intensity can be dimmed by placing the ADVISY PNL BRIGHT-DIM switch to DIM. The circuit powered by 28 Vdc and
is protected by the ADV PNL circuit breaker. See Chapter 98 for wiring diagrams.
4-2. ADVISORY PANEL - OPERATIONAL CHECK
1. Close the ADV PNL LIGHT circuit breaker and check all advisory lights are extinguished.
2. Place the ADVY PNL BRT-DIM switch to BRT, push the ADVY PNL TEST switch and check that all advisory lights
illuminate brightly, and extinguish when switch is released.
3. Place the ADVY PNL BRTDIM switch to DIM, push the ADVY PNL TEST switch and check that all advisory lights
illuminate dimly. Release switch and check that advisory lights extinguish.
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E-AB412-PT6T-2
4-3. ADVISORY PANEL - TROUBLESHOOTING
Table 1. Master caution light and advisory panel troubleshooting
Caution panel lights fail to dim when PILOT INSTR LT rheostat Replace rheostat.
BRIGHT-DIM switch is phased to DIM and defective
PILOT INSTR LT knob is rotated clockwise
from OFF. Dim relay on caution panel Replace caution panel.
defective.
BRIGHT-DIM switch on caution Replace caution panel.

panel defective.
Caution panel lights fail to illuminate with TEST-RESET switch on caution Replace caution panel.
TEST-RESET switch to TEST panel defective.
Any caution panel lights fail to illuminate Lamps defective. Replace lamps.
with TEST-RESET switch set to TEST.
MASTER CAUTION lights do not TEST-RESET switch on caution Replace caution panel.
extinguish with TEST-RESET switch set to panel defective.
RESET.
Caution panel inoperative. MASTER CAUTION circuit Replace circuit breaker.

breaker defective.
CAUTION FAIL circuit breaker Replace circuit breaker.

defective.
Advisory lights fail to dim when ADVY Advisory panel components Replace advisory panel.
PNL BRT-DIM switch is placed to DIM defective.
ADVY PNL BRT-DIM switch Replace switch.

defective
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E-AB412-PT6T-2
(Cont.)
Advisory lights fail to illuminate when ADVY PNL TEST switch Replace switch.
ADVY PNL TEST switch is pressed defective.
Electrical wiring defective Repair electrical wiring.
ADVY PANEL LIGHT circuit Replace circuit breaker.

breaker defective.
Any advisory light fails to illuminate when Lamps defective. Replace lamps.
ADVY PNL TEST switch is pressed.
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E-AB412-PT6T-2
96-31-52
CAUTION AND WARNING SYSTEM - CAUTION LIGHT SYSTEMS
1. CAUTION LIGHT SYSTEMS - OPERATIONAL CHECK
1-1. OPERATIONAL CHECK - DC GENERATOR CAUTION LIGHT SYSTEM
DC GENERATOR caution lights are checked as part of generator system circuitry (module 96-24-33
paragraph "2-1. Operational check - generator No. 1 system" and paragraph "2-2. Operational check - generator No. 2
system").
1-2. OPERATIONAL CHECK - GENERATOR NO. 1 AND NO. 2 OVERHEAT CAUTION LIGHT SYSTEM
1. Install temporary jumper between No. 1 starter-generator temperature sensor terminals.
2. Check ENG 1 GEN OVHT caution light illuminates.
3. Remove temporary jumper.
4. Check ENG 1 GEN OVHT caution light extinguishes.
5. Install temporary jumper between No. 2 starter-generator temperature sensor terminals.
6. Check ENG 2 GEN OVHT caution light illuminates.
7. Remove temporary jumper.
8. Check ENG 2 GEN OVHT caution light extinguishes.
1-3. OPERATIONAL CHECK - INVERTER NO. 1 AND NO. 2 CAUTION LIGHT SYSTEM
Inverter No. 1 and No. 2 caution light systems are checked as a portion of inverter circuitry (module 96-24-21
paragraph "2. Inverter systems - operational checks").
OPERATIONAL CHECK - ENGINE OIL PRESSURE
T98 PRESSURE TESTER, 0 – 150 PSI (0 – 1034 KPA)
NOTE
1. Connect a pressure tester to engine 1 oil pressure switch (S73/8S5) and apply pressure.
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2. Check ENG 1 OIL PRESSURE caution light extinguishes at an increasing pressure of 40 psig (276 kPa).
3. Relieve pressure on engine 1 oil pressure switch.
4. Check ENG 1 OIL PRESSURE caution light illuminates at a decreasing pressure of 31  1,5 psig (214 10 kPa).
5. Connect pressure tester to engine 2 oil pressure switch (8S6) and apply pressure.
6. Check ENG 2 OIL PRESSURE caution light extinguishes at an increasing pressure of 40 psig (276 kPa).
7. Relieve pressure on engine 2 oil pressure switch.
8. Check ENG 2 OIL PRESSURE caution light illuminates at a decreasing pressure of 31 ± 1,5 psig (214 ± 10 kPa).
1-4. OPERATIONAL CHECK - TRANSMISSION OIL PRESSURE CAUTION LIGHT SYSTEM
NOTE
1. Connect a pressure tester to transmission oil pressure switch (8S2).
2. Check XMSN OIL PRESS caution light extinguishes at an increasing pressure of 38 psig (262 kPa) maximum.
3. Relieve pressure on transmission oil pressure switch.
4. Check XMSN OIL PRESS caution light illuminates at 30 3 psig (207 20 kPa) decreasing pressure.
1-5. OPERATIONAL CHECK - TRANSMISSION OIL TEMPERATURE CAUTION LIGHT SYSTEM
1. Connect a temporary short between stud on top of transmission oil temperature switch (located on transmission) and
ground.
2. Check XMSN OIL TEMP caution light illuminates.
3. Remove ground from transmission oil temperature switch.
4. Check XMSN OIL TEMP caution light extinguishes.
1-6. OPERATIONAL CHECK - COMBINING GEARBOX OIL PRESSURE CAUTION LIGHT SYSTEM
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NOTE
1. Connect a pressure tester to gearbox oil pressure switch (S90/8S8) and apply pressure.
2. Check C BOX OIL PRESS caution light extinguishes at an increasing pressure of 40 psig (276 kPa).
3. Relieve pressure on gearbox oil pressure switch.
4. Check C BOX OIL PRESS caution light illuminates at a decreasing pressure of 31 ± 1,5 psig (214 ± 10 kPa).
1-7. OPERATIONAL CHECK - COMBINING GEARBOX OIL TEMPERATURE CAUTION LIGHT SYSTEM
1. Disconnect connector (8S11P1) from gearbox oil temperature switch.
2. Connect a temporary short between pin A and B.
3. Check C BOX OIL TEMP caution light illuminates.
4. Remove temporary short and connect connector.
5. Check C BOX OIL TEMP caution light extinguishes.
1-8. OPERATIONAL CHECK - PARTICLE SEPARATOR CAUTION LIGHT SYSTEM
PART SEP OFF caution light is checked as part of particle separator operational check (module 96-73-01 paragraph "13-2.
Engine particle separator system - operational check").
1-9. OPERATIONAL CHECK - GOVERNOR MANUAL CONTROL CAUTION LIGHT SYSTEM
GOV MANUAL caution lights are checked as portions of the fuel control valve test (module 96-73-01
paragraph "6-2. Fuel control valve system - operational check").
1-10. OPERATIONAL CHECK - ENGINE CHIP DETECTOR CAUTION LIGHT SYSTEM
1-10-1. Engine chip detector caution light system - check engine No. 1 chip detector caution light circuitry
1. Disconnect connector (8E3P1) from engine No. 1 forward chip detector.
2. Connect a temporary short between pins A and B.
3. Check ENG 1 CHIP caution light illuminates.
4. Remove temporary short and connect connector to chip detector.
5. Disconnect connector (8E5P1) from engine No. 1 aft chip detector.
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1-10-2. Engine chip detector caution light system - check engine No. 2 chip detector caution light circuitry
1. Disconnect connector (8E4P1) from engine No. 2 forward chip detector.
5. Disconnect connector (8E6P1) from engine No. 2 aft chip detector.
1-11. OPERATIONAL CHECK - COMBINING GEARBOX CHIP DETECTOR CAUTION LIGHT SYSTEM
1. Disconnect connector (8E2P1) from gearbox chip detector.
3. Check CHIP C BOX caution light illuminates.
1-12. OPERATIONAL CHECK - TRANSMISSION CHIP DETECTOR CAUTION LIGHT SYSTEM
1. Disconnect connector (8E11P1) from transmission oil monitor/detector.
3. Check CHIP XMSN caution light illuminates.
4. Verify XMSN CHIP IND SUMP/OIL MONITOR indicator on right side of pedestal shows three white segments.
5. Remove temporary short and connect connector (8E11P1).
6. Reset indicator (all black).
7. Connect a temporary short from terminal of transmission planetary chip detector to ground.
9. Verify XMSN CHIP IND PLNTY indicator on right side of pedestal shows three white segments.
10. Remove temporary short.
12. Connect a temporary short from terminal of transmission upper mast chip detector to ground.
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14. Verify XMSN CHIP IND UPPER MAST indicator on right side of pedestal shows three white segments.
1-13. OPERATIONAL CHECK - FORTY-TWO/NINETY DEGREE (42°/90°) GEARBOX CHIP DETECTOR

CAUTION LIGHT SYSTEMS
1. Connect a temporary short between terminal (not ground terminal) on 42 chip detector and ground.
2. Check CHIP 42/90 CHIP caution light illuminates.
3. Remove the temporary short from terminal on 42° chip detector and ground. Check that CHIP 42/90 BOX caution
lights extinguishes.
4. Connect a temporary short between terminal (not the ground terminal) on the 90° chip detector and ground. Check that
CHIP 42/90 BOX caution light illuminates.
5. Remove temporary short from terminal on 90° chip detector and ground. Check that CHIP 42/90 BOX caution light
illuminates.
1-14. OPERATIONAL CHECK - DOOR LOCK CAUTION LIGHT SYSTEM
1. Close and lock baggage compartment door and the two passenger compartment doors.
2. Check DOOR LOCK caution light is extinguished.
3. Unlock, open, then close each of three doors in turn.
4. Check DOOR LOCK caution light is illuminated when any one of three doors is unlocked and open.
5. Check DOOR LOCK caution light is extinguished when all doors are closed and locked.
1-14-1. Door lock caution light system - door lock switches/switch levers-adjustment procedure
1. Gain access to switches (8S3, 8S4, and 8S7).
2. Slowly close either door, one at a time, and ensure switch is being activated by switch lever.
NOTE
If switch is activated by switch lever and DOOR LOCK caution light is illuminated,
perform electrical continuity check of system. Repair wire or replace and adjust door
lock switch.
3. If switch is not activated by switch lever, adjust switch bracket (with door in closed position) for 0.12 in (3.05 mm)
nominal switch lever travel.
1-15. OPERATIONAL CHECK - FUEL BOOST CAUTION LIGHT SYSTEM [A] [B]
1. Disconnect wire Q67A22 from terminal 3 of TB11.
2. Verify ENG 1 FUEL BOOST light extinguishes.
3. Connect wire Q67A22 to terminal 3 of TB11.
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4. Verify ENG 1 FUEL BOOST light illuminates.
5. Disconnect wire Q68A22 from terminal 3 of TB10.
6. Verify ENG 2 FUEL BOOST light extinguishes.
7. Connect wire Q68A22 to terminal 3 of TB10.
8. Verify ENG 2 FUEL BOOST light illuminates.
1-16. OPERATIONAL CHECK - FUEL BOOST CAUTION LIGHT SYSTEM [C] [D]
1. Disconnect connector (1S5P1) from No. 1 fuel pressure switch (1S5).
2. Check NO. 1 FUEL BOOST caution light extinguishes.
3. Connect connector (1S5P1) to No. 1 fuel pressure switch.
4. Check NO. 1 FUEL BOOST caution light illuminates.
5. Disconnect connector (1S6P1) from No. 2 fuel pressure switch (1S6).
6. Check NO. 2 FUEL BOOST caution light extinguishes.
7. Connect connector (1S6P1) to No. 2 fuel pressure switch.
8. Check NO. 2 FUEL BOOST caution light illuminates.
1-17. OPERATIONAL CHECK - FUEL FILTER CAUTION LIGHT SYSTEM
1. Disconnect connector (P182/8S9P1) from engine No. 1 fuel filter pressure switch (S100/8S9).
2. Connect a temporary short between pins B and C of connector.
3. Check ENG 1 FUEL FILTER caution light illuminates.
4. Remove temporary short. ENG 1 FUEL FILTER caution light should extinguish.
5. Connect connector (P182/8S9P1) to switch.
6. Disconnect connector (P183/8S10P1) from engine No. 2 fuel filter pressure switch (S101/8S10).
7. Connect a temporary short between pins C and B of connector.
8. Check ENG 2 FUEL FILTER caution light illuminates.
10. ENG 2 FUEL FILTER caution light should extinguish.
11. Connect connector (P183/8S10P1) to switch.
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1-18. OPERATIONAL CHECK - FUEL LOW CAUTION LIGHT SYSTEM [A] [B]
1-18-1. Fuel low caution light system [A] [B] - procedure for low fuel level (10% or less)
NOTE
If there is little or no fuel in the tanks, the low level fuel switches will be closed and
the FUEL LOW caution lights will be illuminated.
1. Disconnect wire E39A22 from terminal 4 of TB11.
2. Verify ENG 1 FUEL LOW caution light extinguishes.
3. Connect wire E39A22 to terminal 4 of TB11.
4. Verify ENG 1 FUEL LOW caution light illuminates.
1-18-2. Fuel low caution light system [A] [B] - procedure for fuel in tanks (10% or more)
NOTE
If there is more than 10 percent fuel in the tanks, the low level fuel switches will be
open and the FUEL LOW caution lights will be extinguished.
2. Temporarily ground wire E39A22.
7. Temporarily ground wire E40A22.
1-19. OPERATIONAL CHECK - FUEL LOW CAUTION LIGHT SYSTEM [C] [D]
The FUEL LOW caution light is checked as a portion of fuel quantity indicator circuitry (module 96-24-36
paragraph "10-1. Fuel quantity indicator system [C] [D] - testing and calibration").
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1-20. OPERATIONAL CHECK - ENGINE NO. 1 AND NO. 2 FUEL VALVE CAUTION LIGHT SYSTEM
1. Close No. 1 FUEL VALVE circuit breaker.
3. Check ENG 1 FUEL VALVE caution light illuminates momentarily and then extinguishes.
5. Check ENG 1 VALVE caution light illuminates momentarily and then extinguishes.
6. Close No. 2 FUEL VALVE circuit breaker.
1-21. OPERATIONAL CHECK - ENGINE NO. 1 AND NO. 2 FUEL TRANSFER CAUTION LIGHT SYSTEM
[C] [D]
NO. 1 and NO. 2 FUEL TRANS caution light systems are checked as a portion of fuel quantity indicator circuitry
(module 96-24-36 paragraph "10-1. Fuel quantity indicator system [C] [D] - testing and calibration").
1-22. OPERATIONAL CHECK - FUEL CROSSFEED VALVE CAUTION LIGHT SYSTEM [A] [B]
2. Verify FUEL XFEED caution light illuminates.
3. Close both FUEL XFEED circuit breakers.
4. Verify fuel crossover valve runs to open position and stops.
5. Verify FUEL XFEED caution light is extinguished.
6. Press FUEL XFEED test switch to TEST BUS 1 and then TEST BUS 2.
7. Verify FUEL XFEED caution light remains extinguished.
8. Open ENGINE NO. 1 FUEL XFEED circuit breaker.
9. Press FUEL XFEED test switch to TEST BUS 1.
12. Verify FUEL XFEED caution light extinguishes.
13. Close ENGINE NO. 1 FUEL XFEED circuit breaker.
14. Open ENGINE NO. 2 FUEL XFEED circuit breaker.
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18. Verify FUEL XFEED caution light extinguishes.
NOTE
FUEL XFEED caution light shall remain extinguished in the following steps unless
otherwise specified.
19. Close both FUEL XFEED circuit breakers.
20. Verify fuel cross over valve runs to open position and stops.
21. Place FUEL XFEED switch to OVRD CLOSE.
22. Verify fuel cross over valve runs to closed position and stops.
23. Place FUEL XFEED switch to NORM.
24. Verify fuel cross over valve runs to open position and stops.
25. Temporarily disconnect wire Q29A20N from terminal 5 of TB11/1Z15TB1.
26. Verify fuel crossover valve remains open.
27. Temporarily disconnect wire Q37A20N from terminal 5 of TB10/1Z14TB1.
28. Verify fuel crossover valve closes.
29. Reconnect wire Q29A20N from terminal 5 of TB11/1Z15TB1.
30. Verify fuel crossover valve returns to open.
31. Reconnect wire Q37A20N from terminal 5 of TB11/1Z15TB1.
32. Verify fuel crossover valve remains open.
33. Verify all wiring connections are tight and secure.
1-23. OPERATIONAL CHECK - FUEL CROSSFEED VALVE CAUTION LIGHT SYSTEM [C] [D]
FUEL XFEED caution light is checked as a portion of fuel crossfeed valve circuitry (module 96-73-01
paragraph "8-2. Fuel crossfeed valve system - operational check").
1-24. OPERATIONAL CHECK - HYDRAULIC CAUTION LIGHT SYSTEM
Hydraulic caution light(s) is checked as part of hydraulic control circuitry (module 96-67-01 paragraph "3-2. Hydraulic
control systems - operational check [A] [B]" and paragraph "3-3. Hydraulic control systems - operational check [C] [D]").
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1-25. OPERATIONAL CHECK - EXTERNAL POWER CAUTION LIGHT SYSTEM
1. Set BATTERY BUS 1 or BUS 2 switch to ON.
2. Open external power access door.
3. Check EXTERNAL POWER caution light illuminates.
4. Close external power access door.
5. Check EXTERNAL POWER caution light extinguishes.
1-26. OPERATIONAL CHECK - BATTERY SENSOR TEMPERATURE CAUTION LIGHT SYSTEM [A] [B]
2. Disconnect connector (P281/8Z10P1) from battery temperature sensor.
3. Jumper pin B to C.
4. Check BATTERY TEMP caution light illuminates.
5. Remove jumper wire.
6. Open MASTER CAUTION LIGHT circuit breaker.
7. Connect connector to battery temperature sensor.
1-26-1. Battery sensor temperature caution light system [A] [B] - test procedures
NOTE
Test procedures are recommended at battery removal interval or a maximum interval
of 500 hours in service.
1. Remove sensor from helicopter.
2. Connect sensor to test harness as shown in figure 1.
3. Submerge sensor in temperature controlled liquid bath.
4. Increase and monitor liquid temperature.
5. Verify sensor operation is as follows:
TEMPERATURE INDICATION
130 3F54 2C) Amber Light ON
130 3F54 2C) Red Light ON
6. After checking both lights illuminate, allow lights to cool.
7. Verify lights extinguish within 6F (3.5C) of the temperature at which lights illuminated.
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8. If unit under test fails the above check, replace sensor.
1-27. OPERATIONAL CHECK - BATTERY SENSOR TEMPERATURE CAUTION LIGHT SYSTEM [C] [D]
2. Disconnect connector (8Z10P1) from battery temperature sensor.
3. Jumper pin B to C.
4. Check BATTERY TEMP annunciator light illuminates.
6. Jumper pin E to F.
7. Check BATTERY TEMP annunciator light illuminates.
9. Open MASTER CAUTION LIGHT circuit breaker.
10. Connect connector to battery temperature sensor.
1-28. OPERATIONAL CHECK - BATTERY CAUTION LIGHT SYSTEM
BATTERY caution light system is checked as part of battery system (module 96-24-31 paragraph "5. Battery system -
operational check").
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G6AB0754A
Figure 1. Battery temp sensor test harness (only) wiring diagram
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1-29. OPERATIONAL CHECK - HEATER AIR LINE CAUTION LIGHT SYSTEM [A] [B]
2. Connect a temporary short between wire H26A22 on heater air line overheat switch (S187/10S4) and helicopter
structure.
3. Check HEATER AIR LINE caution light illuminates.
4. Remove short installed in step 2.
5. Check HEATER AIR LINE caution light extinguishes.
1-30. OPERATIONAL CHECK - HEATER AIR LINE CAUTION LIGHT SYSTEM [C] [D]
2. Connect a temporary short between wire W112C22 on heater air line overheat switch (10S2) and helicopter structure.
3. Check HEATER AIR LINE caution light illuminates.
4. Remove short installed in step 2.
5. Check HEATER AIR LINE caution light extinguishes.
1-31. OPERATIONAL CHECK - AFCS CAUTION LIGHT SYSTEM
1. Set INV 1 and INV 2 switches to ON.
2. Verify AFCS caution light is extinguished.
3. Press HP1 pushbutton on Helipilot controller.
4. Verify HP1 legend illuminates.
5. Verify AFCS caution light illuminates.
7. Verify HP1 legend extinguishes.
8. Verify AFCS caution light extinguishes.
10. Verify HP2 legend illuminates.
13. Verify HP1 and HP2 legend illuminates.
15. Open PILOT ATT SYS circuit breaker.
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17. Close PILOT ATT SYS circuit breaker.
19. Open CPLT ATT SYS circuit breaker.
21. Close CPLT ATT SYS circuit breaker.
1-32. OPERATIONAL CHECK - ROTOR BRAKE CAUTION LIGHT SYSTEM
1. Pull down on ROTOR BRAKE handle until both ROTOR BRAKE caution lights on master caution panel are
illuminated.
2. Return ROTOR BRAKE handle to its original retracted position. Observe both ROTOR BRAKE caution lights
extinguish.
1-33. OPERATIONAL CHECK - CAUTION PANEL CAUTION LIGHT SYSTEM
1. Close MASTER CAUTION and CAUTION FAIL circuit breakers.
2. Momentarily set MASTER CAUTION TEST switch to TEST/PNL.
3. Verify CAUTION PANEL caution light illuminates brightly.
4. Release MASTER CAUTION TEST switch.
5. Verify CAUTION PANEL caution light extinguishes.
1-34. OPERATIONAL CHECK - NO. 3 UTILITY HYDRAULIC SYSTEM OIL PRESSURE CAUTION LIGHT
SYSTEM [B] [C]
1. Remove pressure switch and connect a hydraulic test unit to switch. Apply pressure and check that UTIL HYDR
PRESS caution light extinguish at an increasing pressure of 1422.3 psi.
2. Relieve pressure and check that UTIL HYDR PRESS caution light illuminate at a pressure of 995.6 ± 71 psi (70 ± 5
kg/cm²).
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96-31-53 CAUTION AND WARNING SYSTEM - ROTOR BRAKE WARNING SYSTEM
96-31-53
CAUTION AND WARNING SYSTEM - ROTOR BRAKE WARNING SYSTEM
1. ROTOR BRAKE WARNING SYSTEM - DESCRIPTION
The system consists of two microswitches mounted on the rotor brake assembly and connected, via electrical wiring, to the
ROTOR BRAKE caution lights on the caution panel. Operation of the rotor brake handle causes the application of hydraulic
power to the rotor brake assembly and, in turn, movement of pistons in two cylinders of the brake assembly which close the
microswitches and cause the warning light to illuminate.
2. ROTOR BRAKE WARNING SYSTEM - OPERATIONAL CHECK
1. Pull down on ROTOR BRAKE handle a reasonable but minimum amount. Observe that both ROTOR BRAKE caution
lights on MASTER CAUTION PANEL (8A1) are illuminated.
2. Return ROTOR BRAKE handle to its original retracted position. Observe that both ROTOR BRAKE caution lights
extinguish.
3. ROTOR BRAKE WARNING SYSTEM - ADJUSTMENT
Adjust the actuators of microswitch one the brake assembly as follows:
NOTE
Each microswitch controls one warning light. If one light illuminates at 0.76 mm
(0.030 in.) travel position, only one of the switches is misadjusted.
1. Position microswitch and actuators in their approximate locations so that, with brake off and MASTER CAUTION
circuit breaker closed, the caution lights are off.
2. Note the position of the microswitch actuator and brake assembly piston with respect to a nearly fixed point in the line
of brake assembly piston travel.
3. Carefully apply pressure by pulling downward on the master cylinder handle until the brake assembly piston move
0.76 mm (0.030 in.) from their location noted in step b.
4. If the actuators are properly adjusted, the caution lights should be on when brake assembly piston have moved 0.76
mm (0.030 in.).
5. Loosen switch mounting screw and jamnut on adjusting screw, and adjust switches as necessary so that both lights
illuminate when both pistons have moved 0.76 mm (0.030 in.) from the "brake off" position. Tighten screw and jamnut
after adjustment.
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CAUTION AND WARNING SYSTEM - RPM LIMIT WARNING SYSTEMS
1. RPM LIMIT WARNING SYSTEMS - DESCRIPTION
The rpm limit warning system consists of: RPM limit detector unit located on shelf in nose compartment, RPM caution light
assembly on both pilot and copilot instrument panels, rotor tach generator mounted on transmission, and two gas producer
tachometer generators, one mounted on each engine. The speed of each engine and rotor speed are electronically monitored
by RPM limit detector unit. When a rotor overspeed condition exists, the RPM limit detector will cause the RPM caution
lights on the instrument panel to flash, warning of an overspeed condition. When a rotor underspeed condition exists, the
RPM limit detector will illuminate the RPM caution lights and create an audible signal for the pilot and copilot. When an
engine underspeed condition exists, the RPM limit detector will illuminate the respective ENG 1/2 OUT caution light on the
instrument panel.
2. RPM LIMIT WARNING SYSTEMS - OPERATIONAL CHECK (WITHOUT ENGINES

OPERATING) [A] [B]
1. Apply external electrical power to helicopter.
2. Close ENG 1 RPM and ENG 2 RPM circuit breakers.
3. Check ENG 1 OUT and ENG 2 OUT warning lights on instrument panel are illuminated.
4. Open ENG 1 RPM and ENG 2 RPM circuit breakers.
5. Check ENG 1 OUT and ENG 2 OUT warning lights extinguish.
6. Close ENG 1 RPM and ENG 2 RPM circuit breakers.
7. Check ENG 1 OUT and ENG 2 OUT warning lights illuminate.
3. RPM LIMIT WARNING SYSTEMS - OPERATIONAL CHECK (WITHOUT ENGINES

OPERATING) [C] [D]
1. Apply external electrical power to the helicopter.
2. Close ROTOR RPM (8CB3), ENG RPM (8CB1), and ENG 2 RPM (8CB2) circuit breakers. Check that ROTOR RPM
limit, ENG 1 OUT, and ENG 2 OUT, and warning lights on instrument panel are illuminated.
3. Momentarily open ROTOR RPM circuit breaker. Check that ROTOR RPM limit, ENG 1 OUT, and ENG 2 OUT
warning lights extinguish.
4. Close ROTOR RPM circuit breaker. Check that audio signal is again audible in both pilot and copilot bedsteads and
that ROTOR RPM limit, ENG 1 OUT, and ENG 2 OUT warning lights illuminate.
5. Turn off electrical power and remove external electrical power.
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4. RPM LIMIT WARNING SYSTEMS - OPERATIONAL CHECK AND ALIGNMENT

(WITH ENGINES OPERATING)
NOTE
In addition to a check of warning lights, this check includes a check of audio
warning signal.
1. Remove RPM limit detector unit cover (figure 1).
2. Operate both engines in accordance with Flight Manual operational instructions.
3. With both engines sharing the load:
a. Adjust for a rotor indication of 98%.
b. Observe RPM caution lights are extinguished, and no audio warning signal is audible in headsets.
c. Decrease rotor speed very slowly to point where RPM caution lights and limit detector unit light illuminate, with
an audible warning signal heard in headsets.
4. If RPM caution lights and limit detector unit light did not illuminate at rotor speed of 95%, proceed with following:
a. Rotate RTR LOW (R33) control slowly clockwise, while at a rotor speed of 95%, until RPM caution lights just
illuminate.
b. Vary rotor speed slowly between 94 and 98% while observing RPM caution lights.
c. Verify warning occurs at 95%.
5. Repeat step 3.a. through 4.c. (if required).
6. If RPM caution lights and limit detector unit light illuminated above 95% in step 4.c., proceed with following:
a. While at a rotor speed of 95%, rotate RTR LOW (R33) control slowly counterclockwise until RPM caution lights
just extinguish, and then very slowly clockwise until RPM caution lights just illuminate.
b. Vary rotor speed slowly between 94 and 98% while observing RPM caution lights.
c. Verify warning occurs at 95%.
d. Repeat steps 6. a., b., and c. (if required).
7. If audio was not heard at 95%:
a. Adjust limit detector unit AUDIO control while at a rotor speed of 95% until audio is heard in headsets.
b. Vary rotor speed to 98% to automatically reset audio signal circuit.
8. Position ROTOR RPM AUDIO switch to OFF. Verify audio warning signal ceases.
9. Perform rotor high RPM warning check and alignment as follows:
a. Position ROTOR RPM AUDIO switch to AUDIO.
CAUTION
DO NOT EXCEED ROTOR OR ENGINE RPM AS ESTABLISHED IN FLIGHT

MANUAL.
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b. With engine at idle and rotor at flat pitch, set ENGINE GOV switch to MANUAL.
c. Slowly increase throttle for that engine until RPM caution lights and detector ROTOR light illuminate.
d. Observe RPM caution lights illuminate at an indication of 105% and no audio warning signal is audible in
headsets.
10. If RPM caution lights illuminated before reaching a rotor speed of 105%:
a. Maintain rotor speed of 105%.
b. Rotate RTR HIGH (R18) control clockwise until warning occurs.
c. Rotate control counterclockwise until RPM CAUTION lights just illuminate.
11. If RPM caution lights did not illuminate:
a. Maintain rotor speed of 105%.
b. Rotate RTR HIGH control very slowly counterclockwise until RPM caution lights just illuminate.
12. Vary rotor speed slowly between 105% and 102% while observing RPM caution lights.
13. Verify warning occurs at rotor speed of 103,5% and warning extinguishes between 105% and 102% as rotor speed is
decreased.
14. Repeat steps 10. through 13. (if required).
15. Decrease rotor speed.
16. With engine at idle, set ENGINE GOV switch to AUTOMATIC.
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G6AB0756A
Figure 1. Limit detector unit
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5. RPM LIMIT WARNING SYSTEMS - ENGINE LOW RPM WARNING CHECK AND
ALIGNMENT
NOTE
Procedures for engine 1 are same as for engine 2; therefore, only engine 1 is
explained. For engine 2 procedures, use engine 2 callouts instead of engine 1.
Perform engine low RPM warning check and alignment as follows:
1. Adjust for N1 (gas producer) indication of 56%.
2. Verify RPM caution lights and limit detector unit ENG 1 OUT light are extinguished.
3. Decrease engine 1 speed slowly to 52,5%.
4. Verify ENG 1 OUT caution lights illuminate at N1 indication of 53  2%.
5. If ENG 1 OUT caution lights did not illuminate:
a. Maintain engine rpm of 53%.
b. Rotate limit detector unit ENG 1 (R17) control slowly clockwise until ENG 1 OUT caution lights just illuminate.
c. If ENG 1 OUT caution lights illuminated above 55%.
d. Maintain engine rpm of 53%.
e. Rotate limit detector unit ENG 1 control slowly counterclockwise until light just extinguishes and then rotate
very slowly clockwise until ENG 1 OUT caution lights just illuminate.
6. Vary engine 1 speed slowly between 50% and above 58% while observing ENG 1 OUT caution lights.
7. Verify warning occurs at engine speed between 51 and 55% and that the lights extinguish within 3% higher than the
percentage where the lights illuminated.
8. Repeat steps 1. through 7. (if required).
9. Shut down both engines in accordance with Flight Manual operational instructions.
10. Install RPM limit detector unit cover.
6. RPM LIMIT WARNING SYSTEMS - TROUBLESHOOTING
Table 1. Rpm limit warning systems troubleshooting
No audio tone is present in pilot's or copilot's Defective ROTOR RPM switch Replace switch.
headsets, engines shut down, RPM warning
light illuminated. Defective RPM limit warning box. Replace control box.
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(Cont.d)
Placing ROTOR RPM switch to OFF does Defective ROTOR RPM switch. Replace switch.
not eliminate audio tone in headsets.
RPM warning lights do not illuminate when Defective diode (CR19). Replace diode.
engine No. 1 inoperative.
Defective RPM control box. Replace control box.
RPM warning lights do not illuminate when Defective diode (CR20). Replace diode.
engine No. 2 inoperative.
RPM warning lights do not illuminate, no Defective RPM WARN circuit Replace circuit breaker.
audio tone present in headsets, engine shut breaker.
down.
7. RPM LIMIT WARNING SYSTEMS - RPM WARNING BOX
7-1. RPM WARNING BOX - REMOVAL
1. Open RPM WARN circuit breakers.
2. Disconnect connector from RPM warning box.
3. Remove attaching hardware and remove RPM warning box.
7-2. RPM WARNING BOX - INSTALLATION
1. Position RPM warning box on support and install attaching hardware.
2. Connect connector to box.
7-3. RPM WARNING BOX - INSPECTION, REPAIR OR REPLACEMENT
1. Inspect box for damaged broken or cracked mounting tabs, cracked or frozen adjustment, damaged indicator lights.
2. Replace RPM warning box if inspection requirements are not met.
96-31-54
Page 6 Rev. 1
E-AB412-PT6T-2
96-31-55
CAUTION AND WARNING SYSTEM - FIRE DETECTION WARNING SYSTEM
1. FIRE DETECTION WARNING SYSTEM - DESCRIPTION
Each system consists of two heat sensing elements located on the LH or RH sides of the engine compartment upper cowling.
The heat sensing elements are connected to an amplifier unit located on the cabin roof and connected, via electrical wiring,
to the FIRE PULL warning light of the fire extinguisher handle. These heat sensing elements exhibit high electrical
resistance at normal ambient temperature but their resistance drops radiply when they are heated.
The amplifier unit senses the increasing or decreasing resistance of the heat sensing elements that are connected to the unit.
When resistance of the heat sensing elements decreases the amplifier unit delivers output signal that causes the FIRE PULL
warning light to illuminate. When the resistance of the heat sensing elements rises to its normal value, i. e. when the engine
compartment temperature becomes normal, the amplifier unit cuts off power to the FIRE PULL warning light. Each system
is powered by 28 Vdc and protected by the ENG FIRE DET circuit breaker. The system is provided with a FIRE EXT TEST
push-button switch installed on the instrument panel which, when pressed, connects a low resistance circuit condition in the
engine compartment.
2. FIRE DETECTION WARNING SYSTEM - OPERATIONAL CHECK
2-1. OPERATIONAL CHECK - ENGINE NO. 1 FIRE DETECTION WARNING
1. Close ENG 1 FIRE DET circuit breaker. Depress PRESS TO TEST fire detector test switch (S5) or (1A2S2). Check
that FIRE 1 PULL warning light on left-hand emergency handle is illuminated.
2. Release test switch. Check that FIRE 1 PULL warning light on left-hand emergency handle is extinguished.
2-2. OPERATIONAL CHECK - ENGINE NO. 2 FIRE DETECTION WARNING
1. Close ENG 2 FIRE DET circuit breaker. Depress PRESS TO TEST fire detector test switch. Check that FIRE 2 PULL
warning light on right-hand emergency handle is illuminated.
2. Release test switch. Check that FIRE 2 PULL warning light on right-hand emergency handle is extinguished.
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E-AB412-PT6T-2
3. FIRE DETECTION WARNING SYSTEM - TROUBLESHOOTING
Table 1. Fire detection warning system troubleshooting
FIRE 1 PULL warning light does not Defective lamp in warning light. Replace lamp.
illuminate with FIRE EXT TEST switch to
TEST. Defective FIRE EXT TEST Replace switch.
switch.
Defective ENG 1 FIRE DET Replace circuit breaker.

circuit breaker.
Defective amplifier unit. Replace amplifier unit.
FIRE 1 PULL warning light will only Defective wiring. Repair wiring.
illuminate dim with FIRE EXT TEST switch
to TEST.
FIRE 1 PULL warning light will only Defective dimming resistor. Replace resistor.
illuminate bright with FIRE EXT TEST
switch to TEST. Defective wiring. Repair wiring.
FIRE 2 PULL warning light does not Defective lamp in warning light. Replace lamp.
illuminate with FIRE EXT TEST switch to
TEST. Defective FIRE EXT TEST Replace switch.
switch.
Defective ENG 2 FIRE DET Replace circuit breaker.

circuit breaker.
Defective amplifier unit. Replace amplifier unit.
illuminate dim with FIRE EXT TEST switch
to TEST.
illuminate bright with FIRE EXT TEST
switch to TEST.
96-31-55
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E-AB412-PT6T-2
4. FIRE DETECTION WARNING SYSTEM - AMPLIFIER UNIT
4-1. AMPLIFIER UNIT - REMOVAL
1. Open ENG FIRE DET circuit breaker.
2. Disengage electrical connector from amplifier unit.
3. Remove attaching hardware.
4. Lift amplifier unit from mount.
4-2. AMPLIFIER UNIT - INSTALLATION
1. Position amplifier unit on mount and install attaching hardware.
2. Connect electrical connector to amplifier unit.
4-3. AMPLIFIER UNIT - INSPECTION, REPAIR OR REPLACEMENT
1. Visually inspect the amplifier unit for damaged, cracked case or mounting tabs.
2. Replace amplifier unit that does not meet inspection requirements.
5. FIRE DETECTION WARNING SYSTEM - BAGGAGE COMPARTMENT
5-1. BAGGAGE COMPARTMENT - DESCRIPTION
The system consists of a smoke detector located in the forward end of the baggage compartment roof and protected from
baggage damage by a protective guard. The smoke detector is connected to an amplifier unit located in the helicopter nose
section and connected, via electrical wiring, to the BAGGAGE FIRE warning light on the instrument panel. The smoke
detector is a closed assembly housing solid-state electronic components and a light sensitive detector. The instant that smoke
reduces light transmission in the baggage compartment 30 to 35% below that of clear air, the smoke detector will send a
signal to the fire detector control amplifier. This will cause the fire detection light to illuminate (flashing ON and OFF)
intermittently.
The system is powered by 28 Vdc and protected by the BAG COMPT FIRE DET circuit breaker. A BAGGAGE FIRE TEST
SWITCH push-button installed on the instrument panel permits, when depressed, simulation of a fire condition in the
baggage compartment
NOTE
The fire detection light may be dimmed by actuating PILOT INSTR LT Control.
5-2. BAGGAGE COMPARTMENT - OPERATIONAL CHECK
1. Close BAG COMPT FIRE DET circuit breaker. Depress BAGGAGE FIRE DETECTOR TEST SWITCH (S85) or
(8DS5). Check that BAGGAGE FIRE warning light is illuminated - flashing.
2. Release the test switch. Check that BAGGAGE FIRE warning light is extinguished.
3. Introduce smoke into the baggage compartment near the smoke detection unit. Check that BAGGAGE FIRE warning
light illuminates.
96-31-55
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E-AB412-PT6T-2
4. Remove smoke or allow it to dissipate into the surrounding air. Check that BAGGAGE FIRE warning light
extinguishes.
5-3. BAGGAGE COMPARTMENT - TROUBLESHOOTING
Table 2. Baggage compartment troubleshooting
BAG COMP FIRE DET circuit breaker will Defective circuit breaker. Replace circuit breaker.
not reset.
Internal short in fire detector or fire Replace fire detector and/or fire
detector amplifier. detector amplifier.
With BAG COMP FIRE DET circuit breaker Defective BAGGAGE FIRE light. Repair light.
(CB5) or (8CB11) closed and BAGGAGE
FIRE TEST switch pressed FIRE WARNING Defective BAGGAGE FIRE TEST Replace switch.
light does not illuminate. SWITCH.
96-31-55
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E-AB412-PT6T-2
96-31-56 CAUTION AND WARNING SYSTEM - HYDRAULIC FILTER CLOGGED WARNING SYSTEM
96-31-56
CAUTION AND WARNING SYSTEM - HYDRAULIC FILTER CLOGGED
WARNING SYSTEM
1. HYDRAULIC FILTER CLOGGED WARNING SYSTEM - DESCRIPTION
The hydraulic filter clogged warning indicator is located on the right beam forward of the pedestal and is viewed by looking
inboard through the pilot chin bubble. If filters are not clogged the hydraulic filter clog indicator will display a green dot in
the viewing port. If filters are clogged the indicator will display a red dot in the viewing port.
If any of filters become partially clogged, causing a hydraulic differential pressure exceeding 70 psi (483 kPa), contacts of
either hydraulic 1 or hydraulic 2 switch close. This applies voltage from HYD NO. 2 TEMP circuit breaker the hydraulic
filter clog indicator which shows red dot at viewing sight. The dot in the viewing sight remains red until manually reset at
hydraulic filter clog indicator.
2. HYDRAULIC FILTER CLOGGED WARNING SYSTEM - OPERATIONAL CHECK
Refer to module 96-67-01 paragraph "3-2. Hydraulic control systems - operational check [A] [B]" for helicopters
codes [A] [B], and paragraph "3-3. Hydraulic control systems - operational check [C] [D]" for helicopters codes [C] [D].
96-31-56
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E-AB412-PT6T-2
96-31-56
Page 2
E-AB412-PT6T-2
96-32-0 LIGHTING SYSTEM
96-32-00
LIGHTING SYSTEM
1. LIGHTING SYSTEM - DESCRIPTION
The lighting system comprises interior and exterior lights. The interior lights provide instrument and cabin lighting. The
exterior lights provide navigation search and landing lighting.
96-32-00
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96-32-00
Page 2
E-AB412-PT6T-2
96-3 -0 INTERIOR LIGHTING SYSTEMS
96-33-00
INTERIOR LIGHTING SYSTEMS
1. INTERIOR LIGHTING SYSTEMS - GENERAL
Interior lighting systems include cockpit lights, approach plate and map lights, dome lights, instrument panel lights, engine
instrument panel lights, instrument secondary lights, pedestal lights, overhead console lights, and baggage compartment
lights systems. Refer to Chapter 98 for applicable wiring diagrams.
96-33-00
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96-33-00
Page 2
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96-3 -10 INTERIOR LIGHTING SYSTEMS - COCKPIT LIGHTS SYSTEM
96-33-10
INTERIOR LIGHTING SYSTEMS - COCKPIT LIGHTS SYSTEM
1. COCKPIT LIGHTS SYSTEM - DESCRIPTION
These are multipurpose utility lights designed to selectively provide either red or white illumination utilizing a narrow
spotlight beam or a wide floodlight beam. Electrical protection is provided by LIGHTING MAP PILOT and LIGHTING
MAP CPLT circuit breakers. Controls necessary to obtain operational modes of ON-OFF, DIM-BRIGHT, SPOT-FLOOD,
and red or white illumination are incorporated in lamp body.
2. COCKPIT LIGHTS SYSTEM - REMOVAL
2. Disconnect electrical wiring from terminal board and ground.
3. Remove bolts, washers, nuts and lights.
3. COCKPIT LIGHTS SYSTEM - INSTALLATION
2. Secure light supports to structure with bolts, washers and nuts.
3. Connect electrical wiring to terminal board and ground.
4. COCKPIT LIGHTS SYSTEM - OPERATIONAL CHECK
1. Close MAP PILOT circuit breaker.
2. Check pilot map light is operational in each mode (ON/OFF, DIM/BRIGHT, and SPOT-FLOOD on both red and
white).
3. Check pilot map light illuminates.
4. Close MAP CPLT circuit breaker.
5. Check copilot map light is operational in each mode (ON/OFF, DIM/BRIGHT, and SPOT/FLOOD on both red and
white).
6. Check copilot map light illuminates.
96-33-10
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E-AB412-PT6T-2
5. COCKPIT LIGHTS SYSTEM - TROUBLESHOOTING
Table 1. Cockpit lights system troubleshooting
Pilot’s or copilot’s cockpit lights fail to Defective pilot or copilot cockpit Replace circuit breaker.
illuminate. light circuit breaker.
NOTE
All problems associated with the pilot’s and copilot’s cockpit lights are associated
with the controls incorporated into the body of the cockpit light and defective light
should be replaced.
96-33-10
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E-AB412-PT6T-2
96-3 -1 INTERIOR LIGHTING SYSTEMS - APPROACH PLATE AND MAP LIGHTS SYSTEM
96-33-11
INTERIOR LIGHTING SYSTEMS - APPROACH PLATE AND MAP LIGHTS
SYSTEM
1. APPROACH PLATE AND MAP LIGHTS SYSTEM - DESCRIPTION
Approach plate and map lights system consists of pilot and copilot approach plate and pilot and copilot map light resistor
controls mounted on pilot instrument panel lower right, and copilot instrument panel lower left. Rotating the control will
vary intensity of light.
2. APPROACH PLATE AND MAP LIGHTS SYSTEM - OPERATIONAL CHECK
1. Close MAP PILOT or MAP CPLT circuit breaker.
2. Rotate (pilot or copilot) approach plate and map light control.
3. Check approach plate and map light illuminates from dim to bright as control is rotated clockwise.
4. Rotate approach plate and map light control counterclockwise.
5. Check light decreases in brightness and is extinguished at an extreme counterclockwise direction.
96-33-11
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96-33-11
Page 2
E-AB412-PT6T-2
96-3 -12 INTERIOR LIGHTING SYSTEMS - DOME LIGHTS SYSTEM
96-33-12
INTERIOR LIGHTING SYSTEMS - DOME LIGHTS SYSTEM
1. DOME LIGHTS SYSTEM - DESCRIPTION
The aft dome lights circuit is protected by CABIN DOME circuit breaker on the overhead console breaker panel. Aft dome
lights can be illuminated red or white by placing AFT DOME LIGHTS switch to RED or WHITE position. Brightness level
of aft dome lights is determined by AFT DOME LIGHTS rheostat.
2. DOME LIGHTS SYSTEM - REMOVAL
2. Remove four screws and washers and pull-out light.
3. Disconnect electrical wiring and remove light.
3. DOME LIGHTS SYSTEM - LAMPS REPLACEMENT
2. Remove six screws, retaining ring and glass.
3. Replace lamps.
4. Position light on support and secure with four screws and washers.
4. DOME LIGHTS SYSTEM - INSTALLATION
2. Secure light supports to structure with four screws and washers.
3. Connect electrical wiring to terminal board and ground.
5. DOME LIGHTS SYSTEM - OPERATIONAL CHECK
1. Position NON-ESNTL BUS switch to MANUAL.
2. Close LT DOME circuit breaker.
3. Position AFT DOME LIGHTS switch to RED.
4. Rotate AFT DOME LIGHTS control clockwise.
5. Check red dome lights increase in brightness.
96-33-12
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E-AB412-PT6T-2
6. Rotate AFT DOME LIGHTS control counterclockwise.
7. Check red dome lights decrease in brightness.
8. Position AFT DOME LIGHTS switch to WHITE.
9. Repeat operations of control as described in steps 1. through 7.
10. Check white dome lights respond as described for red dome lights.
6. DOME LIGHTS SYSTEM - TROUBLESHOOTING
Table 1. Dome lights system troubleshooting
Aft dome lights fail to illuminate when AFT Defective AFT DOME LT rheostat Replace rheostat.
DOME LT rheostat is rotated clockwise and (R7).
AFT DOME LT switch set to either RED or
WHITE. Defective AFT DOME LT switch. Replace switch.
Defective LT DOME circuit Replace circuit breaker.

breaker.
With conditions same as Item 1 except aft Defective AFT DOME LT switch. Replace switch.
dome lights fail to illuminate with AFT
DOME LT switch set to RED. Defective wiring. Repair wiring.
With conditions same as Item 1 except aft Defective AFT DOME LT switch. Replace switch.
dome lights fail to illuminate with AFT
DOME LT switch set to WHITE. Defective wiring. Repair wiring.
Brightness level of aft dome lights does not Defective AFT DOME LT rheostat Replace rheostat.
increase with clockwise rotation of AFT (R7).
DOME LT rheostat and AFT DOME LT
switch set to either RED or WHITE. Defective wiring. Repair wiring.
96-33-12
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E-AB412-PT6T-2
96-3 -13 INTERIOR LIGHTING SYSTEMS - INSTRUMENT PANEL LIGHTS SYSTEM
96-33-13
INTERIOR LIGHTING SYSTEMS - INSTRUMENT PANEL LIGHTS SYSTEM
1. INSTRUMENT PANEL LIGHTS SYSTEM - DESCRIPTION
Pilot instrument lighting circuit is protected by INST PILOT circuit breaker. Rotation of PILOT INSTR LT control
clockwise closes attached switch which applies 28 Vdc from essential bus through INST PILOT circuit breaker to
instrument lights power supply. The power supply in turn provides an output voltage of 5 Vdc required to operate 5 volt
lamp instrument lights. Output voltage of power supply is controlled by PILOT INSTR LT control which determines
brightness level of the 5 volt lamps. Copilot instrument lighting circuit is protected by INST CPLT circuit breaker. Copilot
instrument lights circuit and operation is identical to pilot instrument lights circuit. COPLT INSTR LT control determines
brightness level of 5 volt lamps.
2. INSTRUMENT PANEL LIGHTS SYSTEM - OPERATIONAL CHECK
2-1. OPERATIONAL CHECK - PILOT INSTRUMENTS AND PASSENGER WARNING LIGHTING CHECK
1. Set PILOT INSTR LT control to OFF.
2. Close INST PILOT circuit breaker.
3. Rotate PILOT INSTR LT control slightly clockwise out of detent.
4. Check instrument lights on pilot instrument panel are dimly illuminated.
5. Also check passenger warning lights are dimly illuminated.
6. Rotate PILOT INSTR LT control in a clockwise direction.
7. Check instrument lights on pilot instrument panel and passenger warning lights increase in brightness and are brightest
when control is at clockwise extreme.
8. Rotate PILOT INSTR LT control in counterclockwise direction.
9. Check pilot instrument lights and passenger warning lights decrease in brightness.
10. Rotate PILOT INSTR LT control to OFF.
11. Check pilot instrument lights and passenger warning lights extinguish.
2-2. OPERATIONAL CHECK - COPILOT LIGHTING CHECK
1. Set CPLT INSTR LT control to OFF.
2. Close INST CPLT circuit breaker.
3. Rotate CPLT INSTR LT control slightly clockwise out of detent.
4. Check copilot instrument lights are dimly illuminated.
96-33-13
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E-AB412-PT6T-2
5. Rotate CPLT INSTR LT control in a clockwise direction.
6. Check copilot instrument lights increase in brightness and are brightest at clockwise extreme.
7. Rotate CPLT INSTR LT control in a counterclockwise direction.
8. Check copilot instrument lights decrease in brightness and are extinguished at counterclockwise extreme.
9. Rotate CPLT INSTR LT control to OFF.
10. Check copilot instrument lights extinguish.
3. INSTRUMENT PANEL LIGHTS SYSTEM - TROUBLESHOOTING
Table 1. Instrument panel lights system troubleshooting
Pilot's instrument lights or passenger Defective PILOT INSTR LT Replace rheostat.

warning lights fail to illuminate when rheostat (R1) or (8R1) (attached
PILOT INSTR LT rheostat is rotated switch defective).
clockwise.
Defective LT PILOT INSTR circuit Replace circuit breaker.
breaker.
Defective power supply (PS5). Replace power supply.
Brightness level of pilot's instrument lights Defective PILOT INSTR LT Replace rheostat.
or passenger warning lights does not rheostat (R1) or (8R1).
increase with clockwise rotation of PILOT
INSTR LT rheostat. Defective power supply (PS5). Replace power supply.
Copilot's instrument lights fail to illuminate Defective COPLT INSTR LT Replace rheostat.
with clockwise rotation of COPLT INSTR rheostat (R2) or (8R2) (attached
LT rheostat. switch defective).
Defective LT INSTR COPLT circuit Replace circuit.

breaker.
96-33-13
Page 2
E-AB412-PT6T-2
(Cont.)
Brightness level of copilot's instrument Defective INSTR LT rheostat (CR2). Replace rheostat.
lights does not increase with clockwise
rotation of COPLT INSTR LT rheostat. Defective power supply (PS3). Replace power supply.
96-33-13
Page 3
E-AB412-PT6T-2
96-33-13
Page 4
E-AB412-PT6T-2
96-3 -14 INTERIOR LIGHTING SYSTEMS - ENGINE INSTRUMENT LIGHTS SYSTEM
96-33-14
INTERIOR LIGHTING SYSTEMS - ENGINE INSTRUMENT LIGHTS SYSTEM
1. ENGINE INSTRUMENT LIGHTS SYSTEM - DESCRIPTION
This circuit is protected by ENG INST circuit breaker. Engine instrument lights circuit and operation are identical to pilot
and copilot instrument lights circuits. ENG INSTR LT rheostat determines brightness level of 5 volt lamps.
2. ENGINE INSTRUMENT LIGHTS SYSTEM - OPERATIONAL CHECK
1. Set ENG INSTR LT control to OFF.
2. Close ENG INST circuit breaker.
3. Rotate ENG INSTR LT control slightly clockwise until switch just closes.
4. Check engine instrument lights are dimly illuminated.
5. Rotate ENG INSTR LT control in a clockwise direction.
6. Check engine instrument lights increase in brightness and are brightest at extreme clockwise position.
7. Rotate control counterclockwise.
8. Check engine instrument lights decrease in brightness and are extinguished at extreme counterclockwise position.
3. ENGINE INSTRUMENT LIGHTS SYSTEM - TROUBLESHOOTING
Table 1. Engine instrument lights system troubleshooting
Engine instrument lights fail to illuminate Defective ENG INSTR LT control Replace control.
when ENG INSTR LT control is rotated (R3) or (8R3) (attached switch
clockwise. defective).
Defective LT ENG INST circuit Replace circuit breaker.

breaker.
96-33-14
Page 1
E-AB412-PT6T-2
(Cont.)
Brightness level of engine instrument lights Defective ENG INSTR LT control Replace control.
does not increase with clockwise rotation of (R3) or (8R3).
ENG INSTR LT control.
96-33-14
Page 2
E-AB412-PT6T-2
96-3 -15 INTERIOR LIGHTING SYSTEMS - INSTRUMENT SECONDARY LIGHTS SYSTEM
96-33-15
INTERIOR LIGHTING SYSTEMS - INSTRUMENT SECONDARY LIGHTS
SYSTEM
1. INSTRUMENT SECONDARY LIGHTS SYSTEM - DESCRIPTION
This circuit is protected by INST SEC circuit breaker. Rotation of SEC INSTR LT control clockwise closes its attached
switch applying power to instrument secondary lights through instrument secondary lights control transistor. SEC INSTR
LT control determines brightness level of instrument secondary lights by varying base voltage of 28 Vdc secondary
instrument lights transistor.
2. INSTRUMENT SECONDARY LIGHTS SYSTEM - REMOVAL
2. Remove two nuts, screws and washers.
3. Disconnect electrical wiring and remove light assembly.
3. INSTRUMENT SECONDARY LIGHTS SYSTEM - INSTALLATION
2. Connect electrical wiring to light assembly.
3. Secure light assembly to instrument panel shield with two bolts, two nuts and four washers.
4. INSTRUMENT SECONDARY LIGHTS SYSTEM - OPERATIONAL CHECK
1. Set SEC INSTR LT control to OFF.
2. Close INST SEC circuit breaker.
3. Rotate SEC INSTR LT control clockwise until switch just closes.
4. Check instrument secondary lights are dimly illuminated.
5. Rotate SEC INSTR LT control in a clockwise direction.
6. Check instrument secondary lights increase in brightness and are brightest at extreme clockwise position.
7. Rotate control in a counterclockwise direction.
8. Check instrument secondary lights decrease in brightness and are extinguished at extreme counterclockwise position.
96-33-15
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E-AB412-PT6T-2
5. INSTRUMENT SECONDARY LIGHTS SYSTEM - TROUBLESHOOTING
Table 1. Instrument secondary lights system troubleshooting
Instrument secondary lights fail to illuminate Defective SEC INSTR LT control Replace switch
when SEC INSTR LT control is rotated (R4) or (8R4) (attached switch
Defective LT INSTR SEC circuit Replace circuit breaker.

breaker.
Defective transistor (Q4) or (8Q4). Replace transistor.
Defective resistor (R28). Replace resistor.
Brigthness level of instrument secondary Defective SEC INSTR LT control Replace control.
lights does not increase with clockwise (R4) or (8Q4).
rotation of control.
Defecting wiring. Repair wiring.
96-33-15
Page 2
E-AB412-PT6T-2
96-3 -16 INTERIOR LIGHTING SYSTEMS - PEDESTAL LIGHTS SYSTEM
96-33-16
INTERIOR LIGHTING SYSTEMS - PEDESTAL LIGHTS SYSTEM
1. PEDESTAL LIGHTS SYSTEM - DESCRIPTION
Pedestal lights circuit and operation are identical to instrument secondary and overhead console lights circuit. PED LT
control determines brightness level of pedestal lights by varying base voltage of 28 Vdc pedestal lights transistor.
2. PEDESTAL LIGHTS SYSTEM - OPERATIONAL CHECK
1. Set PED LT control to OFF.
2. Close PED circuit breaker.
3. Rotate PED LT control slightly clockwise until switch just closes.
4. Check pedestal lights, panel lights on pilot collective stick, and outlet valve lights on right doorpost are dimly
illuminated.
5. Rotate PED LT control clockwise.
6. Check lights which were illuminated in step 4. increase in brightness and are brightest at extreme clockwise position.
7. Rotate PED LT control counterclockwise.
8. Check lights illuminated in step 4. decrease in brightness and are extinguished at extreme counterclockwise position.
3. PEDESTAL LIGHTS SYSTEM - TROUBLESHOOTING
Table 1. Pedestal lights system troubleshooting
Pedestal lights fail to illuminate when PED Defective PED LT control (R6) or Replace rheostat.
LT control is rotated clockwise. (8R6) (attached switch defective).
Defective LT PED circuit breaker. Replace circuit breaker.
Defective transistor (Q6). Replace transistor.
Brightness level of pedestal lights does not Defective PED LT control (R6) or Replace rheostat.
increase with clockwise rotation of PED LT (8R6).
control.
96-33-16
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E-AB412-PT6T-2
(Cont.)
Defective transistor (Q6) or (8Q6). Replace transistor.
96-33-16
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E-AB412-PT6T-2
96-3 -17 INTERIOR LIGHTING SYSTEMS - OVERHEAD CONSOLE LIGHTS SYSTEM
96-33-17
INTERIOR LIGHTING SYSTEMS - OVERHEAD CONSOLE LIGHTS SYSTEM
1. OVERHEAD CONSOLE LIGHTS SYSTEM - DESCRIPTION
This circuit is protected by OVHD CSL circuit breaker. Overhead console lights circuit and operation are identical to
instrument secondary lights circuit. CONSOLE LT control determines brightness level of overhead console lights by varying
base voltage of the 28 Vdc console lights transistor.
2. OVERHEAD CONSOLE LIGHTS SYSTEM - OPERATIONAL CHECK
1. Set CONSOLE LT control to OFF.
2. Close OVHD CSL circuit breaker.
3. Rotate CONSOLE LT control slightly clockwise until switch just closes.
4. Check panel lights on overhead console are dimly illuminated.
5. Rotate CONSOLE LT control clockwise.
6. Check panel lights on overhead console increase in brightness and are brightest at extreme clockwise position.
7. Rotate CONSOLE LT control counterclockwise.
8. Check panel lights on overhead console decrease in brightness and are extinguished at extreme counterclockwise
position.
3. OVERHEAD CONSOLE LIGHTS SYSTEM - TROUBLESHOOTING
Table 1. Overhead console lights system troubleshooting
Overhead console lights fail to illuminate Defective CONSOLE LT control Replace control.
when CONSOLE LT control is rotated (R5) or (8R5) (attached switch
Defective LT CSL circuit breaker. Replace circuit breaker.
96-33-17
Page 1
E-AB412-PT6T-2
(Cont.)
Brightness level of overhead console light Defective CONSOLE LT control Replace control.
does not increase with clockwise rotation of (R5) or (8R5).
CONSOLE LT control.
Defective transistor (Q5). Replace transistor.
96-33-17
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E-AB412-PT6T-2
96-3 -18 INTERIOR LIGHTING SYSTEMS - UTILITY LIGHTS
96-33-18
INTERIOR LIGHTING SYSTEMS - UTILITY LIGHTS
1. UTILITY LIGHTS - DESCRIPTION
Two utility lights, one for each side of the helicopter can be installed under the passenger doors. The helicopter is provisioned
for lights installation and wires are stowed in proximity of lights location points.
96-33-18
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E-AB412-PT6T-2
96-33-18
Page 2
E-AB412-PT6T-2
96-3 -19 INTERIOR LIGHTING SYSTEMS - POWER SUPPLY (PS3, PS4 OR PS5)
96-33-19
INTERIOR LIGHTING SYSTEMS - POWER SUPPLY (PS3, PS4 OR PS5)
1. POWER SUPPLY (PS3, PS4 OR PS5) - REMOVAL
1. Disengage connector from power supply.
2. Remove attaching hardware and lift power supply from mounting.
2. POWER SUPPLY (PS3, PS4 OR PS5) - INSTALLATION
1. Place power supply in position and secure with mounting hardware.
2. Connect connector to power supply.
96-33-19
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E-AB412-PT6T-2
96-33-19
Page 2
E-AB412-PT6T-2
96-3 -30 INTERIOR LIGHTING SYSTEMS - BAGGAGE COMPARTMENT LIGHTS SYSTEM
96-33-30
INTERIOR LIGHTING SYSTEMS - BAGGAGE COMPARTMENT LIGHTS
SYSTEM
1. BAGGAGE COMPARTMENT LIGHTS SYSTEM - DESCRIPTION
Baggage compartment lights are protected by the BAG COMPT circuit breaker. They illuminate the compartment when door
is opened. Baggage compartment door switch actuates to energize baggage compartment lights as baggage compartment
door is opened.
NOTE
Part of baggage compartment door switch serves to energize caution panel segment
in case baggage compartment door is left open.
2. BAGGAGE COMPARTMENT LIGHTS SYSTEM - REMOVAL
2. Remove two screws and pull out light assembly.
3. Disconnect electrical wiring.
3. BAGGAGE COMPARTMENT LIGHTS SYSTEM - INSTALLATION
2. Connect electrical wiring to light assembly.
3. Position light assembly and secure with two screws.
4. BAGGAGE COMPARTMENT LIGHTS SYSTEM - OPERATIONAL CHECK
1. Close BAG COMPT circuit breaker.
2. Open baggage compartment door.
3. Check baggage compartment lights are illuminated.
4. Manually, press plunger on baggage compartment door switch.
5. Check baggage compartment lights extinguish.
5. BAGGAGE COMPARTMENT LIGHTS SYSTEM - MAINTENANCE
For adjustment procedures of the baggage compartment door switch refer to door lock caution light this chapter.
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6. BAGGAGE COMPARTMENT LIGHTS SYSTEM - TROUBLESHOOTING
Table 1. Baggage compartment light system troubleshooting
When baggage compartment door is opened Defective LT BAG COMPT circuit Replace circuit breaker.
lights (DS20) fail to illuminate. breaker.
Defective switch (S82) or (8S7). Replace (S82) or (8S7).
Defective wiring. Check circuitry for loose

connection and faulty wiring.
Open lamp filament. Replace lamp.
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E-AB412-PT6T-2
96-3 -40 EXTERIOR LIGHTING SYSTEMS
96-33-40
EXTERIOR LIGHTING SYSTEMS
1. EXTERIOR LIGHTING SYSTEMS - DESCRIPTION
Exterior lighting systems include position lights, anticollision lights, searchlight, and landing light systems. Refer to Chapter
98 for applicable wiring diagrams.
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96-3 -41 EXTERIOR LIGHTING SYSTEMS - POSITION LIGHTS SYSTEM
96-33-41
EXTERIOR LIGHTING SYSTEMS - POSITION LIGHTS SYSTEM
1. POSITION LIGHTS SYSTEM - DESCRIPTION
Position lights system serves to give constant navigation signals during flight. Position lights, fuselage and tail, are powered
from 28 Vdc nonessential bus No. 1, and are protected by LIGHTING POSN/POS circuit breaker. The position lights are
controlled by the POSITION LIGHT switch on the overhead console. When the POSITION LIGHT switch is in the ON
position the lights illuminate at full brilliance.
2. POSITION LIGHTS SYSTEM - REMOVAL
2. Remove screw, lens and lamp.
3. Remove two securing screws and withdraw light assembly. Disconnect electrical wiring.
3. POSITION LIGHTS SYSTEM - INSTALLATION
2. Connect electrical wiring and secure light assembly to helicopter fuselage.
3. Install lamp.
4. Secure lens with screw.
4. POSITION LIGHTS SYSTEM - OPERATIONAL CHECK
1. Close LIGHTING POSN/POS circuit breaker.
2. Set POSITION switch to ON.
3. Verify right and left upper position lights illuminate.
4. Verify right and left lower position lights Illuminate.
5. Verify left and right tail lights illuminated.
6. Set POSITION switch to OFF.
7. Verify all position lights extinguish.
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E-AB412-PT6T-2
5. POSITION LIGHTS SYSTEM - TROUBLESHOOTING
Table 1. Position lights system troubleshooting
With LT POSN circuit breaker closed, Defective circuit breaker. Replace circuit breaker.
EXTERIOR LIGHTS POSITION switch set
to ON and ESS 28 Vdc BUS No. 2 energized, Detective switch. Replace switch.
light(s) fail to illuminate.
Defective light(s) (DS15, DS16 or Replace light(s).
DS17) or (8DS15, 8DS16 or
8DS17).
Poor grounding of light fixture. Check fixture for proper

grounding.
Defective airframe wiring. Repair or replace wiring.
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E-AB412-PT6T-2
96-3 -42 EXTERIOR LIGHTING SYSTEMS - ANTICOLLISION LIGHTS SYSTEM
96-33-42
EXTERIOR LIGHTING SYSTEMS - ANTICOLLISION LIGHTS SYSTEM
1. ANTICOLLISION LIGHTS SYSTEM - DESCRIPTION
Anticollision lights system serves to give constant navigation signals during flight. The lights are powered from 28 Vdc
nonessential bus No. 2 and are protected by ANTI COLL LT circuit breaker and controlled by ANTI-COLL LT switch.
When the switch is set to ON, the anticollision strobe light assemblies flash at a rate of approximately 80 flashes per minute.
One light is mounted on aft pylon fairing and one light is mounted on bottom of fuselage.
2. ANTICOLLISION LIGHTS SYSTEM - REMOVAL
2. Remove screws and washers from mounting flange.
3. Withdraw anti-collision light assembly and disconnect connector.
4. Remove light assembly.
3. ANTICOLLISION LIGHTS SYSTEM - INSTALLATION
2. Connect connector to anticollision light.
3. Secure screws and washers.
4. For extra safety, secure screw of lens clamp, use Loctite 241.
4. ANTICOLLISION LIGHTS SYSTEM - OPERATIONAL CHECK
1. Close ANTI COLL LT circuit breaker.
2. Place ANTI-COLL LT switch to ON.
3. Check upper and lower anticollision lights are illuminated and flashing approximately 80 to 90 times per minute.
4. Set ANTI-COLL LT switch to OFF.
5. Check anticollision lights extinguish.
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E-AB412-PT6T-2
5. ANTICOLLISION LIGHTS SYSTEM - TROUBLESHOOTING
Table 1. Anticollision lights system troubleshooting
Anti-collision light(s) fails to illuminate or Defective ANTI COLL light Replace switch.
flash with ANTI COLL light switch set to switch.
ON.
Defective LT ANTI COLL circuit Replace circuit breaker.
breaker.
Anti-collision light(s) illuminates but fails to Defective anti-collision light Replace defective anti-collision
rotate or flash. assembly (defective motor) in light assembly.
(DS7 or DS8) or (8DS3 or 8DS8).
Anti-collision light flashes at one-half its One lamp filaments open (two Replace lamp.
normal flash rate (approximately 90 flashes lamps assumed).
per minute).
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E-AB412-PT6T-2
96-3 -43 EXTERIOR LIGHTING SYSTEMS - SEARCHLIGHT SYSTEM
96-33-43
EXTERIOR LIGHTING SYSTEMS - SEARCHLIGHT SYSTEM
1. SEARCHLIGHT SYSTEM - DESCRIPTION
Searchlight system provides close range illumination of terrain and obstacles to aid in low level flight and landing. The
searchlight is powered from 28 Vdc emergency bus No. 2, protected by SCH LT PWR and SCH LT CNTL circuit breakers,
and controlled by SEARCH LIGHT NORM/OFF switch. The searchlight assembly includes a sealed beam type light,
rotation motor, extend-retract motor, control relays, and limit switches. The SRCH LT ON/OFF switch controls search light
lamp. The four-way SRCH LT EXT/L/R/RETR switch controls extend/retract and rotate right/left motion of searchlight.
The search light is installed in the helicopter lows fuselage. The search light electrical circuit is controlled by two switches
located on the pilot's collective stick box. A 3-way (SLT-OFF-STOW) switch control search light operation. A 4-way
(RETREXT-R-L and center neutral) switch controls the extension, the retraction and right or left rotation of the searchlight.
The lamp circuit is protected by the SCH LT PWR circuit breaker, while the control circuit is protected by the SCH LT
CONT circuit breaker. Both circuit breakers are located on the overhead console panel. The search light comprises two sec-
tions, one fixed and one mobile. The mobile consists of a case that contains the lamp and an extension supporting the motor
and the rotate mechanism assembly. A limit switch cuts-off the electrical power to the lamp when the search light is
retracted, while two microswitches, actuated by cams, cut-off electrical power to the lamp when the light is directed
towards the helicopter. The fixed section consists of a base for search light attachment and for the installation of the motor,
the extend gearbox assembly, the limit switches and the control relays.
The lamp power is 450W the maximum extension is 120° and the rotation in 360° in both directions.
2. SEARCHLIGHT SYSTEM - REMOVAL
2. Remove four mounting screws and washers.
3. Pull-out search light.
4. Remove terminal cover by removing two screws and disconnect electrical wiring from light.
5. Remove search light from helicopter.
3. SEARCHLIGHT SYSTEM - LAMP REPLACEMENT
2. Remove lamp retainer ring by removing three securing screws. Loosen the three screws, one turn at a time, to avoid
bending tubing located on screws.
3. Pull-out lamp from protective case.
4. Disconnect electrical wiring from lamp.
5. Connect electrical wiring to new lamp.
6. Position lamp in protective case, aligning reference marks on lamp and protective case.
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E-AB412-PT6T-2
7. Position retaining ring on lamp and tighten screws in sequence, one turn a time to avoid bending tubing
4. SEARCHLIGHT SYSTEM - INSTALLATION
2. Connect electrical wiring to search light. Secure terminal cover with two screws.
3. Position search light on helicopter structure and secure four screws and washers.
5. SEARCHLIGHT SYSTEM - OPERATIONAL CHECK
1. Close SCHLT PWR and SCHLT CONTR circuit breakers.
2. Set SRCH LT ON/OFF switch on pilot collective stick to ON.
3. Verify searchlight illuminates.
4. Set four-way SRCH LT switch to EXT.
5. Check searchlight extends approximately 120 degrees.
6. Set four-way SRCH LT switch to RETR.
7. Check searchlight retracts.
8. With searchlight partially extended:
a. Set four-way SRCH LT switch to L.
b. Check searchlight rotates to left.
c. Set four-way SRCH LT switch to R.
d. Check searchlight rotates to right.
e. Using four-way SRCH LT switch rotate search light to point forward.
9. With searchlight partially extended:
10. Set SRCH LT ON/OFF switch to OFF.
11. Set four-way SRCH LT switch to RETR.
12. Check searchlight retracts.
13. Open SCHLT PWR and SCHLT CONTR circuit breakers.
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E-AB412-PT6T-2
6. SEARCHLIGHT SYSTEM - TROUBLESHOOTING
Table 1. Searchlight system troubleshooting
Searchlight fails to illuminate with SLT/OFF/ Defective searchlight lamp. Replace searchlight assembly or
STOW switch set to SLT. replace lamp.
Defective SLT/OFF/STOW Replace switch.

switch.
Defective LIGHT RELAY in Replace searchlight assembly.

searchlight assembly (DS12) or
(8DS12).
Defective LT PWR SRCH or LT Replace circuit breaker.

CONT SRCH circuit breaker.
Searchlight fails to rotate left or right with Defective ROTATION motor in Replace searchlight assembly.
SLT EXT/L/R/RETR switch (S25) set to L or searchlight assembly (DS12) or
R. (8DS12).
Defective SLT EXT/L/R/RETR Replace switch.

switch (S25).
Searchlight fails to extend with SLT EXT/L/ Defective EXT or RETR motor in Replace searchlight assembly.
R/RETR switch set to EXT. searchlight assembly (DS12) or
(8DS12).
Defective SLT EXT/L/R/RETR Replace switch.

switch.
Defective extend relay in Replace searchlight.

(8DS12).
Defective extend limit switch in Replace searchlight assembly.

searchlight assembly.
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E-AB412-PT6T-2
(Cont.)
Searchlight fails to retract or stow. Defective retract limit switch in Replace searchlight assembly.
(8DS12).
Defective retract relay in Replace searchlight assembly.

(8DS12).
Searchlight will not stow with SLT/OFF/ Defective SLT/OFF/STOW Replace switch.
STOW with set to STOW. switch.
Searchlight will not rotate to right with SLT/ Defective SLT/EXT/L/R/RETR Replace switch.
EXT/L/R/RETR switch set to R. switch.
Defective right rotation relay in Replace searchlight assembly.

(8DS12).
Searchlight will not rotate left with SLT/EXT/ Defective SLT/EXT/L/R/RETR Replace switch.
L/R/RETR switch to set L. switch.
Defective left rotation relay in Replace searchlight assembly.

(8DS12).
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E-AB412-PT6T-2
96-3 -4 EXTERIOR LIGHTING SYSTEMS - LANDING LIGHT SYSTEM
96-33-44
EXTERIOR LIGHTING SYSTEMS - LANDING LIGHT SYSTEM
1. LANDING LIGHT SYSTEM - DESCRIPTION
The landing light system provides illumination of the landing area during the final approach to landing. The landing light is
powered from 28 Vdc essential bus no. 1, protected by LDN LT PWR and LND LT CNTL circuit breakers, and controlled
by LNDG LT ON/OFF and LNDG EXT/RET switches. The landing light assembly includes one sealed beam type light, an
extend-retract motor, a control relay, and limit switches. LDG LT ON/OFF switch controls ON and OFF functions. LDG LT
EXT/RETR switch controls extend and retract motion of landing light. The landing light is installed on the helicopter lower
fuselage. The lamp power is 600 W and the extension is 115°.
2. LANDING LIGHT SYSTEM - REMOVAL
2. Remove mounting screw and lower light.
3. Disconnect connector and remove light from helicopter.
3. LANDING LIGHT SYSTEM - LAMP REPLACEMENT
2. Remove retaining ring from lamp.
3. Pull-out lamp and disconnect electrical wiring.
4. Connect electrical wiring to lamp.
5. Secure lamp to its case with retaining ring and springs.
4. LANDING LIGHT SYSTEM - INSTALLATION
2. Connect connector to light.
3. Position light on helicopter structure and secure with screws.
5. LANDING LIGHT SYSTEM - LIGHT ADJUSTMENT
Refer to manufacturer publication for landing light adjustment (See E-AB412-PT6T-1).
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E-AB412-PT6T-2
6. LANDING LIGHT SYSTEM - OPERATIONAL CHECK
1. Close both LDG PWR and LDG CONTR circuit breakers.
2. Place and hold LDG LT EXT/RETR switch on pilot collective stick to EXT.
3. Check landing light extends and stops at approximately 90 degrees.
4. Set LDG LT ON/OFF switch to ON.
5. Check landing light is illuminated.
6. Open LDG PWR circuit breaker.
7. Check landing light is extinguished.
8. Close LDG PWR circuit breaker and open LDG CONTR circuit breaker.
9. Set LDG LT EXT/RETR switch to RETR.
10. Check LDG LT EXT/RETR switch cannot operate landing light.
11. With LDG CONTR circuit breaker closed and landing light illuminated.
12. Set LDG LT EXT/RETR switch to RETR and hold.
13. Check landing light retracts completely.
14. Check landing light remains illuminated.
15. Set LDG LT ON/OFF switch to OFF.
16. Check landing light is extinguished.
7. LANDING LIGHT SYSTEM - TROUBLESHOOTING
Table 1. Landing light system troubleshooting
Landing light fails to illuminate with LDG LT Defective landing light lamp. Replace landing light assembly.
ON/OFF switch set to ON.
Defective LDG LT ON/OFF Replace switch.
switch.
Defective LIGHT RELAY in Replace landing light.

landing light assembly (DS13) or
(8DS13).
Defective LT LDG PWR or LT Replace circuit breaker.

LDG CONT circuit breaker.
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E-AB412-PT6T-2
(Cont.)
Landing light fails to extend with LDG LT Defective LDG LT EXT/OFF/RET Replace switch.
EXT/OFF/RETR switch set to EXT. switch.
Defective landing light assembly Replace landing light assembly.

(DS13) or (8DS13).
Landing light fails to retract with LDG LT Defective LDG LT EXT/OFF/RET Replace switch.
EXT/OFF/RET switch set to RET. switch.
Defective landing light assembly Replace landing light assembly.

(DS13) or (8DS13).
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E-AB412-PT6T-2
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E-AB412-PT6T-2
96-67-01
FLIGHT CONTROL SYSTEMS
1. FLIGHT CONTROL SYSTEMS - DESCRIPTION
Flight control systems include force trim and hydraulic control solenoid systems. Refer to chapter 98 for applicable wiring
diagrams.
2. FLIGHT CONTROL SYSTEMS - FORCE TRIM SYSTEM
2-1. FORCE TRIM SYSTEM - DESCRIPTION
For helicopters codes [A] [B] magnetic brake, pitch trim actuator, and roll trim actuator are wired in parallel to 28 Vdc ESS
BUS NO. 2 through control switches and FORCE TRIM circuit breakers.
For helicopters codes [C] [D], magnetic brake, pitch trim actuator, and roll trim actuator are wired in parallel to 28 Vdc
EMERGENCY BUS NO. 2 through control switches and FORCE TRIM circuit breakers.
Control switching is accomplished through series wired FORCE TRIM switch located on the MISC control panel, and
normally closed pilot and copilot pushbutton cyclic stick force trim switches. The force trim system provides spring forces
to maintain control system linkage position and thus relieve pilot/copilot from the strain of holding the controls in a
particular position. The switches allow the magnetic brakes and trim actuators to be disengaged and repositioned as required.
The force trim system is deenergized when the FORCE TRIM switch is set to OFF.
2-2. FORCE TRIM SYSTEM - OPERATIONAL CHECK
NOTE
If the copilot stick is not installed, a 412-075-037-119 cable assembly must be
installed in copilot cyclic stick receptacle.
1. Close FORCE TRIM circuit breaker.
2. Set FORCE TRIM switch on MISC control panel to ON.
3. Verify cyclic stick has holding force in fore/aft and lateral directions.
4. Verify control pedals have holding force in both directions.
5. Verify FT OFF light, on pilot instrument panel, is extinguished.
6. Press FORCE TRIM RELEASE switch on pilot cyclic stick.
7. Verify forces in steps 3. and 4. are no longer present.
8. Release FORCE TRIM RELEASE switch on pilot cyclic stick.
9. Verify forces in steps 3. and 4. are now present.
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E-AB412-PT6T-2
10. Repeat steps 3. through 9. using copilot cyclic stick FORCE TRIM RELEASE switch.
11. Set FORCE TRIM switch on MISC control panel to OFF.
12. Open FORCE TRIM circuit breaker.
2-3. FORCE TRIM SYSTEM - TROUBLESHOOTING
Table 1. Force trim system troubleshooting
All magnetic brakes, fail to energize, FORCE Defective FORCE TRIM circuit Replace circuit breaker.
TRIM switch set to ON. breaker.
Defective FORCE TRIM switch. Replace switch.
Any one magnetic brake fails to energize. Defective magnetic brake. Replace magnetic brake.
FORCE TRIM switch set to ON.
Magnetic brakes fail to de-energize when one Defective FORCE TRIM switch. Replace switch
FORCE TRIM switch is depressed.
Unable to reset FORCE TRIM circuit Defective diode. Replace diode.

breaker.
Defective FORCE TRIM circuit Replace circuit breaker.
breaker.
3. FLIGHT CONTROL SYSTEMS - HYDRAULIC CONTROL SYSTEMS
3-1. HYDRAULIC CONTROL SYSTEMS - DESCRIPTION
The hydraulic bypass solenoid systems receive electrical power from 28 Vdc essential buses through NO. 1 HYD SYST and
NO. 2 HYD SYST circuit breakers. Hydraulic bypass solenoid valves are controlled by switches on the miscellaneous
control panel. The valves are normally deenergized (open) when switches are in ON position and energized (closed) when
switches are placed to OFF.
3-2. HYDRAULIC CONTROL SYSTEMS - OPERATIONAL CHECK [A] [B]
3-2-1. Operational check [A] [B] - clogged filter check
NOTE
An electrical interlock prevents both hydraulic systems from being switched off at
the same time. If one system is off and second system is switched off, second system
will remain on.
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E-AB412-PT6T-2
— NO. 1 HYD SYST

— NO. 2 HYD SYST
— NO. 1 HYD TEMP
— NO. 2 HYD TEMP
— MASTER CAUTION
2. Place NO. 1 and NO. 2 HYD SYS switches ON.
3. Check HYDRAULIC caution lights illuminate.
4. Check No. 1 and No. 2 hydraulic temperature indicators indicate ambient temperature.
5. Disconnect hydraulic 1 filter switch connector (P174/9S1P1).
6. Place a jumper between pins C and B.
7. Check hydraulic filter clog indicator (located in right side of nose below and forward of pilot pedals) displays a red
indication.
8. Remove jumper.
9. Press reset plunger on hydraulic filter clog indicator.
10. Check indicator is displaying a green indication.
11. Repeat steps 5. through 10. for hydraulic 2 filter switch connector.
12. Connect and secure connectors to hydraulic 1 and 2 filter switches.
3-2-2. Operational check [A] [B] - systems check
NOTE
Maintain proper hydraulic pressure during these tests. Failure to do so may result in
unsatisfactory results from these tests.
1. Apply external hydraulic pressure, 750 psig (5171 kPa) minimum, to helicopter hydraulic system.
2. Check HYDRAULIC caution light extinguishes.
3. Verify hydraulic filter clog indicator displays green indication.
4. Operate cyclic stick, collective stick, and pedal controls.
5. Check only normal force is required to operate controls.
6. Set NO. 1 HYD SYS switch to OFF.
7. Check HYDRAULIC caution light illuminates.
8. Check only normal force is required to operate cyclic and collective controls.
9. Check pedal controls are harder.
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E-AB412-PT6T-2
11. Check for same results as in steps 19. through 21. (No. 2 hydraulic does not turn off).
12. Set NO. 1 HYD SYS switch to ON.
13. Check HYDRAULIC caution light remains illuminated.
14. Verify only normal force is required to operate cyclic, collective and pedal controls.
16. Check HYDRAULIC caution light extinguishes.
17. Disconnect No. 1 hydraulic temperature switch connector (P106/8S13P1) from No. 1 hydraulic temperature switch.
20. Remove jumper.
21. Disconnect No. 2 hydraulic temperature switch connector (P105/8S14P1) from No. 2 hydraulic temperature switch.
24. Remove jumper.
25. Connect and secure connectors to hydraulic temperature switches.
26. Check HYDRAULIC caution light is extinguished.
3-3. HYDRAULIC CONTROL SYSTEMS - OPERATIONAL CHECK [C] [D]
3-3-1. Operational check [C] [D] - clogged filter check
NOTE
An electrical interlock prevents both hydraulic systems from being switched off at
the same time. If one system is off and second system is switched off, second system
will remain on.
— NO. 1 HYD SYST
— NO. 2 HYD SYST
— NO. 1 HYD TEMP
— NO. 2 HYD TEMP
— MASTER CAUTION
2. Place NO. 1 and NO. 2 HYD SYS switches ON.
3. Check NO. 1 HYDRAULIC and NO. 2 HYDRAULIC caution lights illuminate.
4. Check No. 1 and No. 2 hydraulic temperature indicators indicate ambient temperature.
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E-AB412-PT6T-2
5. Disconnect hydraulic 1 filter switch connector (9S1P1).
7. Check hydraulic filter clog indicator (located in right side of nose below and forward of pilot pedals) displays a red
indication.
8. Remove jumper.
9. Press reset plunger on hydraulic filter clog indicator.
10. Check indicator is displaying a green indication.
11. Repeat steps 5. through 10. for hydraulic 2 filter switch connector.
12. Connect and secure connectors to hydraulic 1 and 2 filter switches.
3-3-2. Operational check [C] [D] - systems check
NOTE
Maintain proper hydraulic pressure during these tests. Failure to do so may result in
unsatisfactory results from these tests.
1. Apply external hydraulic pressure, 750 psig (5171 kPa) minimum, to helicopter hydraulic system.
2. Check HYDRAULIC caution lights extinguish.
3. Verify hydraulic filter clog indicator displays green indication.
4. Operate cyclic stick, collective stick, and pedal controls.
5. Check only normal force is required to operate controls.
7. Check NO. 1 HYDRAULIC caution light illuminates.
8. Check only normal force is required to operate cyclic and collective controls.
9. Check pedal controls are harder.
11. Check for same results as in steps 19. through 21. (No. 2 hydraulic does not turn off).
13. Check NO. 1 HYDRAULIC caution light extinguishes.
15. Verify only normal force is required to operate cyclic, collective and rudder controls.
17. Check NO. 2 HYDRAULIC caution light extinguishes.
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E-AB412-PT6T-2
18. Disconnect No. 1 hydraulic temperature switch connector from No. 1 hydraulic temperature switch.
21. Disconnect No. 2 hydraulic temperature switch connector from No. 2 hydraulic temperature switch.
24. Remove jumpers.
25. Connect and secure connectors to hydraulic temperature switches.
26. Check NO. 1 HYDRAULIC and NO. 2 HYDRAULIC caution lights extinguish.
3-4. HYDRAULIC CONTROL SYSTEMS - TROUBLESHOOTING
Table 2. Hydraulic control systems troubleshooting
No. 1 HYDR or No. 2 HYDR circuit breaker Defective circuit breaker. Replace circuit breaker.
will not reset.
Internal short in solenoid. Replace defective solenoid.
Either hydraulic solenoid fails to actuate Defective circuit breaker. Replace circuit breaker.
when associated hydraulic control switch is
placed to OFF position. Faulty wiring or loose connections. Repair wiring and/or secure
connections.
Defective hydraulic control switch. Replace switch.
Defective hydraulic solenoid. Replace solenoid.
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E-AB412-PT6T-2
96-73-01
ENGINE CONTROL AND ACCESSORIES SYSTEMS
1. ENGINE CONTROL AND ACCESSORIES SYSTEMS - DESCRIPTION
Engine controls and accessories systems include fuel control heaters, fuel boost pumps, fuel transfer pumps, fuel shutoff
valves, fuel control valves, fuel interconnect valves and crossfeed valves, governor rpm actuator, sump drain valves, idle
stop release solenoid, and engine particle separator systems. Refer to Chapter 98 for applicable wiring diagrams.
2. ENGINE CONTROL AND ACCESSORIES SYSTEMS - FUEL CONTROL HEATER
Fuel control sense line heaters prevent accumulation of ice in engine governing system. Fuel control No. 1 heater receives
power from No. 1 essential dc bus through ENGINE NO 1 FUEL CONTR HTR circuit breaker and is controlled by ENGINE
1 FUEL switch located on engine and fuel control panel. Fuel control No. 2 heater is supplied power from No. 2 essential
bus through ENGINE NO 2 FUEL CONTR HTR circuit breaker and is controlled by ENGINE 2 FUEL switch on engine
and fuel control panel.
2-1. FUEL CONTROL HEATER - OPERATIONAL CHECK
1. Close ENGINE NO 1 FUEL CONTR HTR circuit breaker.
3. Verify fuel control No. 1 heater (1HR1) begins to heat.
5. Verify fuel control No. 1 heater begins to cool.
6. Open ENGINE NO 1 FUEL CONTR HTR circuit breaker.
7. Close ENGINE NO 2 FUEL CONTR HTR circuit breaker.
9. Verify fuel control No. 2 heater (1HR2) begins to heat.
11. Verify fuel control No. 2 heater begins to cool.
12. Open ENGINE NO 2 FUEL CONTR HTR circuit breaker.
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E-AB412-PT6T-2
2-2. FUEL CONTROL HEATER - TROUBLESHOOTING
Table 1. Fuel control heater troubleshooting
ENG No. 1 fuel control heater will not Defective FUEL CONT HTR Replace circuit breaker.
energize. circuit breaker.
Defective ENGINE 1 FUEL Replace switch.

switch.
Defective heater. Replace heater.
ENG No. 1 fuel control heater will not Defective ENGINE 1 FUEL Replace switch.
deenergize. switch.
ENG No. 2 fuel control heater will not Defective FUEL CONT HTR Replace circuit breaker.
energize. circuit breaker.

switch.
Defective heater. Replace heater.
ENG No. 2 fuel control heater will not Defective ENGINE 2 FUEL Replace switch.
deenergize. switch.
3. ENGINE CONTROL AND ACCESSORIES SYSTEMS - FUEL BOOST PUMP SYSTEM
3-1. FUEL BOOST PUMP SYSTEM - DESCRIPTION
3-1-1. Description - helicopters codes [A] [B]
The two electrically operated fuel boost pumps are submerged one each in the right hand and left hand fuel cells and
connected to a common fuel line when the crossfeed valve is energized. The pumps are energized from the essential dc power
bus through the No. 1 FUEL BOOST and No. 2 FUEL BOOST circuit breakers and controlled by either ENG 1 or ENG 2
BUST PUMP switches in the pilot engine control panel.
3-1-2. Description - helicopters codes [C] [D]
Each lower main cell sump assembly is equipped with a fuel boost pump that provides a flow of fuel to the respective engine
(crossfeed operation enables a single boost pump to supply fuel to both engines). No. 1 dc essential bus powers No. 1 (left)
boost pump. That circuit is protected by ENGINE NO 1 FUEL BOOST circuit breaker. ENGINE 1 BOOST PUMP switch
on engine and fuel control panel controls the pump. Similarly, No. 2 (right) boost pump is powered by No. 2 dc essential bus
through ENGINE NO 2 FUEL BOOST circuit breaker and is controlled by ENGINE 2 BOOST PUMP switch on engine
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E-AB412-PT6T-2
3-2. FUEL BOOST PUMP SYSTEM - OPERATIONAL CHECK
3-2-1. Operational check - engine 1
1. Close ENGINE NO 1 FUEL BOOST circuit breaker.
2. Set ENGINE 1 BOOST PUMP switch to ON.
3. Verify No. 1 (left) boost pump is operating.
4. Set ENGINE 1 BOOST PUMP switch to OFF.
5. Verify No. 1 (left) boost pump stops operating.
6. Open ENGINE NO 1 FUEL BOOST circuit breaker.
2. Set ENGINE 2 BOOST PUMP switch to ON.
3. Verify No. 2 (right) boost pump is operating.
4. Set ENGINE 2 BOOST PUMP switch to OFF.
5. Verify No. 2 (right) boost pump stops operating.
3-3. FUEL BOOST PUMP SYSTEM - TROUBLESHOOTING
Table 2. Fuel boost pump system troubleshooting
Right hand fuel boost pump inoperative. Open No. 2 FUEL BOOST circuit Check circuit breaker, replace if
breaker or defective. necessary.
Defective ENGINE 2 BOOST Replace switch.

PUMP switch.
Fuel pump defective. Replace fuel boost pump.
Defective ground wire on (TB10). Repair wiring.
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E-AB412-PT6T-2
(Cont.)
Left hand fuel boost pump inoperative. Open No. 1 defective FUEL Check circuit breaker, replace if
BOOST circuit breaker. necessary.
Defective ENGINE 1 BOOST Replace on ENGINE CONTROL

PUMP switch. PANEL in pedestal.
Fuel pump defective. Replace fuel boost pump.
Defective ground wire on (TB11). Repair wiring.
4. ENGINE CONTROL AND ACCESSORIES SYSTEMS - FUEL TRANSFER PUMP

SYSTEMS
4-1. FUEL TRANSFER PUMP SYSTEM - DESCRIPTION [C] [D]
Sump assemblies in both lower forward cells are equipped with transfer pumps that pump fuel from lower forward cells to
lower main cells through ejector pumps mounted in lower middle cells. Fuel flowing from transfer pumps provides motive
force for ejector pumps to empty fuel from lower middle cells into lower main cells. In normal operations, fuel level sensors
(thermistors) in forward fuel cells trigger the fuel signal conditioners to shut off the transfer pumps 60 seconds after forward
fuel cells empty.
Left lower forward cell transfer pump is powered by No. 1 dc essential bus through ENGINE NO 1 FUEL TRANS circuit
breaker and in addition to the automatic shutoff feature, is controlled by ENGINE 1 FUEL TRANS switch located on engine
Similarly, right lower forward cell transfer pump is powered by 28 Vdc emergency bus No. 2 through ENGINE NO 2 FUEL
TRANS circuit breaker and is controlled by ENGINE 2 FUEL TRANS switch on engine and fuel control panel.
4-2. FUEL TRANSFER PUMP SYSTEM - OPERATIONAL CHECK
1. Close ENGINE NO 1 FUEL TRANS circuit breaker.
2. Set ENGINE 1 FUEL TRANS switch to ON.
3. Verify left lower forward transfer pump (1B17) is operating.
4. Set ENGINE 1 FUEL TRANS switch to OFF.
5. Verify left lower forward transfer pump stops operating.
6. Open ENGINE NO 1 FUEL TRANS circuit breaker.
1. Close ENGINE NO 2 FUEL TRANS circuit breaker.
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2. Set ENGINE 2 FUEL TRANS switch to ON.
3. Verify right lower forward transfer pump (1B18) is operating.
4. Set ENGINE 2 FUEL TRANS switch to OFF.
5. Verify right lower forward transfer pump stops operating.
6. Open ENGINE NO 2 FUEL TRANS circuit breaker.
4-3. FUEL TRANSFER PUMP SYSTEM - TROUBLESHOOTING
Table 3. Fuel transfer pump system troubleshooting
Engine No. 1 FUEL TRANS pump Open ENGINE No. 1 FUEL Check circuit breaker, replace if
inoperative. TRANS circuit breakers. necessary

TRANS switch.
Fuel trans pump 1 defective. Replace fuel trans pump.
Engine No. 2 FUEL TRANS pump Open ENGINE No. 2 FUEL Check circuit breaker, replace if
inoperative. TRANS circuit breaker. necessary.

TRANS switch.
Fuel trans pump 2 defective. Replace fuel trans pump.
5. ENGINE CONTROL AND ACCESSORIES SYSTEMS - FUEL SHUTOFF VALVE

SYSTEMS
5-1. FUEL SHUTOFF VALVE SYSTEMS - DESCRIPTION
The fuel valves open or close to control the flow of fuel to the engines and between the tanks. Power is supplied to these
valves by the essential buses through circuit breakers No. 1 FUEL VALVE, No. 2 FUEL VALVE. Engine No. 1 fuel control
valve is controlled by ENG 1 FUEL switch for a normal operation. Engine No. 2 fuel control valve is controlled by ENG 2
FUEL switch for normal operation. Engine No. 1 fuel control valve will return to its closed position when the FIRE 1 PULL
handle is pulled out. This stops the flow of fuel to engine No. 1 in the event of fire in the engine area. Engine No. 2 fuel
control valve will close when the FIRE 2 PULL handle is pulled out. This stops the flow of fuel to engine No. 2 in the event
of fire in that engine area.
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5-1-2. Description - helicopters codes [C] [D]
Motor-operated fuel shutoff valves open or close to control flow of fuel to engines. The valves receive power from dc
emergency buses through ENGINE NO 1 FUEL VALVE and ENGINE NO 2 FUEL VALVE circuit breakers.
During normal operation No. 1 fuel shutoff valve is controlled by ENGINE 1 FUEL switch located on engine and fuel
control panel. When pulled during an engine fire emergency, FIRE 1 PULL handle switch, located on instrument panel,
causes valve to close, stopping flow of fuel to engine No. 1. No. 2 fuel shutoff valve is similarly controlled by ENGINE 2
FUEL switch on engine and fuel control panel and instrument panel-mounted FIRE 2 PULL handle switch.
5-2. FUEL SHUTOFF VALVE SYSTEMS - OPERATIONAL CHECK
5-2-1. Operational check - description
WARNING

(REFER TO FIGURE 1).
NOTE
Due to presence of diodes (1A1CR7 and 1A1CR8) on ENGINE 1 FUEL and
ENGINE 2 FUEL switches, FUEL VALVE caution segment on master caution panel
will illuminate when engine fuel switch position does not agree with fuel shutoff
valve position after a fire pull handle is pulled. Also, illumination will occur during
opening or closing of fuel shutoff valve provided an engine fuel switch is positioned
to ON or OFF or when a fire pull handle is actuated.
1. Close ENGINE NO 1 FUEL VALVE circuit breaker.
3. Verify No. 1 fuel shutoff valve opens.
5. Verify No. 1 fuel shutoff valve closes.
6. Push FIRE 1 PULL handle switch in.
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6. Push FIRE 2 PULL handle switch in.
5-3. FUEL SHUTOFF VALVE SYSTEMS - TROUBLESHOOTING
Table 4. Fuel shutoff valve systems troubleshooting
Engine No. 1 fuel valve fails to open when Defective engine No. 1 fuel valve. Replace valve.
ENGINE 1 FUEL switch it set to ON.
switch.
Defective FIRE 1 PULL handle. Replace handle.
Defective No. 1 FUEL VALVE Replace circuit breaker.

circuit breaker.
Engine No. 1 fuel valve fails to close when Defective engine No. 1 fuel valve. Replace valve.
ENG 1 FUEL switch is set to OFF.
switch.
Engine No. 2 fuel valve fails to open when Defective engine No. 2 fuel valve. Replace valve.
ENGINE 2 FUEL switch is set to ON.
switch.
Defective FIRE 2 PULL handle. Replace handle.
Defective No. 2 FUEL VALVE Replace circuit breaker.

circuit breaker.
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(Cont.)
Engine No. 2 fuel valve fails to close when Defective engine No. 2 fuel valve. Replace valve.
ENGINE 2 FUEL switch in set to OFF.
switch.
G6AB0757A
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6. ENGINE CONTROL AND ACCESSORIES SYSTEMS - FUEL CONTROL VALVE

SYSTEM
6-1. FUEL CONTROL VALVE SYSTEM - DESCRIPTION
The fuel control solenoid valves, one for each engine, provide a method of bypassing the engine fuel control governors. Each
solenoid is protected by a separate FUEL CONT circuit breaker. When ENG No. 1 GOV and ENG No. 2 GOV switches are
to the AUTO position, the solenoids are deenergized, the twist grip throttle controls are manually set full on and the speed
of each engine is controlled by the governor. When the switches are set to MANUAL, the solenoids are energized, the
governors are bypassed, and engine control is by the manual twist grip operation.
Placing either switch to MANUAL also provides a 28 Vdc signal to the master caution panel and the legend GOV MAN is
illuminated.
6-1-2. Description - helicopters code [D]
Each engine fuel control contains a solenoid valve that provides a method of bypassing engine fuel control governors. Fuel
control valve No. 1 solenoid is powered by dc essential bus No. 1 through ENGINE NO 1 FUEL CONTR circuit breaker
and is controlled by ENGINE 1 GOV switch located on engine and fuel control panel. Similarly, fuel control valve No. 2
solenoid is powered from dc essential bus No. 2 through ENGINE NO 2 FUEL CONTR circuit breaker and is controlled by
ENGINE 2 GOV switch on engine and fuel control panel.
When switches ENG 1 GOV and ENG 2 GOV are positioned to AUTO, solenoids are deenergized, twist grip throttle
controls are manually set full-on, and speed of each engine is controlled by the governor. When switches ENG 1 GOV and
ENG 2 GOV are positioned to MANUAL, solenoids are energized, governors are bypassed, and engine fuel control is by
manual twist grip operation.
6-2. FUEL CONTROL VALVE SYSTEM - OPERATIONAL CHECK
1. Close ENGINE NO 1 FUEL CONTR circuit breaker.
2. Set ENGINE 1 GOV switch to MANUAL.
3. Verify fuel control valve No. 1 solenoid opens to bypass position.
4. Verify ENG 1 GOV MANUAL caution light illuminates.
5. Set ENGINE 1 GOV switch to AUTO.
6. Verify fuel control valve No. 1 closes.
7. Verify ENG 1 GOV MANUAL caution panel segment extinguishes.
1. Close ENGINE NO 2 FUEL CONTR circuit breaker.
2. Set ENGINE 2 GOV switch to MANUAL.
3. Verify fuel control valve No. 2 opens to bypass position.
4. Verify ENG 2 GOV MANUAL caution light illuminates.
5. Set ENGINE 2 GOV switch to AUTO.
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6. Verify fuel control valve No. 2 closes.
7. Verify ENG 2 GOV MANUAL caution light extinguishes.
6-3. FUEL CONTROL VALVE SYSTEM - TROUBLESHOOTING
Table 5. Fuel control valve system troubleshooting
ENG 2 GOV MANUAL caution light does Defective ENG 2 FUEL CONT Replace circuit breaker.
not illuminate. circuit breaker.
Defective ENGINE No. 2 GOV Repair wiring.

switch.
ENG 2 GOV MANUAL caution light Defective engine No. 2 solenoid Replace solenoid valve.
illuminates but fuel control solenoid valve valve.
does not actuate.
ENG 1 MANUAL caution light does not Defective ENG 1 FUEL CONT Replace circuit breaker.
illuminate. circuit breaker.
Defective ENGINE No. 1 GOV Replace switch.

switch.
ENG 1 GOV MANUAL caution light Defective engine No.1 solenoid Replace solenoid valve.
illuminates but fuel control solenoid valve valve.
does not actuate.
7. ENGINE CONTROL AND ACCESSORIES SYSTEMS - FUEL INTERCONNECT VALVE

SYSTEM
7-1. FUEL INTERCONNECT VALVE SYSTEM - DESCRIPTION
7-1-1. Description - helicopters code [A] [B]
Two motor-operated valves enable interconnection or isolation of the forward fuel cells. The forward interconnect valve is
in the line between the forward compartments of the forward cells, and the aft interconnect valve is in the line between the
aft compartments of those cells. Powered by the 28 V dc emergency bus No. 2 through the FUEL INTCON circuit breaker,
both valves are controlled by the INTCON switch on the engine and fuel control panel. Both valves are closed when the
ITCON switch is in the normal (NORM) operating position, thus isolating forward cells from each other. Both valves open
when the INTCON switch is positioned to OPEN, and fuel is free to move from on forward cell to the other by gravity feed.
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7-1-2. Description - helicopters code [C] [D]
Lower main cells are connected by a fuel line containing a fuel interconnect valve. This motor-operated fuel interconnect
valve enables interconnection or isolation of lower main cells, as desired. Powered by dc emergency buses through ENGINE
NO 1 FUEL INTCON and ENGINE NO 2 FUEL INTCON circuit breakers, the valve is controlled by FUEL INTCON
switch, located on engine and fuel control panel and by associated fuel interconnect relays.
The fuel interconnect valve is closed when FUEL INTCON switch is in normal (NORM) operating position, thus isolating
lower main cells from each other and, therefore, isolating all lower right cells from all lower left cells. The valve opens when
FUEL INTCON switch is positioned to OPEN, and it opens automatically when the FUEL LOW caution light on master
caution panel illuminates. Positioning FUEL INTCON switch to OVRD CLOSE, closes the valve after it has opened
automatically.
The FUEL INTCON switch is mounted on the engine and fuel control panel, and permits testing of the system on the ground.
Verification of proper operation is possible by monitoring FUEL INTCON caution light on master caution panel. Caution
panel segment should be illuminated only during valve transit.
7-2. FUEL INTERCONNECT VALVE SYSTEM - OPERATIONAL CHECK
NOTE
Verify sufficient fuel is on board to cause FUEL LOW caution panel segment to
remain extinguished.
— ENGINE NO 1 FUEL QTY
— ENGINE NO 2 FUEL QTY
— ENGINE NO 1 FUEL INTCON
— ENGINE NO 2 FUEL INTCON
— MASTER CAUTION
2. Set FUEL INTCON and FUEL XFEED/INTCON switches to NORM.
3. Verify FUEL INTCON caution panel segment is extinguished.
4. Set FUEL INTCON switch to OPEN.
5. Verify FUEL INTCON caution light illuminates and extinguishes (indicating valve has opened).
6. Return FUEL INTCON switch to NORM.
7. Verify FUEL INTCON caution light illuminates and extinguishes (valve has closed).
8. Set FUEL XFEED/INTCON switch to TEST BUS 1, then to TEST BUS 2.
9. Verify FUEL INTCON caution light remains extinguished (indicating valve remained closed).
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NOTE
In the following step, monitor FUEL LOW and FUEL INTCON caution panel
segments on master caution panel. With helicopter level, FUEL INTCON segment
should illuminate and then extinguish at about the moment FUEL LOW segment
illuminates. If fuel level in upper right and upper left cells is unequal, FUEL LOW
segment may illuminate while FUEL INTCON segment remains extinguished. If
this condition occurs, additional fuel must be drained to cause AFT fuel interconnect
valve to move from closed to open.
10. Refer to Chapter 12 and drain fuel from helicopter until FUEL LOW caution panel segment illuminates.
11. Verify FUEL INTCON caution panel segment illuminates and then extinguishes (indicating valve opened
automatically in response to low fuel level condition).
12. Set FUEL INTCON switch to OVRD CLOSE.
13. Verify FUEL INTCON caution panel segment illuminates and then extinguishes (indicating valve has closed).
8. ENGINE CONTROL AND ACCESSORIES SYSTEMS - FUEL CROSSFEED VALVE

SYSTEM
8-1. FUEL CROSSFEED VALVE SYSTEM - DESCRIPTION
8-1-1. Description - helicopters code [A] [B]
The motor-operated fuel crossfeed valve (B19) or (1B10) enables interconnection or isolation of the engine No. 1 powered
from both 28 V dc essential buses through the 4-ampere FUEL XFEED circuit breakers. The valve is controlled manually
by the FUEL XFEED switch (S16) or (1A1AS8) on the engine fuel control panel (A3) or (1A1) and is controlled (opened)
automatically by a ground provided to the coil of the fuel crossfeed relay (K23) or (1A1K1) by the right forward cell flow
switch (S86) or (1Z4S1) or the left forward cell flow switch (S87) or (1Z5S1).
The fuel crossfeed valve is closed when the FUEL XFEED switch is in the normal (NORM) operating position. Loss of fuel
flow through in either of the flow switches causes the fuel crossfeed relay to actuate, thus opening the valve and allowing a
single boost pump to provided fuel to both engines. Positioning the FUEL XFEED switch to OVRD CLOSE closes the valve
after it has been opened automatically.
The system is equipped with the FUEL XEED test switch (S203) or (1A1S9) that permits testing the system on the ground.
Verification of proper operation of the fuel crossfeed valve and associated circuit is possible by monitoring the FUEL
XFEED caution panel segment. The caution panel segment should be illuminated only during valve transit.
8-1-2. Description - helicopters code [C] [D]
The motor-operated fuel crossfeed valve enables interconnection, or isolation, of engine No. 1 and engine No. 2 fuel feed
lines. The system is powered from both dc essential buses through ENGINE NO 1 FUEL XFEED and ENGINE NO 2 FUEL
XFEED circuit breakers. The valve is controlled by FUEL XFEED switch on engine and fuel control panel and is controlled
automatically (opened) when a loss of fuel pressure in either engine feed line is sensed by No. 1 fuel pressure switch (left)
or No. 2 fuel pressure switch (right).
Fuel crossfeed valve is closed when FUEL XFEED switch is in normal (NORM) operating position. Loss of fuel pressure
in either engine feed line causes fuel crossfeed relay, located in engine and fuel control panel, to actuate, thus opening the
valve and allowing a single boost pump to provide fuel to both engines. Positioning FUEL XFEED switch to OVRD CLOSE
closes the valve after it has been opened automatically.
The FUEL XFEED switch permits testing the system on the ground. Verification of proper operation of fuel crossfeed valve
and associated circuitry is possible by monitoring FUEL XFEED caution panel segment on master caution panel. Caution
panel segment should be illuminated only during valve transit.
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8-2. FUEL CROSSFEED VALVE SYSTEM - OPERATIONAL CHECK
— MASTER CAUTION
— ENGINE NO 1 FUEL XFEED
— ENGINE NO 2 FUEL XFEED
— ENGINE NO 1 FUEL BOOST
— ENGINE NO 2 FUEL BOOST
— ENG 1 FUEL PRESS
— ENG 2 FUEL PRESS
2. Verify NO. 1 FUEL BOOST and NO. 2 FUEL BOOST caution panel segments are illuminated.
3. Verify No. 1 FUEL PRESS and No. 2 FUEL PRESS indicators indicate zero or low end of dial.
4. Set FUEL XFEED switch to NORM.
5. Set ENGINE 1 BOOST PUMP and ENGINE 2 BOOST PUMP switches to ON.
6. Verify NO. 1 FUEL BOOST and NO. 2 FUEL BOOST caution panel segments extinguish.
7. Verify both fuel pressure indicators indicate normal fuel pressure.
8. Set FUEL XFEED switch to TEST BUS 1 and then to TEST BUS 2.
9. Verify there is no change in caution panel segment indications or fuel pressure indication.
11. Verify No. 1 FUEL PRESS indicator continues to indicate normal fuel pressure, indicating that fuel crossfeed valve is
open.
12. Position FUEL XFEED switch to OVRD CLOSE.
13. Verify No. 1 FUEL PRESS indicator indicates zero or low end of the dial.
14. Verify No. 2 FUEL PRESS indicator indicates normal fuel pressure.
18. Verify No. 2 FUEL PRESS indicator indicates zero or low end of dial.
19. Verify No. 1 FUEL PRESS indicator indicates normal fuel pressure.
20. Set FUEL XFEED switch to NORM.
21. Verify both fuel pressure indicators indicate normal fuel pressure, indicating fuel crossfeed valve is open.
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9. ENGINE CONTROL AND ACCESSORIES SYSTEMS - GOVERNOR RPM ACTUATOR

SYSTEM [A] [B] [C]
9-1. GOVERNOR RPM ACTUATOR SYSTEM [A] [B] [C] - DESCRIPTION
Governor rpm actuator allows engine rpm of both engines to be fine tuned over a small range centered around a value
determined by engine governors. The actuator has no effect when in MANUAL control mode. The system consists of a two
spring loaded center off, RPM loop switches, pilot and copilot, and governor rpm actuator. The circuit is powered through
the 5-ampere GOV CONT circuit breaker. When ever the pilot or copilot switch is positioned to INCR, the actuator will
retract, and RPM to increase. Positioning the switch to DECR will cause the actuator to extend and the RPM to decrease.
9-2. GOVERNOR RPM ACTUATOR SYSTEM [A] [B] [C] - OPERATIONAL CHECK
1. Close GOV/CONTR circuit breaker.
2. Set RPM INCR/DECR switch on pilot collective stick to INCR.
3. Verify governor rpm actuator retracts.
4. Set RPM INCR/DECR switch on pilot collective stick to DECR.
5. Verify governor rpm actuator extends.
6. If a copilot collective is installed repeat steps 2. through 5. with the copilot switch.
7. If a copilot collective is installed simultaneously set pilot switch to INCR and copilot switch to DECR.
8. Verify engine 2 governor actuator retracts.
9. Simultaneously set pilot switch to DECR and copilot switch to INCR.
10. Verify engine 2 governor actuator extends.
9-3. GOVERNOR RPM ACTUATOR SYSTEM [A] [B] [C] - TROUBLESHOOTING
Table 6. Governor RPM actuator system [A] [B] [C] troubleshooting
Governor actuator does not extend or retract Defective GOV CONT circuit Replace circuit breaker.
from either pilot's and copilot's position. breaker.
Defective actuator. Replace actuator.
Actuator does not operate from pilot's Defective pilot's RPM switch. Replace switch.
position only.
Actuator does not operate from copilot's Defective copilot's GOV RMP Replace switch.
position switch.
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10. ENGINE CONTROL AND ACCESSORIES SYSTEMS - GOVERNOR RPM ACTUATOR

SYSTEM [D]
10-1. GOVERNOR RPM ACTUATOR SYSTEM [D] - DESCRIPTION
Governor rpm actuator allows rpm of both engines to be fine tuned over a small range centered around a value determined
by engine governors through the use of INCR-DEC switch located on pilot and copilot collective. Engine 2 rpm actuator
allows engine 2, only, fine tuning by using +2/–2 switch, located on pilot collective.
This system consists of spring loaded, center-off, pilot rpm loop beep switch for increasing or decreasing engine rpm on both
engines simultaneously or rpm loop beep switch for increasing or decreasing engine 2 rpm only. Copilot collective contains
a spring loaded, center-off, rpm loop beep switch for increasing or decreasing engine rpm on both engines simultaneously.
10-2. GOVERNOR RPM ACTUATOR SYSTEM [D] - OPERATIONAL CHECK
1. Close GOV/CONTR circuit breaker.
2. RPM INCR/DECR switch on pilot collective stick to INCR.
3. Verify governor rpm actuator retracts.
4. Set RPM INCR/DECR switch on pilot collective stick to DECR.
6. Set +2/–2 switch on pilot collective stick to +2.
7. Verify engine 2 governor actuator retracts.
8. Set +2/–2 switch on pilot collective stick to –2.
9. Verify engine 2 governor actuator extends.
10. Repeat steps 1. through 5. for RPM INCR/DECR switch on copilot collective stick.
11. Repeat step 6. except set copilot RPM INCR/DECR switch to INCR.
11. ENGINE CONTROL AND ACCESSORIES SYSTEMS - SUMP DRAIN SYSTEM
11-1. SUMP DRAIN SYSTEM - DESCRIPTION
Sump drain valve systems enable fuel to be drained from lower main cell sumps by depressing remote switches located on
either side of fuselage.
The lower left main cell sump drain valve solenoid, located on lower left main cell sump assembly, is powered from No. 1
dc emergency bus through ENGINE NO 1 FUEL VALVE circuit breaker and is controlled by left SUMP DRAIN VALVE
1 switch located on fuselage skin.
Lower right main cell sump drain valve solenoid located on lower right main cell sump assembly, is powered from No. 2 dc
emergency bus through ENGINE NO 2 FUEL VALVE circuit breaker and is controlled by right SUMP DRAIN VALVE 2
switch located on fuselage skin.
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11-2. SUMP DRAIN SYSTEM - OPERATIONAL CHECK
3. Press left SUMP DRAIN VALVE 1 switch.
4. Verify lower left main cell sump drain valve solenoid opens.
5. Release left SUMP DRAIN VALVE 1 switch.
6. Verify lower left main cell dump drain valve closes.
8. Press left SUMP DRAIN VALVE 1 switch.
9. Verify lower left main cell sump drain valve solenoid does not open.
12. Press right SUMP DRAIN VALVE 2 switch.
13. Verify lower right main cell sump drain valve solenoid opens.
14. Release right SUMP DRAIN VALVE 2 switch.
15. Verify lower right main cell sump drain valve solenoid closes.
17. Press right SUMP DRAIN VALVE 2 switch.
18. Verify lower right main cell sump drain valve solenoid does not open.
11-3. SUMP DRAIN SYSTEM - TROUBLESHOOTING
Table 7. Sump drain system troubleshooting
FUEL VALVE circuit breakers will not reset. Defective circuit breaker(s). Replace circuit breaker.
Defective switch(es) (S41 or S42). Replace switch(es).
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(Cont.)
The sump drain valve on LH or RH fuel cell Relative push-button switch (S41 Replace push-button switch.
does not open with relative FUEL VALVE or S42) defective.
circuit breaker closed. ENGINE FUEL switch
placed to OFF and push-button switch Relative ENGINE FUEL switch Replace switch.
depressed. defective.
Relative sump drain valve (L12 or Replace valve.

L13) defective.
The lower left main all sump drain valve Defective circuit breakers. Replace circuit breakers.
solenoid (1L7) does not open with relative
ENGINE No. 1 FUEL VALVE circuit
breakers closed.
The lower right main all sump drain valve Defective circuit breakers. Replace circuit breakers.
solenoid (1L8) does not open with relative
ENGINE No. 2 FUEL VALVE circuit
breakers closed.
12. ENGINE CONTROL AND ACCESSORIES SYSTEMS - IDLE STOP RELEASE

SOLENOID SYSTEM
12-1. IDLE STOP RELEASE SOLENOID SYSTEM - DESCRIPTION
Idle stop circuits limit minimum throttle setting for each engine to flight idle during normal or ground run operations. The
solenoids receive power from 28 Vdc essential bus No. 1 through IDLE STOP circuit breaker. When pilot IDLE STOP
switch is placed in ENG 1 or ENG 2 position, engine No. 1 or engine No. 2 idle stop solenoid causes the stop to retract. This
allows throttle to be actuated further toward OFF position, thus slowing or stopping engine No. 1 or engine No. 2,
respectively. Time delay relays keep solenoid energized for 5 seconds after switch is released.
12-2. IDLE STOP RELEASE SOLENOID SYSTEM - OPERATIONAL CHECK
1. Close IDLE STOP circuit breaker.
2. Press IDLE STOP switch on pilot collective stick to ENG 1.
3. Check idle stop 1 solenoid retracts, then after approximately 5 seconds, extends again.
4. Press IDLE STOP switch on pilot collective stick to ENG 2.
5. Check idle stop 2 solenoid retracts, then after approximately 5 seconds, extends again.
6. Repeat steps 1. through 5. for IDLE STOP switch on copilot collective.
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12-3. IDLE STOP RELEASE SOLENOID SYSTEM - TROUBLESHOOTING
Table 8. Idle stop release solenoid system troubleshooting
Engine No. 1 and engine No. 2 idle stops do Defective IDLE STOP circuit Replace circuit breaker.
not retract when IDLE STOP REL switch is breaker.
positioned to ENG 1 and ENG 2, respectively.
Defective IDLE STOP REL Replace switch.
switch.
Defective time delay relay (K15 or Replace relay.

K16) or (1K3 or 1K4).
Engine No. 1 idle stop does not retract when Defective IDLE STOP switch. Replace switch.
IDLE STOP REL switch is positioned to ENG
1. Defective engine No. 1 idle stop Replace relay.
relay (K15) or (1K3).
Defective engine No. 1 idle stop Replace solenoid.

solenoid (L5) or (1L5).
Engine No. 1 idle stop does not extend in Defective engine No. 1 idle stop Replace relay.
approximately 5 seconds after IDLE STOP relay (K15) or (1K3).
REL switch is released from ENG 1 position.
Defective idle stop solenoid (L5) Replace solenoid.
or (1L5).
Engine No. 2 idle stop does not retract when Defective IDLE STOP switch. Replace switch.
IDLE STOP REL switch positioned to ENG
2. Defective engine No. 2 idle stop Replace relay.
relay (K16) or (1K4).
Defective engine No. 2 idle stop Replace solenoid.

solenoid (L6) or (1L6).
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(Cont.)
Engine No. 2 idle stop does not extend in Defective engine No. 2 idle stop Replace relay.
approximately 5 seconds after IDLE STOP relay (K16) or (1K4).
REL switch is released from ENG 2 position.
Defective idle stop solenoid (L6) Replace solenoid.
or (1L6).
13. ENGINE CONTROL AND ACCESSORIES SYSTEMS - ENGINE PARTICLE

SEPARATOR SYSTEM
13-1. ENGINE PARTICLE SEPARATOR SYSTEM - DESCRIPTION
This system provides a means of filtering intake air so that foreign objects will be prevented from entering engines. The
system consists of engine No. 1 and No. 2 particle separator, engine No. 1 and No. 2 particle separator actuators, No. 1 and
No. 2, particle separator 1 and 2 relays, and ENG 1 PART SEP OFF and ENG 2 PART SEP OFF caution lights. Particle
separator actuators are energized from essential dc buses via ENGINE NO 1 PART SEP and ENGINE NO 2 PART SEP
circuit breakers. Control of particle separator actuators is accomplished by signals from RPM LIMIT DETECTOR which
extend engine No. 1 and engine No. 2 particle separator actuators and illuminate ENG 1 PART SEP OFF and ENG 2 PART
SEP OFF caution lights. When engines are operating at flight idle speed or above, particle separator control relays are
deenergized, enabling engine No. 1 and No. 2 particle separator actuators to retract and extinguish ENG 1 PART SEP OFF
and ENG 2 PART SEP OFF caution lights. FIRE 1 PULL handle switch and FIRE 2 PULL handle switch override the above
control when energized. Pulling either fire pull handle extends corresponding particle separator actuator and illuminates
corresponding caution light.
13-2. ENGINE PARTICLE SEPARATOR SYSTEM - OPERATIONAL CHECK
WARNING

(REFER TO FIGURE 1).
1. Check engine No. 1 particle separator as follows:
a. Open ENG 1 RPM circuit breaker.
b. Close MASTER CAUTION and ENGINE NO 1 PART SEP circuit breakers.
c. Check engine No. 1 air particle separator opens.
d. Check ENG 1 PART SEP OFF caution light extinguishes.
e. Pull FIRE 1 PULL handle switch.
f. Check engine No. 1 air particle separator closes.
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g. Check ENG 1 PART SEP OFF caution light illuminates.
h. Push FIRE 1 PULL handle switch in.
i. Check engine No. 1 air particle separator opens.
j. Check ENG 1 PART SEP OFF caution light extinguishes.
k. Close ENG 1 RPM circuit breaker.
l. Check No. 1 air particle separator closes.
m. Check ENG 1 PART SEP OFF caution light illuminates.
n. Set ENGINE 1 PART SEP switch to OVRD ON.
o. Check air particle separator opens.
p. Check ENG 1 PART SEP OFF caution light extinguishes.
q. Set ENGINE 1 PART SEP switch to NORM.
r. Check No. 1 air particle separator closes.
s. Check ENG 1 PART SEP OFF caution light illuminates.
2. For helicopters codes [A] [B], check engine No. 2 particle separator by repeating Engine No. 1 particle separator tests
except use ENG 2 PART SEP circuit breaker in lieu of ENG 1 PART SEP circuit breaker, ENG 2 PART SEP OFF
caution light in lieu of ENG 1 PART SEP OFF caution light, and FIRE 2 PULL handle in lieu of FIRE 1 PULL handle.
For helicopters codes [C] [D], check engine No. 2 particle separator by repeating engine No. 1 particle separator tests
except use ENGINE NO 2 PAR SEP circuit breaker in lieu of ENGINE NO 1 PART SEP circuit breaker, ENGINE 2
PART SEP OFF caution light in lieu of FIRE 2 PULL handle switch in lieu of FIRE 2 PULL handle switch in lieu of
FIRE 1 PULL handle switch, ENG 2 RPM circuit breaker in lieu of ENG 1 RPM circuit breaker, and ENG 2 PART
SEP switch in lieu of ENG 1 PART SEP switch.
13-3. ENGINE PARTICLE SEPARATOR SYSTEM - TROUBLESHOOTING
Table 9. Engine particle separator system troubleshooting
Engine No. 1 particle separator actuator fails Defective engine No. 1 particle Replace relay.
to retract, engine No. 1 operating. separator control relay (K27) or
(1K6).
Defective FIRE 1 PULL handle Replace switch.

switch.
RPM warning box defective. Replace unit.
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(Cont.)
Defective ENG 1 PART SEP Replace circuit breaker.

circuit breaker.
Defective ENG 1 PART SEP Replace switch.

switch.
Engine No. 1 particle separator actuators fails Defective engine No. 1 particle Replace actuator.
to extend. separator actuator.

switch.
Engine No. 2 particle separator actuators fails Defective engine No. 2 particle Replace relay.
to retract engine No. 2 operating. separator control relay (K26) or
(1K5).
Defective FIRE 2 PULL handle Replace switch.

switch.
RPM warning box defective. Replace unit.

switch.
Defective ENG 2 PART SEP Replace circuit breaker.

circuit breaker.
Engine No. 2 particle separator actuator fails Defective engine No. 2 particle Replace actuator.
to extend. separator actuator.

switch.
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96-73-01
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CHAPTER 97 - AVIONICS

Module Page
Number Title Number
97-00-00 AVIONIC SYSTEMS
1. Avionic systems - description ................................................................................................................. 1

2. Avionic systems - visual inspection ........................................................................................................ 1
3. Avionic systems - cleaning procedures for electronic equipments ......................................................... 2
4. Avionic systems - repair or replacement criteria .................................................................................... 2
5. Avionic systems - voltage measurements................................................................................................ 3
6. Avionic systems - continuity testing ....................................................................................................... 3
7. Avionic systems - general repair techniques .......................................................................................... 4
8. Avionic systems - safety wiring .............................................................................................................. 4
9. Avionic systems - energization of DC and AC buses for the operational check procedures ................. 4
97-20-01 INTERCOMMUNICATION SYSTEM (ICS) AG-06-1(A)
1. Intercommunication system (ICS) AG-06-1(A) - description and operation ......................................... 1

2. Intercommunication system (ICS) AG-06-1(A) - operational check ..................................................... 1
3. Intercommunication system (ICS) AG-06-1(A) - troubleshooting ......................................................... 3
4. Intercommunication system (ICS) AG-06-1(A) - general maintenance.................................................. 4
5. Intercommunication system (ICS) AG-06-1(A) - ICS control panels .................................................... 4
5-1. ICS control panels - removal ......................................................................................................... 4
5-2. ICS control panels - installation .................................................................................................... 4
5-3. ICS control panels - inspection ...................................................................................................... 4
5-4. ICS control panels - repair or replacement .................................................................................... 4
6. Intercommunication system (ICS) AG-06-1(A) - headsets ..................................................................... 5
7. Intercommunication system (ICS) AG-06-1(A) - pilot and copilot ICS/RADIO keying switches ........ 5
7-1. Pilot and copilot ICS/radio keying switches - removal ................................................................. 5
7-2. Pilot and copilot ICS/radio keying switches - installation ............................................................. 5
7-3. Pilot and copilot ICS/radio keying switches - inspection .............................................................. 5
7-4. Pilot and copilot ICS/radio keying switches - repair or replacement ............................................ 5
97-20-02 VHF/AM RADIO SET ART-151
1. VHF/AM radio set ART-151 - description and operation ...................................................................... 1

2. VHF/AM radio set ART-151 - operational check .................................................................................. 1
3. VHF/AM radio set ART-151 - troubleshooting ..................................................................................... 6
4. VHF/AM radio set ART-151 - general maintenance .............................................................................. 6
5. VHF/AM radio set ART-151 - VHF communication antenna ................................................................ 7
5-1. VHF communication antenna - removal ........................................................................................ 7
5-2. VHF communication antenna - installation ................................................................................... 7
5-3. VHF communication antenna - inspection .................................................................................... 7
5-4. VHF communication antenna - repair or replacement ................................................................... 7
6. VHF/AM radio set ART-151 - VHF/AM receiver-transmitter .............................................................. 7
6-1. VHF/AM receiver-Transmitter - removal ...................................................................................... 7
6-2. VHF/AM receiver-Transmitter - installation ................................................................................. 7
6-3. VHF/AM receiver-Transmitter - inspection .................................................................................. 8
6-4. VHF/AM receiver-Transmitter - repair or replacement ................................................................ 8
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Module Page
Number Title Number
7. VHF/AM radio set ART-151 - VHF/AM control unit ............................................................................8

7-1. VHF/AM control unit - removal ....................................................................................................8
7-2. VHF/AM control unit - installation ................................................................................................8
7-3. VHF/AM control unit - inspection .................................................................................................8
7-4. VHF/AM control unit - repair or replacement ...............................................................................8
97-20-03 GYROCOMPASS SYSTEM AN/ASN-75
1. Gyrocompass system AN/ASN-75 - description ....................................................................................1

2. Gyrocompass system AN/ASN-75 - operational check ..........................................................................1
3. Gyrocompass system AN/ASN-75 - troubleshooting .............................................................................5
4. Gyrocompass system AN/ASN-75 - compensation ................................................................................6
4-1. Compensation - index error adjustment .........................................................................................6
4-2. Compensation - single-cycle error compensator adjustment .........................................................7
5. Gyrocompass system AN/ASN-75 - general maintenance ....................................................................7
6. Gyrocompass system AN/ASN-75 - directional gyro and amplifier ......................................................8
6-1. Directional gyro and amplifier - removal .......................................................................................8
6-2. Directional gyro and amplifier - installation ..................................................................................8
6-3. Directional gyro and amplifier - inspection ...................................................................................8
6-4. Directional gyro and amplifier - repair or replacement ..................................................................8
7. Gyrocompass system AN/ASN-75 - synchro amplifier ..........................................................................8
7-1. Synchro amplifier - removal ..........................................................................................................8
7-2. Synchro amplifier - installation.......................................................................................................9
7-3. Synchro amplifier - inspection .......................................................................................................9
7-4. Synchro amplifier - repair or replacement .....................................................................................9
8. Gyrocompass system AN/ASN-75 - compass transmitter ......................................................................9
8-1. Compass transmitter - removal ......................................................................................................9
8-2. Compass transmitter - installation ..................................................................................................9
8-3. Compass transmitter - inspection ..................................................................................................10
8-4. Compass transmitter - repair or replacement ...............................................................................10
9. Gyrocompass system AN/ASN-75 - remote compensator ....................................................................10
9-1. Remote compensator - removal ....................................................................................................10
9-2. Remote compensator - installation ...............................................................................................10
9-3. Remote compensator - inspection ................................................................................................10
9-4. Remote compensator - repair or replacement ..............................................................................10
10. Gyrocompass system AN/ASN-75 - control panel ...............................................................................10
10-1. Control panel - removal ................................................................................................................10
10-2. Control panel - installation ...........................................................................................................11
10-3. control panel - inspection .............................................................................................................11
10-4. Control panel - repair or replacement ..........................................................................................11
11. Gyrocompass system AN/ASN-75 - indicator (HSI) ............................................................................12
97-20-04 VHF/UHF AM-FM COMMUNICATION SYSTEM (ARC-182) SET 1
1. VHF/UHF AM-FM communication system (ARC-182) set 1 - description ..........................................1

2. VHF/UHF AM-FM communication system (ARC-182) set 1 - maintenance ........................................1
3. VHF/UHF AM-FM communication system (ARC-182) set 1 - VHF/UHF communication antenna ....1
3-1. VHF/UHF communication antenna - removal ...............................................................................1
3-2. VHF/UHF communication antenna - installation ..........................................................................1
3-3. VHF/UHF communication antenna - inspection.............................................................................2
3-4. VHF/UHF communication antenna - repair or replacement ..........................................................2
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Module Page
Number Title Number
4. VHF/UHF AM-FM communication system (ARC-182) set 1 - transceiver .......................................... 2

4-1. Transceiver - removal .................................................................................................................... 2
4-2. Transceiver - installation ............................................................................................................... 2
4-3. Transceiver - inspection ................................................................................................................. 2
4-4. Transceiver - repair or replacement ............................................................................................... 2
5. VHF/UHF AM-FM communication system (ARC-182) set 1 - homing antenna ................................... 5
5-1. Homing antenna - removal ............................................................................................................ 5
5-2. Homing antenna - installation ........................................................................................................ 5
6. VHF/UHF AM-FM communication system (ARC-182) set 1 - control panel ....................................... 5
6-1. Control panel - removal ................................................................................................................. 5
6-2. Control panel - installation ............................................................................................................ 5
6-3. Control panel - inspection............................................................................................................... 6
6-4. Control panel - repair or replacement ............................................................................................ 6
1. VHF/UHF AM-FM communication system (ARC-182) SET 2 - description ........................................ 1

2. VHF/UHF AM-FM communication system (ARC-182) SET 2 - general maintenance ......................... 1
3. VHF/UHF AM-FM communication system (ARC-182) SET 2 - VHF/UHF communication
antenna ..................................................................................................................................................... 1
3-1. VHF/UHF communication antenna - removal .............................................................................. 1
3-2. VHF/UHF communication antenna - installation .......................................................................... 1
3-3. VHF/UHF communication antenna - inspection ............................................................................ 2
3-4. VHF/UHF communication antenna - repair or replacement ......................................................... 2
4. VHF/UHF AM-FM communication system (ARC-182) SET 2 - homing antenna ............................... 2
4-1. Homing antenna - removal ............................................................................................................ 2
4-2. Homing antenna - installation ........................................................................................................ 2
4-3. Homing antenna - inspection ......................................................................................................... 2
4-4. Homing antenna - repair or replacement ........................................................................................ 3
5. VHF/UHF AM-FM communication system (ARC-182) SET 2 - transmitter-receiver .......................... 3
5-1. Transmitter-receiver - removal ...................................................................................................... 3
5-2. Transmitter-receiver - inspection ................................................................................................... 3
5-3. Transmitter-receiver - repair or replacement ................................................................................. 3
5-4. Transmitter-receiver - installation ................................................................................................. 3
6. VHF/UHF AM-FM communication system (ARC-182) SET 2 - course softener ................................. 3
6-1. Course softener - removal .............................................................................................................. 3
6-2. Course softener - installation .......................................................................................................... 4
7. VHF/UHF AM-FM communication system (ARC-182) SET 2 - control panel .................................... 4
7-1. Control panel - removal ................................................................................................................. 4
7-2. Control panel - installation ............................................................................................................ 4
7-3. Control panel - inspection .............................................................................................................. 4
7-4. Control panel - repair or replacement ............................................................................................ 4
8. VHF/UHF AM-FM communication system (ARC-182) SET 2 - course indicator ............................... 4
97-20-06 HF SYSTEM ARC-174 (718U-5)
1. HF System ARC-174 (718U-5) - description and operation .................................................................. 1

2. HF System ARC-174 (718U-5) - operational check ............................................................................... 2
3. HF System ARC-174 (718U-5) - troubleshooting .................................................................................. 5
4. HF System ARC-174 (718U-5) - general maintenance .......................................................................... 6
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Module Page
Number Title Number
5. HF System ARC-174 (718U-5) - HF communication antenna ...............................................................6

5-1. HF communication antenna - removal ...........................................................................................6
5-2. HF communication antenna - installation ......................................................................................7
5-3. HF communication antenna - inspection ........................................................................................7
5-4. HF communication antenna - repair or replacement ......................................................................7
6. HF System ARC-174 (718U-5) - HF power amplifier/coupler ..............................................................7
6-1. HF power amplifier/coupler - removal ...........................................................................................7
6-2. HF power amplifier/coupler - installation ......................................................................................8
6-3. HF power amplifier/coupler - inspection .......................................................................................8
6-4. HF power amplifier/coupler - repair or replacement .....................................................................8
7. HF System ARC-174 (718U-5) - HF receiver-exciter ............................................................................8
7-1. HF receiver-exciter - removal ........................................................................................................8
7-2. HF receiver-exciter - installation ....................................................................................................8
7-3. HF receiver-exciter - inspection .....................................................................................................8
7-4. HF receiver-exciter - repair or replacement ...................................................................................9
8. HF System ARC-174 (718U-5) - HF control unit ...................................................................................9
8-1. HF control unit - removal ...............................................................................................................9
8-2. HF control unit - installation ..........................................................................................................9
8-3. HF control unit - inspection ...........................................................................................................9
8-4. HF control unit - repair or replacement ..........................................................................................9
8-5. HF control unit - renewal of RF TEST lamp bulb .........................................................................9
97-20-07 AUTOMATIC DIRECTION FINDER (ADF-60A)
1. Automatic direction finder (ADF-60A) - description and operation ......................................................1

2. Automatic direction finder (ADF-60A) - operational check....................................................................4
3. Automatic direction finder (ADF-60A) - troubleshooting ......................................................................4
4. Automatic direction finder (ADF-60A) - general maintenance ..............................................................5
5. Automatic direction finder (ADF-60A) - control panel ..........................................................................5
5-3. Control panel - inspection ..............................................................................................................5
5-4. Control panel - repair or replacement ............................................................................................5
6. Automatic direction finder (ADF-60A) - receiver ..................................................................................7
6-1. Receiver - removal .........................................................................................................................7
6-2. Receiver - installation .....................................................................................................................7
6-3. Receiver - inspection ......................................................................................................................7
6-4. Receiver - repair or replacement ....................................................................................................7
7. Automatic direction finder (ADF-60A) - antenna ...................................................................................7
7-1. Antenna - removal ..........................................................................................................................7
7-2. Antenna - installation .....................................................................................................................7
7-3. Antenna - inspection........................................................................................................................8
7-4. Antenna - repair or replacement .....................................................................................................8
97-20-08 VOR/LOC/MB/GS SYSTEM ARN-126 (VIR-31A)
1. VOR/LOC/MB/GS system ARN-126 (VIR-31A) - description and operation ......................................1

2. VOR/LOC/MB/GS system ARN-126 (VIR-31A) - operational check ..................................................2
3. VOR/LOC/MB/GS system ARN-126 (VIR-31A) - troubleshooting ......................................................5
4. VOR/LOC/MB/GS system ARN-126 (VIR-31A) - general maintenance...............................................6
97-Index
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E-AB412-PT6T-2

Module Page
Number Title Number
5. VOR/LOC/MB/GS system ARN-126 (VIR-31A) - VOR receiver ........................................................ 6

5-1. VOR receiver - removal ................................................................................................................. 6
5-2. VOR receiver - installation ............................................................................................................ 6
5-3. VOR receiver - inspection ............................................................................................................. 6
5-4. VOR receiver - repair or replacement ............................................................................................ 6
6. VOR/LOC/MB/GS system ARN-126 (VIR-31A) - VOR control unit .................................................. 6
6-1. VOR control unit - removal ........................................................................................................... 6
6-2. VOR control unit - installation ...................................................................................................... 7
6-3. VOR control unit - inspection ........................................................................................................ 7
6-4. VOR control unit - repair or replacement ...................................................................................... 7
7. VOR/LOC/MB/GS system ARN-126 (VIR-31A) - VOR antenna ........................................................ 7
7-1. VOR antenna - removal ................................................................................................................. 7
7-2. VOR antenna - installation ............................................................................................................ 7
7-3. VOR antenna - inspection .............................................................................................................. 7
7-4. VOR antenna - repair or replacement ............................................................................................ 7
8. VOR/LOC/MB/GS system ARN-126 (VIR-31A) - HSI indicator ......................................................... 8
9. VOR/LOC/MB/GS system ARN-126 (VIR-31A) - MKR beacon control unit ..................................... 8
9-1. MKR beacon control unit - removal .............................................................................................. 8
9-2. MKR beacon control unit - installation ......................................................................................... 8
9-3. MKR beacon control unit - inspection ........................................................................................... 8
9-4. MKR beacon control unit - repair or replacement ......................................................................... 8
10. VOR/LOC/MB/GS system ARN-126 (VIR-31A) - MKR beacon antenna .......................................... 10
10-1. MKR beacon antenna - removal .................................................................................................. 10
10-2. MKR beacon antenna - installation ............................................................................................. 10
10-3. MKR beacon antenna - inspection ............................................................................................... 10
10-4. MKR beacon antenna - repair or replacement ............................................................................. 10
11. VOR/LOC/MB/GS system ARN-126 (VIR-31A) - GS antenna .......................................................... 10
11-1. GS antenna - removal .................................................................................................................. 10
11-2. GS antenna - installation .............................................................................................................. 10
11-3. GS antenna - inspection ................................................................................................................ 11
11-4. GS antenna - repair or replacement ............................................................................................. 11
97-20-09 RADAR ALTIMETER SYSTEM AN/APN-198(V)
1. Radar altimeter system AN/APN-198(V) - description and operation ................................................... 1

2. Radar altimeter system AN/APN-198(V) - operational check ................................................................ 5
3. Radar altimeter system AN/APN-198(V) - troubleshooting .................................................................. 5
4. Radar altimeter system AN/APN-198(V) - general maintenance .......................................................... 6
5. Radar altimeter system AN/APN-198(V) - transmit and receive antennas ............................................ 6
5-1. Transmit and receive antennas - removal ....................................................................................... 7
5-2. Transmit and receive antennas - installation ................................................................................. 7
5-3. Transmit and receive antennas - inspection ................................................................................... 7
5-4. Transmit and receive antennas - repair or replacement ................................................................. 7
6. Radar altimeter system AN/APN-198(V) - altimeter transmitter-receiver ............................................. 7
6-1. Altimeter transmitter-Receiver - removal ...................................................................................... 7
6-2. Altimeter transmitter-Receiver - installation ................................................................................. 7
6-3. Altimeter transmitter-Receiver - inspection ................................................................................... 8
6-4. Altimeter transmitter-Receiver - repair or replacement ................................................................. 8
7. Radar altimeter system AN/APN-198(V) - zero altitude calibration ..................................................... 8
8. Radar altimeter system AN/APN-198(V) - pilot and copilot radar altimeter indicators ........................ 8
9. Radar altimeter system AN/APN-198(V) - low altitude warning lamp replacement.............................. 9
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Module Page
Number Title Number
97-20-10 TACAN SYSTEM (TCN-40)
1. Tacan system (TCN-40) - description and operation ..............................................................................1

2. Tacan system (TCN-40) - operational check ..........................................................................................1
3. Tacan system (TCN-40) - troubleshooting ..............................................................................................3
4. Tacan system (TCN-40) - general maintenance ......................................................................................3
5. Tacan system (TCN-40) - receiver-transmitter .......................................................................................3
5-1. Receiver-transmitter - removal .......................................................................................................3
5-2. Receiver-transmitter - installation ..................................................................................................3
6. Tacan system (TCN-40) - bearing adapter ..............................................................................................4
6-1. Bearing adapter - removal ..............................................................................................................4
6-2. Bearing adapter - installation .........................................................................................................4
7. Tacan system (TCN-40) - antenna ..........................................................................................................4
7-1. Antenna - removal ..........................................................................................................................4
7-2. Antenna - installation .....................................................................................................................4
8. Tacan system (TCN-40) - control panel...................................................................................................7
9. Tacan system (TCN-40) - DME indicator ...............................................................................................7
97-20-11 IFF SYSTEM (SIT-421A)
1. IFF System (SIT-421A) - description and operation ..............................................................................1

2. IFF System (SIT-421A) - general maintenance ......................................................................................1
3. IFF System (SIT-421A) - IFF antennas ..................................................................................................1
3-1. IFF antennas - removal ...................................................................................................................1
3-2. IFF antennas - installation ...............................................................................................................2
3-3. IFF antennas - inspection ...............................................................................................................2
3-4. IFF antennas - repair or replacement ..............................................................................................2
4. IFF System (SIT-421A) -IFF receiver-transmitter and control unit .......................................................2
4-1. IFF receiver-transmitter and control unit - removal .......................................................................2
4-2. IFF receiver-transmitter and control unit - installation ..................................................................2
4-3. IFF receiver-transmitter and control unit - inspection ...................................................................2
4-4. IFF receiver-transmitter and control unit - repair or replacement ..................................................2
5. IFF System (SIT-421A) -IFF computer ...................................................................................................5
5-1. IFF computer - removal ..................................................................................................................5
5-2. IFF computer - installation .............................................................................................................5
5-3. IFF computer - inspection ..............................................................................................................5
5-4. IFF computer - repair or replacement ............................................................................................5
6. IFF System (SIT-421A) - altimeter encoder indicator ............................................................................5
97-20-12 DOPPLER NAVIGATION SYSTEM (AN/APN-208V/CMA-708C)
1. Doppler navigation system (AN/APN-208V/CMA-708C) - description and operation .........................1

2. Doppler navigation system (AN/APN-208V/CMA-708C) - operational check .....................................1
3. Doppler navigation system (AN/APN-208V/CMA-708C) - troubleshooting ........................................1
4. Doppler navigation system (AN/APN-208V/CMA-708C) - general maintenance .................................1
5. Doppler navigation system (AN/APN-208V/CMA-708C) - doppler radar transmitter-receiver ............3
5-1. Doppler radar transmitter-receiver - removal .................................................................................3
5-2. Doppler radar transmitter-receiver - installation ............................................................................3
5-3. Doppler radar transmitter-receiver - inspection .............................................................................3
5-4. Doppler radar transmitter-receiver - repair or replacement ...........................................................3
97-Index
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Module Page
Number Title Number
6. Doppler navigation system (AN/APN-208V/CMA-708C) - doppler radar signal data converter ......... 4
6-1. Doppler radar signal data converter - removal .............................................................................. 4
6-2. Doppler radar signal data converter - installation .......................................................................... 4
6-3. Doppler radar signal data converter - inspection ........................................................................... 4
6-4. Doppler radar signal data converter - repair or replacement ......................................................... 4
7. Doppler navigation system (AN/APN-208V/CMA-708C) - control display unit .................................. 4
7-1. Control display unit - removal ....................................................................................................... 4
7-2. Control display unit - installation .................................................................................................. 4
7-3. Control display unit - inspection..................................................................................................... 5
7-4. Control display unit - repair or replacement .................................................................................. 5
8. Doppler navigation system (AN/APN-208V/CMA-708C) - power supply unit .................................... 5
8-1. Power supply unit - removal .......................................................................................................... 5
8-2. Power supply unit - installation ..................................................................................................... 5
8-3. Power supply unit - inspection ...................................................................................................... 5
8-4. Power supply unit - repair or replacement ..................................................................................... 5
9. Doppler navigation system (AN/APN-208V/CMA-708C) - pilot steering indicator ............................. 7
97-20-13 WEATHER RADAR SYSTEM (RDR-1400)
1. Weather radar system (RDR-1400) - description and operation ............................................................ 1

2. Weather radar system (RDR-1400) - testing ........................................................................................... 4
3. Weather radar system (RDR-1400) - troubleshooting ............................................................................ 6
4. Weather radar system (RDR-1400) - general maintenance ..................................................................... 8
5. Weather radar system (RDR-1400) - display unit .................................................................................. 8
5-1. Display unit - removal ................................................................................................................. 10
5-2. Display unit - installation ............................................................................................................. 10
6. Weather radar system (RDR-1400) - display unit support .................................................................... 12
6-1. Display unit support - removal .................................................................................................... 12
6-2. Display unit support - installation ................................................................................................ 12
7. Weather radar system (RDR-1400) - transmitter-receiver ................................................................... 12
7-1. Transmitter-Receiver - removal ................................................................................................... 12
7-2. Transmitter-Receiver - installation .............................................................................................. 12
8. Weather radar system (RDR-1400) - scanner........................................................................................ 13
8-1. Scanner - removal ........................................................................................................................ 13
8-2. Scanner - installation ................................................................................................................... 13
9. Weather radar system (RDR-1400) - waveguide .................................................................................. 13
9-1. Waveguide - removal ................................................................................................................... 13
9-2. Waveguide - installation .............................................................................................................. 14
97-20-14 FLIGHT DIRECTOR
1. Flight director - description .................................................................................................................... 1

2. Flight director - operational check........................................................................................................... 3
3. Flight director - troubleshooting ............................................................................................................. 3
4. Flight director - general maintenance ..................................................................................................... 3
5. Flight director - flight director computer ................................................................................................ 3
5-1. Flight director computer - removal ................................................................................................ 3
5-2. Flight director computer - installation ........................................................................................... 3
6. Flight director - mode selector................................................................................................................. 4
6-1. Mode selector - removal ................................................................................................................ 4
6-2. Mode selector - installation ........................................................................................................... 4
6-3. Mode selector - lamps replacement ............................................................................................... 4
97-Index
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Module Page
Number Title Number
7. Flight director - altitude sensor ...............................................................................................................4

7-1. Altitude sensor - removal ...............................................................................................................4
7-2. Altitude sensor - installation ..........................................................................................................4
8. Flight director - airspeed sensor ...............................................................................................................6
8-1. Airspeed sensor - removal ..............................................................................................................6
8-2. Airspeed sensor - installation .........................................................................................................6
97-20-15 EMERGENCY LOCATOR TRANSMITTER (ELT C406-2HM)
1. Emergency locator transmitter (ELT C406-2HM) - description..............................................................1

2. Emergency locator transmitter (ELT C406-2HM) - removal procedures................................................1
2-1. Antenna - removal...........................................................................................................................1
2-2. Remove switch - removal................................................................................................................1
2-3. Transmitter - removal......................................................................................................................2
2-4. Battery pack - removal ....................................................................................................................2
3. Emergency locator transmitter (ELT C406-2HM) - removal procedures................................................2
3-1. Antenna - installation ......................................................................................................................2
3-2. Remote switch - installation............................................................................................................3
3-4. Transmitter - installation .................................................................................................................3
3-5. Battery pack - installation ...............................................................................................................3
4. Emergency locator transmitter (ELT C406-2HM) - inspection ...............................................................3
4-1. Antenna - inspection........................................................................................................................3
4-2. Remote switch - inspection .............................................................................................................3
4-3. Transmitter - inspection ..................................................................................................................4
4-4. Battery pack - inspection.................................................................................................................4
5. Emergency locator transmitter (ELT C406-2HM) - repair or replacement .............................................4
5-1. Antenna - repair or replacement......................................................................................................4
5-2. Remote switch - repair or replacement ...........................................................................................4
5-3. Transmitter - repair or replacement.................................................................................................4
5-4. Battery pack - repair or replacement ...............................................................................................4
6. Emergency locator transmitter (ELT C406-2HM) - cleaning ..................................................................4
7. Emergency locator transmitter (ELT C406-2HM) - functional test.........................................................5
97-21-01 NAVIGATION INSTRUMENTS - STANDBY MAGNETIC COMPASS
1. Standby magnetic compass - description ................................................................................................1

2. Standby magnetic compass - removal .....................................................................................................1
3. Standby magnetic compass - installation ................................................................................................1
4. Standby magnetic compass - inspection ..................................................................................................1
5. Standby magnetic compass - calibration (with compass rose) ................................................................1
5-1. Calibration (with compass rose) - compass swing-initial setup .....................................................1
5-2. Calibration (with compass rose) - index error check .....................................................................2
5-3. Calibration (with compass rose) - cycle error check ......................................................................2
6. standby magnetic compass -calibration (with compass tool) ..................................................................2
6-1. calibration (with compass tool) - preliminary operations ..............................................................2
6-2. calibration (with compass tool) - procedure ...................................................................................3
7. standby magnetic compass - calibration (with gyrocompass/ahrs) .........................................................5
8. Standby magnetic compass - troubleshooting .........................................................................................5
97-22-01 AUTOMATIC FLIGHT CONTROL SYSTEM
1. Automatic flight control system - description .........................................................................................1
97-Index
Page 8 Rev. 2
E-AB412-PT6T-2

Module Page
Number Title Number
97-23-01 FLIGHT INSTRUMENTS - VG14H VERTICAL GYRO
1. VG14H vertical gyro - description ......................................................................................................... 1

2. VG14H vertical gyro - removal .............................................................................................................. 1
3. VG14H vertical gyro - installation ......................................................................................................... 1
4. VG14H vertical gyro - inspection ........................................................................................................... 1
5. VG14H vertical gyro - cleaning............................................................................................................... 2
6. VG14H vertical gyro - repair or replacement ......................................................................................... 2
97-23-02 FLIGHT INSTRUMENTS - ATTITUDE DIRECTOR INDICATOR (ADI)
1. Attitude director indicator (ADI) - description ....................................................................................... 1
97-30-00 AVIONICS SYSTEM - WIRING DIAGRAMS
1. Wiring diagrams - description ................................................................................................................. 1

2. Wiring diagrams - use of underlined capital letters ................................................................................. 1
97-Index
Rev. 2 Page 9
E-AB412-PT6T-2
FIGURES
Figure Page
Number Title Number
Figure 1. Avionics installation (sheet 1 of 2) .................................................................................................................6

Figure 2. ICS system AG-06-1 (A) - block diagram ......................................................................................................8
Figure 3. ICS control panels ...........................................................................................................................................9

Figure 2. VHF/AM-151 - block diagram........................................................................................................................4
Figure 3. VHF/AM radio set control panel (141-1788-01) ............................................................................................5

Figure 2. Gyrocompass system (AN/ASN-75) - block diagram ....................................................................................5
Figure 3. Control panel (2586047-( )) ..........................................................................................................................11
Figure 4. Indicator (HSI) 111302-5..............................................................................................................................12
Figure 1. VHF/UHF AM-FM communication system (ARC-182) equipment location SET 1 .....................................3
Figure 2. VHF/UHF AM-FM communication system (ARC-182) SET 1 - block diagram ..........................................4
Figure 1. VHF/UHF AM-FM communication system (ARC-182) equipment location SET 2 .....................................5
Figure 2. VHF/UHF AM-FM communication system (ARC-182) SET 2 - block diagram ..........................................6
Figure 3. Course indicator (5205160006).......................................................................................................................7
97-20-06 HF SYSTEM ARC-174 (718U-5)
Figure 1. HF system ARC-174 (718U-5) equipment location .......................................................................................3

Figure 2. HF system - block diagram .............................................................................................................................4
Figure 3. HF system control panel (514A-4)..................................................................................................................4
Figure 1. ADF-60A system equipment location.............................................................................................................2

Figure 2. ADF system - block diagram ..........................................................................................................................3
Figure 3. ADF control unit 614L-12 ..............................................................................................................................6
Figure 1. VOR system (VIR-31A) equipment location..................................................................................................3

Figure 2. VOR/LOC/GS/MB (AN/ARN-126) system - block diagram.........................................................................4
Figure 3. Control unit VOR/LOC (313N-4D) ................................................................................................................9
Figure 4. Control panel NAV TEST & MB ...................................................................................................................9
97-Index
Page 10 Rev. 2
E-AB412-PT6T-2
FIGURES (CONT.D)
Figure Page
Number Title Number
Figure 1. Radar altimeter system AN/APN-198(V) equipment location....................................................................... 2

Figure 2. Radar altimeter system - block diagram ......................................................................................................... 3
Figure 3. Radar altimeter indicator (13ID1001-1) ......................................................................................................... 4
97-20-10 TACAN SYSTEM (TCN-40)
Figure 1. Tacan system (TCN-40) equipment location.................................................................................................. 5

Figure 2. Tacan system - block diagram ........................................................................................................................ 6
Figure 3. DME indicator (IND-41) ................................................................................................................................ 7
Figure 4. Tacan control unit (378N-2) ........................................................................................................................... 8
97-20-11 IFF SYSTEM (SIT-421A)
Figure 1. IFF system (SIT-421A) equipment location................................................................................................... 3

Figure 2. IFF system - block diagram ............................................................................................................................ 4
Figure 3. IFF system receiver-transmitter and control panel (S7261-W4001-A3)........................................................ 4
Figure 4. Altimeter encoder indicator (B45152-10-013) ............................................................................................... 6
Figure 1. Radar doppler AN/APN-208(V) with navigation computer CMA-708C equipment location....................... 2
Figure 2. Doppler sensor with navigation computer system - block diagram ............................................................... 3
Figure 3. Control display unit (C9392C/APN-208(V)) ................................................................................................. 6
Figure 4. Pilot steering indicator (ID-1905C/APN-208(V)) .......................................................................................... 6
97-20-14 FLIGHT DIRECTOR
Figure 1. Flight director equipment location ................................................................................................................. 2

Figure 2. Mode selector (MS-702)................................................................................................................................. 5
97-20-15 EMERGENCY LOCATOR TRANSMITTER (ELT C406-2HM)
Figure 1. Emergency locator transmitter (ELT C406-2HM) ......................................................................................... 6

Figure 2. ELT battery pack ............................................................................................................................................ 7
Figure 1. Standby magnetic compass calibration........................................................................................................... 6

Figure 2. Compass correction card ................................................................................................................................ 7
97-Index
Rev. 2 Page 11
E-AB412-PT6T-2
MODULES/FIGURES
Module/Figure Page
Number Title Number
97-30-01
Figure 1. ICS (AG-06-1(A)) system...............................................................................................................................1
97-30-02
Figure 1. VHF/AM (ART-151) communication system ................................................................................................1
97-30-03
Figure 1. Gyrocompass (AN/ASN-75) system...............................................................................................................1
97-30-04
Figure 1. VHF/UHF AM-FM communication system (ARC-182, Set 1)......................................................................1
97-30-05
Figure 1. VHF/UHF AM-FM communication system (ARC-182, Set 2)......................................................................1
97-30-06
Figure 1. HF system ARC-174 (718U-5) .......................................................................................................................1
97-30-07
Figure 1. Automatic direction finder (ADF-60A) ..........................................................................................................1
97-30-08
Figure 1. VOR/LOC/MB/GS system ARN-126 (VIR-31A) ..........................................................................................1
97-30-09
Figure 1. Radar altimeter system (AN/APN-198) ..........................................................................................................1
97-30-10
Figure 1. Tacan system (TCN-40)..................................................................................................................................1
97-30-11
Figure 1. IFF system (SIT-421A) ...................................................................................................................................1
97-30-12
Figure 1. Doppler navigation system AN/APN-208(V) with navigation computer CMA-708C...................................1
97-30-13
Figure 1. Weather radar system (RDR-1400).................................................................................................................1
97-30-14
Figure 1. Flight director system [A] [B] (sheet 1 of 4)...................................................................................................1
97-30-15
Figure 1. Flight director system [C] [D] (sheet 1 of 7)...................................................................................................1
97-30-16
Figure 1. HSI indicators (sheet 1 of 2) ...........................................................................................................................1
97-30-17
Figure 1. Emergency locator transmitter (ELT C406-2HM)..........................................................................................1
97-Index
Page 12 Rev. 2
E-AB412-PT6T-2
MODULES/FIGURES (CONT.D)
Module/Figure Page
Number Title Number
97-30-18
Figure 1. ADI-STBY battery segnalator ........................................................................................................................ 1
97-Index
Rev. 2 Page 13
E-AB412-PT6T-2
TABLES
Table Page
Number Title Number
Table 1. Intercommunication system (ICS) AG-06-1-(A) troubleshooting..................................................................3
Table 1. VHF/AM radio set ART-151 troubleshooting ................................................................................................6
Table 1. Gyrocompass system AN/ASN-75 troubleshooting .......................................................................................5
97-20-06 HF SYSTEM ARC-174 (718U-5)
Table 1. Hf system ARC-174 (718U-5) troubleshooting..............................................................................................5
Table 1. Automatic direction finder (ADF-60A) troubleshooting ................................................................................4
Table 1. VOR/LOC/MB/GS system ARN-126 (VIR-31A) troubleshooting................................................................5
Table 1. Radar altimeter system AN/APN-198(V) troubleshooting .............................................................................5
Table 1. Pilot steering indicator functions ....................................................................................................................7
97-20-13 WEATHER RADAR SYSTEM (RDR-1400)
Table 1. Weather radar system troubleshooting............................................................................................................6

Table 2. .Display unit operating controls ......................................................................................................................8
Table 1. Magnetic compass deviation, A coefficient ....................................................................................................4

Table 2. Magnetic compass, B and C coefficients ........................................................................................................4
Table 3. Standby magnetic compass - troubleshooting.................................................................................................5
97-Index
Page 14 Rev. 2
E-AB412-PT6T-2
97-0 -0 AVIONIC SYSTEMS
97-00-00
AVIONIC SYSTEMS
1. AVIONIC SYSTEMS - DESCRIPTION
The avionics communication and navigation systems installed in the model 412 helicopter consist of the following:
Nomenclature Type
Intercommunication system (ICS) AG-06-1(A)
VHF-AM communications system ART-151
Gyromagnetic compass system AN/ASN-75
The following avionic systems can also be installed on the model 412 helicopter:
Nomenclature Type
VHF/UHF, AN-FM Comm. system ARC-182, Set 1 & 2
HF system ARC-174 (718U-5)
Automatic direction finder ADF-60A
VOR/LOC/MB/GS system ARN-126 (VIR-31A)
Radar altimeter AN/APN-198
Tacan system TCN-40
IFF system SIT-421A
Doppler navigation system AN/APN/208V/CMA-708C
Weather radar system RDR-1400
Flight director
AFCS
2. AVIONIC SYSTEMS - VISUAL INSPECTION
Inspect all the avionic equipment and the avionic installation equipment for dirt and corrosion. All surfaces should be free
of dirt, grease and fungus. All avionic equipment and avionic installation equipment shall be inspected for security, and shall
be secured only by the methods described in this section
97-00-00
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E-AB412-PT6T-2
3. AVIONIC SYSTEMS - CLEANING PROCEDURES FOR ELECTRONIC EQUIPMENTS
The general cleaning procedure for electronic equipment is as follows:
1. Remove moisture, dust and loose dirt with a clean, soft cloth.
WARNING
CLEANING COMPOUND IS FLAMMABLE AND ITS FUMES ARE TOXIC.

PROVIDE ADEQUATE VENTILATION. DO NOT USE NEAR A FLAME.
2. Remove grease, fungus, and ground-in dirt from the avionic equipment cases and mountings: use a damp cloth
moistened (not wet) with cleaning compound.
4. AVIONIC SYSTEMS - REPAIR OR REPLACEMENT CRITERIA
Before performing the Operational Check procedures for an avionic system, visually inspect or check that the units and
components of the avionic system are free from ”defects”. If any of the following conditions exist on the components or
equipment, make the necessary repairs or replace.
1. The term ”defect” applies to the following conditions:
— Connectors with corroded, loose or bent pins.
— Connectors with broken safety wire.
— Frayed or broken insulation or conductors or interconnecting cabling.
— Faulty circuit breakers which will not remain closed when inserted under normal load conditions. Switches
(rotary, sliding, tumbler, push-pull) with loose mounting, weak position detents or intermittent circuit
connections.
— Panels with poor legibility of switch and selector setting markings or defective lighting. Loose knobs on control
panels.
— Burned or discoloured panel lights.
— Faulty ICS Junction Box printed - circuit board (cracked or corroded printed-circuit board: intermittent or loose
connector: loose mounting).
— Burned, discoloured, corroded, cracked or broken components of the ICS Junction Box.
— Relays with dented, cracked or corroded connectors. Relays which are loose in the receptacle or mounting or
make an intermittent connection when lightly tapped by hand or a small insulated object. Loose terminal boards
and components with defective mounting: components that are cracked, dented, chipped, discoloured from
overload or open circuit including resistors, diodes and capacitors.
2. The term “damage” applies to the following conditions:
— Broken connectors, terminal boards and conductors: corroded, dented, cracked or broken equipment and/or
mountings.
— Corroded, dented, cracked or broken antennas and/or mountings.
97-00-00
Page 2
E-AB412-PT6T-2
5. AVIONIC SYSTEMS - VOLTAGE MEASUREMENTS
Follow the procedure outlined below for a logical approach to voltage measurements.
NOTE
Make certain that the multimeter is correctly connected. Select the applicable
voltage range for the most accurate reading to match the value given on the
respective avionic system circuit diagram
1. Perform AC and DC voltage measurements where applicable if the units and airframe components of the respective
avionic system do not allow a satisfactory Operational Check to be carried out.
2. Check the primary input voltage on the load side of the appropriate circuit breaker as shown in the avionic system
circuit diagram.
6. AVIONIC SYSTEMS - CONTINUITY TESTING
Ensure that all supply voltages are removed from the system under investigation. Carry out impedance measurements using
a multimeter set to the resistance ranges. Apply the continuity trace technique to localize defects in connectors, conductors,
terminal boards, diodes, resistors, capacitors, transistors, relays, inductors, switches, selectors and units, where possible. For
a logical approach to the analysis of faults. When checking airframe conductors and components within an avionic system,
follow the following suggested sequence:
NOTE
Apply continuity trace techniques after faulty component(s) and/ or unit(s) are
suspected during the Operational Check of the avionic system. The fault may be
apparent from unsatisfactory operation in a particular mode, abnormal voltage,
abnormal signal levels or from equipment substitution.
NOTE
With certain component and/or equipment faults it may be necessary to make
voltage measurements and/or use continuity trace techniques to locate the fault.
1. Analyze the respective avionic system circuit diagram for airframe inter-unit conductor paths (single, parallel and
series): consider resistors, diodes and relay holding coils etc. which may after the sum total resistance of individual
conductor paths.
NOTE
Check that the multimeter movement is free and that the meter will zero on all
ranges.
NOTE
In performing resistance measurements, select the multimeter range to give the most
accurate reading of the inter-unit conductor path, conductor, resistor, diode, relay
holding coil, transistor or capacitor.
2. Check the continuity and resistance of the individual conductors within the inter-unit cable forms.
3. Check the continuity and resistance of the individual conductors for abnormal conductivity with respect to the adjacent
conductors, conductor shield and earth.
4. Check resistors for correct values.
97-00-00
Page 3
E-AB412-PT6T-2
5. Check diodes for forward and reverse resistance ratio.
6. Check capacitors for stowage factor. (Deflection of multimeter pointer and rate of return to zero).
7. AVIONIC SYSTEMS - GENERAL REPAIR TECHNIQUES
The general techniques for repairs are as follows:
1. Repair of avionic systems consists in general of the removal of a defective unit and replacement from maintenance
stocks. When removal and replacement of a unit or other repair procedures require performing repairs on the airframe,
aircraft engine controls or other items that directly affect the flight of the aircraft, the repair effort must be performed
by, or coordinated with, the pilot of the helicopter.
2. When a troubleshooting procedure indicates a defective unit, follow the applicable removal procedures given in the
respective section. Replace the unit with a known serviceable unit. After the unit has been replaced, install safety
wiring on the mounting hardware and electrical connectors.
CAUTION
ENSURE THAT THE BATT SWITCH IS SET TO OFF AND EXTERNAL

POWER SOURCE IS DISCONNECTED BEFORE ATTEMPTING THE
REMOVAL AND REPLACEMENT PROCEDURES. IF THIS IS NOT
POSSIBLE, OPEN THE APPROPRIATE CIRCUIT BREAKER. WHEN A
PUSHPULL CIRCUIT BREAKER IS OPENED, INSTALL A CLIP TO PREVENT
THE CIRCUIT BREAKER BEING RESET.
8. AVIONIC SYSTEMS - SAFETY WIRING
Mounting hardware and electrical connectors for the individual units must be secured with safety wire to prevent the
hardware or connectors becoming loose during normal operation. Tighten the mounting hardware and install the safety wire
in such a way that loosening of the hardware will cause the safety wire to tighten. Use new safety wire and take care not to
kink the wire.
Use steel, corrosion-resistant wire with the ”double twist” method for mounting hardware and electrical connectors of all
units in the avionics systems. For complete safety wiring practices, refer to Appendix I.
9. AVIONIC SYSTEMS - ENERGIZATION OF DC AND AC BUSES FOR THE

OPERATIONAL CHECK PROCEDURES
When using a DC External Power Source to perform the operational check procedures in the following paragraphs, insert
the DC Circuit Breakers listed below to energize the DC and AC System of the helicopter.
— NO. 1 ESSENTIAL BUS FEEDERS (4)
— NO. 2 ESSENTIAL BUS FEEDERS (4)
— GEN RESET 1
— GEN RESET 2
— MASTER CAUTION
— AC CONT.
97-00-00
Page 4
E-AB412-PT6T-2
97-20-01
INTERCOMMUNICATION SYSTEM (ICS) AG-06-1(A)
1. INTERCOMMUNICATION SYSTEM (ICS) AG-06-1(A) - DESCRIPTION AND

OPERATION
NOTE
See module 97-30-01 for the Interphone System wiring diagram. See figure 1 for
location of the Interphone System components and figure 2 for system block
diagram.
The Interphone Communication System (ICS) provides communication between pilots and between pilots and passenger as
well as the selection and control of associated navigation and communication equipment.
The ICS includes four Control Panels; the pilot's and copilot's Control Panels located on the Pedestal and the passenger
Control Panels located in the passenger cabin. Power is supplied by the + 28V DC System via the ICS PLT, CPLT and
CABIN Circuit Breakers.
Each ICS Control Panel carries the following controls:

— Mixing switches, for the selection of audio lines (COM 1, COM 2).
— HOT MIC switch for hot microphone function.
— ICS VOLume knob to adjust ICS audio level.
— RCVR VOLume Knob to adjust receiver audio level.
The ICS/RADIO switches located on cyclic stick grip provide interphone transmission and radio transmission. Two foot
switches are located adjacent to the pilot and copilot's seats and are used to provide hand free operation of the radio
transmitters.
A HOT MIC switch on each audio control panel provides hand free operation of the interphone function.
Signals received by the navigation and communication equipment are directed to the ICS Control Panels, where signal
selection is made and volume is controlled, and then directed to the headsets.
In the case of internal communication, signals from a station where ICS has been selected pass via the associated ICS Control
Panel to the other stations where they may be selected and monitored. During radio transmission, signals pass from the
microphone to the selected transmitter via the Control Panel.
2. INTERCOMMUNICATION SYSTEM (ICS) AG-06-1(A) - OPERATIONAL CHECK
Visually inspect the intercommunication equipment, interconnecting cabling and connectors for damage and security.
Connect an external power source adjusted to 28 V DC to the helicopter external power receptacle.
NOTE
Ascertain that transmitters are set to authorized frequencies.
97-20-01
Page 1
E-AB412-PT6T-2
1. Test procedure. Preliminary steps:
a. Apply power to ICS controls by closing INTERCOM PILOT, INTERCOM CABIN, INTERCOM COPLT
circuit breakers.
b. Apply power to all associated systems, called out on mixing switches, by closing respective circuit breakers.
Observe that control lamps illuminate.
c. Allow three minutes warm-up period of the system, including all associated receivers and transmitters.
2. Control positions.
Initially set controls and switches at each station as follows:
Control Position
RCVRS - VOL Midrange
VOL - ICS Midrange
Mixing Switches All down
Rotary Selector Switch Fully clockwise
HOT MIC Switch Down (OFF)
3. Hot MIC Test. Proceed as follows:
a. Set HOT MIC toggle switch on pilot's control panel to up (on) position.
b. Without keying, talk into microphone. Sidetone should be heard in the pilot's headset and a received audio should
be heard in the headset at the other stations.
c. Repeat steps a. and b. at the other stations.
d. Place all HOT MIC switches in the down (off) position.
4. Intercom Test. Proceed as follows:
a. Key pilot's cyclic stick switch to the ICS position and speak into microphone. Sidetone should be heard in pilot's
headset and a received audio should be heard in headsets at the other stations.
b. Key copilot's cyclic switch and speak into microphone. Sidetone should be heard in copilot's headset and a
received audio should be heard in headsets at the other stations.
c. Key pilot's and copilot's foot switches one at a time and speak into microphone. Sidetone should be heard in
pilot's and copilot's headsets and a received audio should be heard in headsets at the stations.
d. Key crew push-to-talk switches one at a time and speak into microphone. Sidetone should be heard in crew
headset and a received audio should be heard in headsets at the other stations.
e. Rotation of the VOL-ICS volume control on the pilot's ICS control panel should vary the pilot's headset volume.
f. Repeat step e. for the other control stations.
5. Transmit Position Checks. Perform following steps:
a. Set all mixing switches on pilot's control panel to the down position and set volume control (RCVRS-VOL) to
mid-position. Set pilot's rotary selector switch to the HF position, press pilot's cyclic stick switch to RADIO
(second position) and speak into microphone. The selected transmitter should be operational and sidetone should
be audible in the headset. Release keying switch.
97-20-01
Page 2
E-AB412-PT6T-2
b. Repeat step a. with rotary selector switch on pilot's control panel selected to positions COM 1 and COM 2.
c. Repeat steps a. and b. for copilot's station.
d. Repeat steps a. and b. for each crew station using the appropriate keying switch and with ICS - RADIO switch
in RADIO position.
3. INTERCOMMUNICATION SYSTEM (ICS) AG-06-1(A) - TROUBLESHOOTING
Table 1. Intercommunication system (ICS) AG-06-1-(A) troubleshooting
NOTE
It is assumed that the appropriate circuit breakers are closed.
No audio signals in any headset. Power supply system defective. Refer to Chapter 96.
No audio signals in one headset. Defective headset. Substitute headset if defective.
Defective wiring. Replace or repair wires.
ICS control panel defective. Replace ICS control panel if

defective.
Impossible to communicate from any station. Power supply system defective. Refer to Chapter 96.
Impossible to communicate from one pilot's Radio/ICS cyclic stick switch Replace switch if defective.
station or passenger's station when RADIO/ defective.
ICS cyclic stick switch or footswitch is
pressed. Foot switch defective. Replace footswitch if defective.
Microphone defective. Replace microphone if defective.
Defective wiring. Replace or repair wires.
ICS control panel defective. Replace ICS control panel if

defective.
97-20-01
Page 3
E-AB412-PT6T-2
4. INTERCOMMUNICATION SYSTEM (ICS) AG-06-1(A) - GENERAL MAINTENANCE
CAUTION
REVERSAL OF THE POLARITY OF THE SUPPLY VOLTAGE MAY DAMAGE

THE ICS CONTROL PANELS.
CAUTION
ENSURE THAT ALL ELECTRICAL POWER IS OFF PRIOR TO PERFORMING

THE FOLLOWING MAINTENANCE PROCEDURES.
5. INTERCOMMUNICATION SYSTEM (ICS) AG-06-1(A) - ICS CONTROL PANELS
The pilot's and copilot's ICS control panel are installed on the pedestal. The crew ICS control panels are installed on supports
on the cabin ceiling.
NOTE
The maintenance procedure for the four ICS control panels is identical.
5-1. ICS CONTROL PANELS - REMOVAL
1. Disengage the four Dzus fasteners and pull ICS control panel away from mounting.
2. Disconnect rear electrical connector and remove ICS control panel.
5-2. ICS CONTROL PANELS - INSTALLATION
1. Place ICS control panel in position and connect electrical connector.
2. Secure ICS control panel by engaging the four Dzus fasteners.
5-3. ICS CONTROL PANELS - INSPECTION
Visually inspect the ICS control panel for the following defects:
1. Physical damage to the case, front panel or plastic panel.
2. Binding or loose controls: loose or faulty switches.
3. Damaged connector or corroded connector receptacle: bent or broken connector pins.
5-4. ICS CONTROL PANELS - REPAIR OR REPLACEMENT
Replace the ICS control panel if inspection criteria are not met.
97-20-01
Page 4
E-AB412-PT6T-2
6. INTERCOMMUNICATION SYSTEM (ICS) AG-06-1(A) - HEADSETS
Maintenance information for the Pilot's, Copilot's, and crew headsets is obtained by reference to the Manufacturer’s
Maintenance Manual.
7. INTERCOMMUNICATION SYSTEM (ICS) AG-06-1(A) - PILOT AND COPILOT ICS/

RADIO KEYING SWITCHES
The pilot and copilot ICS/RADIO keying switches are installed on the pilot's and copilot's cyclic stick grips.
7-1. PILOT AND COPILOT ICS/RADIO KEYING SWITCHES - REMOVAL
1. Remove the screw which secures the ICS/RADIO Keying Switch to the cyclic stick grip.
2. Slide the ICS/RADIO Keying Switch out of the cyclic stick grip and unsolder the electrical connections.
7-2. PILOT AND COPILOT ICS/RADIO KEYING SWITCHES - INSTALLATION
1. Position the ICS/RADIO keying switch and solder electrical connections.
2. Slide ICS/RADIO keying switch into the cyclic stick grip and secure with screws.
7-3. PILOT AND COPILOT ICS/RADIO KEYING SWITCHES - INSPECTION
Visually inspect the ICS/RADIO keying switch for the following defects:
1. Physical damage.
2. Loose or faulty switching action.
3. Bent or broken terminals.
7-4. PILOT AND COPILOT ICS/RADIO KEYING SWITCHES - REPAIR OR REPLACEMENT
Replace the ICS/RADIO keying switch if any of the inspection defects exist.
97-20-01
Page 5
E-AB412-PT6T-2
G6AB0861A
Figure 1. Avionics installation (sheet 1 of 2)
97-20-01
Page 6
E-AB412-PT6T-2
G6AB0862A
97-20-01
Page 7
E-AB412-PT6T-2
G6AB0863A
Figure 2. ICS system AG-06-1 (A) - block diagram
97-20-01
Page 8
E-AB412-PT6T-2
G6AB0864A
Figure 3. ICS control panels
97-20-01
Page 9
E-AB412-PT6T-2
97-20-01
Page 10
E-AB412-PT6T-2
97-20-02
VHF/AM RADIO SET ART-151
1. VHF/AM RADIO SET ART-151 - DESCRIPTION AND OPERATION
NOTE
See module 97-30-02 for VHF/AM system wiring diagram. See figure 1 for location
of the units of the VHF/AM System in the helicopter and figure 2 for system block
diagram.
The VHF Radio Set is used for voice communication between aircraft, and between aircraft and fixed or mobile ground
stations.
The VHF Radio Set provides transmission and reception of amplitude-modulated (AM) signals within the very
high-frequency (VHF) range of 116.000 through 155.975 MHz on any of its 1599 channels spaced 25 KHz apart.
The VHF Radio Set is powered by 28 V DC and protected by VHF COMM circuit breaker.
To allow a quick check of the transceiver, a B.I.T.E (built in test equipment) module has been provided.
The transceiver provides three main operating control functions selectable by acting on the related rotary switch located in
the control unit which are:
— B.I.T.E. (out-test)
— Transmission-Reception
— Data Transmission-Reception
The control panel is located on the control pedestal and is secured in position by four dzus fasteners. The control panel
contains a lamp assembly (behind the front panel), a power switch, a volume control, two frequency selector controls and a
test push button.
All the electrical connections are made thru a connector at the rear of the control panel.
2. VHF/AM RADIO SET ART-151 - OPERATIONAL CHECK
Visually inspect the radio system installation, interconnecting wiring and connectors for damage and security.Connect an
external power source of 28 V DC to the helicopter external power receptacle.
1. Close VHF COMM circuit breaker.
2. Set OFF/PWR switch to PWR position. The indicator dials should glow.
3. Set VHF COMM frequency selectors on the control unit to a frequency at which no signal is heard in headset. Press
COMM TEST switch. Background noise will be heard in headset.
4. Set VHF COMM frequency selectors to control tower frequency and contact control tower for a COMM check.
Control tower should receive a clear and audible transmission, and reception from tower should be clear and audible.
5. Set VOL control to a desired audio level when receiving tower transmission. VOL control on the control unit varies
the audio level.
6. Set OFF/PWR switch to OFF position. Indicator dials shall not glow.
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Figure 2. VHF/AM-151 - block diagram
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Figure 3. VHF/AM radio set control panel (141-1788-01)
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3. VHF/AM RADIO SET ART-151 - TROUBLESHOOTING
Table 1. VHF/AM radio set ART-151 troubleshooting
Indicator lights do not glow. Defective radio control unit. Replace radio control unit.
No rushing noise heard in headset. Defective receiver-transmitter. Replace receiver-transmitter.
No communication signal present in either Defective receiver circuits in Replace receiver-transmitter.

headset when selector switch on ICS control receiver-transmitter.
panels is in position VHF 1 and VHF 1 toggle
switch is in up position. Defective ICS control panel. Replace defective ICS control
panel.
Weak transmission to all ground stations. Defective transmitter circuits in Replace receiver-transmitter.
receiver-transmitter.
No communications to any station from only Defective amplifier circuits in Replace defective ICS control
one operator's position. associated ICS control panel. panel.
No communications established with any Defective transmitter power Replace receiver-transmitter.

ground station. switching relay.
Defective antenna. Replace antenna.
No sidetone signals heard in headset of Defective selector switch on Replace defective ICS control
headset-microphone when pilot's or copilot's associated ICS control panel. panel.
radio cyclic stick switch is pressed, or foot
switch is depressed. Defective cyclic stick switch. Replace defective switch.
Defective VHF COMM circuit Replace circuit breaker.

breaker.
No RF power output. Defective or incorrect cable Check cable connections.

connections.
4. VHF/AM RADIO SET ART-151 - GENERAL MAINTENANCE
CAUTION
ENSURE ALL ELECTRICAL POWER IS OFF PRIOR TO PERFORMING

REMOVAL OR INSTALLATION PROCEDURES.
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5. VHF/AM RADIO SET ART-151 - VHF COMMUNICATION ANTENNA
The VHF communication antenna is installed on the cabin roof.
5-1. VHF COMMUNICATION ANTENNA - REMOVAL
1. Remove screws that secure communication antenna to mounting plate on helicopter.
2. Lift communication antenna, and disconnect antenna cable connector from receptacle in its base.
5-2. VHF COMMUNICATION ANTENNA - INSTALLATION
1. Connect antenna cable connector to receptacle in antenna base.
2. Position communication antenna on its mounting plate and secure with screws.
5-3. VHF COMMUNICATION ANTENNA - INSPECTION
Visually inspect the VHF communication antenna for the following defects:
1. Damage to the VHF communication antenna.
2. Damaged connector, corroded or broken connector receptacle; bent or broken connector pins.
5-4. VHF COMMUNICATION ANTENNA - REPAIR OR REPLACEMENT
Replace the VHF communication antenna if inspection criteria are not met.
6. VHF/AM RADIO SET ART-151 - VHF/AM RECEIVER-TRANSMITTER
The VHF/AM receiver-transmitter is installed on a shockmount in the helicopter nose compartment.
6-1. VHF/AM RECEIVER-TRANSMITTER - REMOVAL
1. Loosen the knurled retainer nuts on the front of the mount until the hold down hooks can be slipped off the lugs on the
front of the receiver-transmitter.
2. Disconnect the electrical connector.
3. Slide the RT unit out of its mount.
6-2. VHF/AM RECEIVER-TRANSMITTER - INSTALLATION
1. Place RT unit on mount and push toward rear until connector on rear of receiver-transmitter mates with receptacle in
mount.
2. Connect the electrical connector.
3. Connect hold down hooks to lugs on front of RT unit and tighten knurled retainer nuts on front of mount.
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6-3. VHF/AM RECEIVER-TRANSMITTER - INSPECTION
Inspect the VHF/AM receiver-transmitter for the following conditions:
1. Physical damage to case or shockmount.
6-4. VHF/AM RECEIVER-TRANSMITTER - REPAIR OR REPLACEMENT
Replace the VHF/AM receiver-transmitter if inspection criteria are not met.
7. VHF/AM RADIO SET ART-151 - VHF/AM CONTROL UNIT
The VHF/AM control unit (figure 3) is installed on the pedestal.
7-1. VHF/AM CONTROL UNIT - REMOVAL
1. Loosen the Dzus fasteners that secure control panel to bracket assembly.
2. Lift panel far enough from the bracket assembly to reach and disconnect electrical cable from unit.
3. Lift control panel free of mounting.
7-2. VHF/AM CONTROL UNIT - INSTALLATION
1. Connect electrical cable to control panel.
2. Secure unit to mounting with the Dzus fasteners.
7-3. VHF/AM CONTROL UNIT - INSPECTION
Inspect the VHF/AM control unit for the following defects:
1. Physical damage to the case, control panel or plastic panel.
2. Binding loose or faulty switches.
3. Damaged connector or corroded connector receptacle, bent or broken connector pins.
7-4. VHF/AM CONTROL UNIT - REPAIR OR REPLACEMENT
Replace the VHF/AM control unit if inspection criteria are not met.
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97-20-03
GYROCOMPASS SYSTEM AN/ASN-75
1. GYROCOMPASS SYSTEM AN/ASN-75 - DESCRIPTION
NOTE
See module 97-30-03 for gyrocompass system wiring diagram. See figure 1 for
location of the units of the gyrocompass system in the helicopter and figure 2 for
system block diagram.
The gyrocompass system provides to the pilots the helicopter magnetic heading indication. The system is composed of two
indicators (HSI), a compass transmitter, a remote compensator, a directional gyro and amplifier, a synchro amplifier and a
control panel. The indicators (HSI), figure 9-8, are installed on the instrument panel and present the signals supplied by the
system. The rotating scale shows the heading with respect to the fixed reference index. The indicators are powered by 26
and 115 V AC, thru the COURSE HSI (2), PILOT HSI, and CPLT HSI circuit breakers. The compass transmitter is located
in the tailboom and is provided to survey the force lines of the earth magnetic field. The remote compensator, secured close
to the transmitter, compensates the foreign magnetic fields that can affect the transmitter. The directional gyro senses the
helicopter heading while the amplifier and the synchro amplifier provide a proper amplitude of the heading signal in order
to drive the indicator instrument. The base of the directional gyro is provided with a knob for the latitude correction. By
positioning this knob on the local latitude value the apparent procession of the gyro caused by the earth rotation is rectified.
The correction must be positive or negative for the northern or southern hemisphere. This selection is performed by actuating
the switch placed besides the latitude correction knob. The synchro amplifier and the directional gyro and amplifier are
located on the helicopter nose lower compartment.
The control panel is located on the central pedestal LH side (figure 3); it is provided with a COMPASS DG/MAG switch, a
synchronizing knob, and a synchronizing warning indicator. The COMPASS DG/MAG switch selects the operating mode
of the system; gyroscope slaved to earth magnetic field thru the transmitter (MAG) or free gyroscope (DG).
The system normally operates with slaved gyroscope (MAG) and will be switched into DG at the extreme latitudes, where,
the lines of force of the earth magnetic field do not give reliable bearings.
The synchronizing knob is used to line-up the gyroscope to the direction of the force lines surveyed by the transmitter; it
must be rotated to the direction shown by the synchronizing warning indicator. The gyrocompass system is powered by 115
V AC and is protected by the GYRO CMPS circuit breaker.
2. GYROCOMPASS SYSTEM AN/ASN-75 - OPERATIONAL CHECK
1. Set COMPASS DG-MAG switch to MAG position (down).
2. Connect an external power source adjusted to 28 V DC to the helicopter external power receptacle.
3. Engine 115 V AC and 26 V AC bus.
4. Energize the system by closing GYRO CMPS, COURSE HSI (2), PILOT HSI and CPLT HSI circuit breakers.
5. Ensure that OFF flag on the indicators disappears.
6. Synchronize the system by turning the synchronizing knob in the direction indicated by the warning eight until the
index of the warning indicator returns to center position.
7. When the system is synchronized, the indication on the pilot's HSI must coincide with the known magnetic heading
towards the helicopter is oriented.
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8. Observe the magnetic heading of the system, as shown on the pilot's HSI and note that the copilot's HSI displays a
heading 2° of the pilot's HSI.
NOTE
Unless the helicopter engine is running, each indicator should be tapped lightly
before indication is read.
9. Turn the synchronizing knob until heading indication is 10° greater than indicated in step g.
Watch synchronizing warning indicator to see that correct indication dot (.) appears.
10. Synchronize the system and observe heading indication. Also observe that HSI rotate smoothly.
11. Turn the synchronizing knob until heading indication is 10° less than indicated in step j.
Watch synchronizing warning indicator to see that correct indication cross (+) appears. Observe indicator for sufficient
period of time to see that indication of instruments return to original values.
12. Place COMPASS switch to DG position. With any previous synchronizing condition the indication on the warning
indicator must return and remain to center position.
13. Position LATITUDE knob, located at the base of the directional gyro, on the local latitude value. Position LATITUDE
switch to N if the helicopter operates in northern emisphere, to S if operates in southern emisphere.
14. Rotate the synchronizing knob until the indicator dial is positioned to the known heading. The indication of the
warning indicator must remain in center position.
15. Ascertain that the indicator panel lights illuminate when instrument lighting is turned on.
16. Disengage the circuit breakers. Ascertain that OFF flag is visible on the HSI.
17. Disconnect the 28 V DC external power source from the helicopter.
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Figure 2. Gyrocompass system (AN/ASN-75) - block diagram
3. GYROCOMPASS SYSTEM AN/ASN-75 - TROUBLESHOOTING
Table 1. Gyrocompass system AN/ASN-75 troubleshooting
OFF flag of one HSI does not disappear. Defective HSI. Substitute HSI.
Off flag of both HSI does not disappear. GYRO CMPS circuit breaker Replace circuit breaker.
defective.
Defective circuits in directional Replace directional gyro.

gyro.
Synchronizing indicator does not give Defective circuits in directional Replace directional gyro.
indication. gyro.
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(Cont.)
Defective synchronizing indicator. Replace control panel.
HSI rotating card does not move while Defective HSI. Replace HSI.
synchronizing indicator operates correctly.
Defective amplifier. Replace amplifier.
Synchronizing indicator does not remain in Defective COMPASS DG/MAG Replace switch.
center position. switch.
Defective circuits in directional Replace directional gyro.

gyro.
4. GYROCOMPASS SYSTEM AN/ASN-75 - COMPENSATION
When an adjustment of the gyrocompass system is required, perform the following procedure:
CAUTION
FOR AN ACCURATE COMPENSATION THE FOLLOWING PRECAUTIONS

MUST BE FOLLOWED.
1. The helicopter shall be positioned at least 100 m (30 ft) away from cars, steel constructions, other helicopters or
magnetic fields in general.
2. The tools used for compensation shall be of non-magnetic material.
3. Personnel engaged in operation shall not carry steel tools or devices.
4. The helicopter shall be placed in an area without ferrous materials and magnetic fields, such as underground pipes and
electrical cables.
5. All equipments normally installed on the helicopter and that can produce magnetic effects shall be set in flight altitude.
4-1. COMPENSATION - INDEX ERROR ADJUSTMENT
NOTE
Ground swinging can generally be considered satisfactory for most types of aircraft.
Unless it is found that for a particular type of aircraft the engine operation affects the
indication of the transmitter, the engines do not need running during the adjustment.
In this case, the proper excitation voltage is supplied by means of an auxiliary power
source.
1. Place the Slaved Gyro Magnetic Compass in operation and allow several minutes for the gyro to come up to speed and
”slave” to magnetic north.
2. Set the aircraft on the compass rose and rotate it to each of the four cardinal headings. Record the differences in
readings as plus or minus, depending on whether the readings are greater or less than the correct headings. Allow
sufficient time for the dial to settle out at each heading before taking the readings.
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NOTE
Instead of the compass rose, a magnetic sighting compass may be used. To take a
reading, the compass is located at a considerable distance forward or aft of the
aircraft and is moved back and forth from the line of sight coinciding with the fore
and aft (longitudinal) axis of the plane. When a sight is taken facing aft, 180°t must
be added or substracted from the sighting compass reading. When facing forward,
the compass reads directly.
3. Add the errors algebrically and divide by four. The result is the index error. Loosen the screws holding the transmitter
flange to its mounting surface and rotate the flange of the unit to cancel out the index error. If the error is positive, the
flange should be rotated in the minus (-) or counterclockwise direction, as observed from above the unit. If the error
is negative, rotate the flange in the positive (+) or clockwise direction. The amount of rotation should be equal the
index error.
4. Tighten the mounting screws and recheck the readings at the four cardinal headings. Recalculate the index error to
make sure it is zero. If it is not zero, readjust the transmitter flange until this error is cancelled. Any remaining errors
in excess of ± 1 ° are caused by extraneous magnetic influences and should be counteracted by using single-cycle
compensating.
4-2. COMPENSATION - SINGLE-CYCLE ERROR COMPENSATOR ADJUSTMENT
1. Set the single-cycle error compensator to the neutral position by lining up the two dots, one on each adjusting shaft
and one on the case adjacent to each shaft.
2. To remove the single-cycle error, perform the following steps: place the aircraft on a north heading (0°) (if it is not
already on that heading). Correct for all the error at this heading by turning the north-south adjusting shaft on the
transmitter compensator until the slaved gyro magnetic compass reading changes by an amount equal to the error at
this heading, but in the apposite direction. The correction must be made to within ± 0.5°.
3. Turn the aircraft to an east heading (90°). Correct for all the errors at this heading by turning the east-west adjusting
shaft until the slaved gyro magnetic compass reading changes an amount equal to the error at this heading, but in the
opposite direction. The correction must be made to within ± 0.5°.
4. Position the aircraft on a south heading (180°). Take out half the error, if any, with the north-south adjusting shaft by
observing the reading on the Slaved Gyro Magnetic Compass. The correction must be made to within ± 0.5°.
5. Place the aircraft on a west heading (270°). Take out half the error, if any, with the east-west adjusting shaft by
observing the reading on the Slaved Gyro Magnetic Compass. The correction must be made to within ± 0.5°.
6. As a check, swing the aircraft on 30° increments and note the readings. All readings should be within ± 1.0 of the
magnetic heading. If the errors noted are not tolerable, repeat the Index Error and Single-Cycle Error Compensator
Adjustment procedures.
5. GYROCOMPASS SYSTEM AN/ASN-75 - GENERAL MAINTENANCE
CAUTION
ENSURE ALL ELECTRICAL POWER IS OFF PRIOR TO PERFORMING THE

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6. GYROCOMPASS SYSTEM AN/ASN-75 - DIRECTIONAL GYRO AND AMPLIFIER
The directional gyro is installed on a support on the lower shelf of the nose compartment.
6-1. DIRECTIONAL GYRO AND AMPLIFIER - REMOVAL
1. Disconnect connector from directional gyro.
2. Remove securing screws and remove directional gyro.
CAUTION
BE VERY CAREFUL WHEN HANDLING THE DIRECTIONAL GYRO. DO

NOT DORP OR JOLT, SINCE SHOCKS CAN EASILY DAMAGE THE
DIRECTIONAL GYRO CAUSING INACCURACY AND EARLY FAILURE.
3. Remove directional gyro.
6-2. DIRECTIONAL GYRO AND AMPLIFIER - INSTALLATION
1. Position and secure directional gyro to support using securing screws.
2. Connect electrical connector to directional gyro.
6-3. DIRECTIONAL GYRO AND AMPLIFIER - INSPECTION
Visually inspect the directional gyro for the following defects:
1. Physical damage to the case.
6-4. DIRECTIONAL GYRO AND AMPLIFIER - REPAIR OR REPLACEMENT
Replace the directional gyro if inspection criteria are not met.
7. GYROCOMPASS SYSTEM AN/ASN-75 - SYNCHRO AMPLIFIER
The synchro amplifier is located on the lower shelf of the helicopter nose compartment.
7-1. SYNCHRO AMPLIFIER - REMOVAL
1. Remove mounting screws.
2. Disconnect electrical connector and remove synchro amplifier.
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7-2. SYNCHRO AMPLIFIER - INSTALLATION
1. Connect electrical connector to synchro amplifier.
2. Position amplifier on the lower shelf and secure with mounting screws.
7-3. SYNCHRO AMPLIFIER - INSPECTION
Visually inspect the synchro amplifier for the following defects:
1. Physical damage to the case.
7-4. SYNCHRO AMPLIFIER - REPAIR OR REPLACEMENT
Replace the synchro amplifier if inspection criteria are not met.
8. GYROCOMPASS SYSTEM AN/ASN-75 - COMPASS TRANSMITTER
The compass transmitter is installed on the tail boom near the horizontal stabilizer.
NOTE
The replacement of the compass transmitter necessitates re-alignment of the
gyromagnetic compass system.
8-1. COMPASS TRANSMITTER - REMOVAL
1. Disconnect electrical connector from transmitter.
2. Disconnect electrical connector from transmitter.
8-2. COMPASS TRANSMITTER - INSTALLATION
1. Position the compass transmitter.
NOTE
Check to see that the mounting flange graduations on the compass transmitter are
facing the forward section of the Helicopter.
2. Secure the compass transmitter with the securing screws.
4. Perform the compass swinging procedure to align the replacement compass transmitter.
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8-3. COMPASS TRANSMITTER - INSPECTION
Visually inspect the compass transmitter for the following failure conditions:
1. Physical damage or corrosion of the case.
8-4. COMPASS TRANSMITTER - REPAIR OR REPLACEMENT
Replace the compass transmitter if inspection criteria are not met.
9. GYROCOMPASS SYSTEM AN/ASN-75 - REMOTE COMPENSATOR
The remote compensator is installed in the tail boom close to the compass transmitter.
9-1. REMOTE COMPENSATOR - REMOVAL
1. Disconnect the electrical connector from the compensator.
2. Remove attaching hardware and remove compensator.
9-2. REMOTE COMPENSATOR - INSTALLATION
1. Position the compensator and secure to support with attaching hardware.
2. Connect electrical connector to compensator.
9-3. REMOTE COMPENSATOR - INSPECTION
Visually inspect the compensator for the following failure conditions:
2. Damaged connector or corroded receptacle; bent or broken connector pins.
9-4. REMOTE COMPENSATOR - REPAIR OR REPLACEMENT
Replace the compensator if inspection criteria are not met.
10. GYROCOMPASS SYSTEM AN/ASN-75 - CONTROL PANEL
The control panel (figure 3) is located on the central pedestal.
1. Loosen DZUS fasteners and lift panel out of pedestal.
2. Disconnect electrical connector from rear of panel.
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1. Connect electrical connect or the rear of panel.
2. Position control panel into pedestal and secure it in position by tightening Dzus fasteners.
Visually Inspect the control panel for the following failure conditions:
1. Physical damage to the case and/or to the front panel.
G6AB0866A
Figure 3. Control panel (2586047-( ))
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11. GYROCOMPASS SYSTEM AN/ASN-75 - INDICATOR (HSI)
Two horizontal situation indicators (figure 4) installed on the instrument panel provide overall navigational information by
means of the following displays:
the rotating azimuth dial (compass card) presents heading data received from the three axis reference sensor. Helicopter
heading is read under the upper lubber line.
The command heading marker is a movable reference point which indicates the selected command heading. It is set to a
selected heading by the heading set knob. When the helicopter is flying the selected heading, the command heading marker
will be aligned on the lubber line. The marker moves with the azimuth dial except when being mechanically positioned by
the heading set knob.
The command course pointer is a movable reference point indicating the selected command radio course.
It is set to a selected course with the course set knob.
When the helicopter is flying the selected course, the course pointer will be aligned on the lubber line.
The digital course readout presented in the course window is set by the course set knob and corresponds to the setting of the
command course pointer.
The deviation bar depicts the relationship of the selected radio beam centerline with respect to the present navigation
situation.
The fixed aircraft symbol represents the helicopter and the deviation bar depicts the radio beam position in respect to the
helicopter. When the helicopter is on the selected radio course, the deviation bar will be aligned with the course pointer and
the fixed aircraft symbol.
The to-from pointer depicts the location of the selected station will respect to the helicopter's position. The TO pointer is
displayed at the nose of the fixed aircraft symbol and the FROM pointer is displayed at the tail of the fixed aircraft symbol.
The No. 1 and No. 2 bearing pointers indicate the magnetic bearing from the helicopter to the ground station.
The two warning flags-power (OFF) and deviation flag (red flag) provide visual indication of system malfunctions. The
warning flag will come into view whenever a malfunction occurs. For maintenance procedures, refer to module 95-31-10
"INSTRUMENT SYSTEM". See module 97-30-16 for hsi indicators wiring diagram.
Figure 4. Indicator (HSI) 111302-5
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97-20-04
VHF/UHF AM-FM COMMUNICATION SYSTEM (ARC-182) SET 1
1. VHF/UHF AM-FM COMMUNICATION SYSTEM (ARC-182) SET 1 - DESCRIPTION
NOTE
See module 97-30-04 for VHF/UHF, Set 1 system wiring diagram. See figure 1 for
VHF/UHF system equipment location on the helicopter and figure 2 for system
block diagram.
The system consists of a control panel (on the pedestal), two antennas (one on the roof and the other one on the lower skin
of the fuselage) and a receiver-transmitter (in the nose compartment).
The system is interfaced with DF301E homing function (UHF/AM) and connected to the HSI pilot's-copilot's for indication.
The system is powered by 28 V DC and protected by VHFI COMM and UHF DF circuit breakers.
NOTE
This system cannot be installed when ART-151 VHF AM system is installed.
2. VHF/UHF AM-FM COMMUNICATION SYSTEM (ARC-182) SET 1 - MAINTENANCE
CAUTION

3. VHF/UHF AM-FM COMMUNICATION SYSTEM (ARC-182) SET 1 - VHF/UHF

COMMUNICATION ANTENNA
The VHF/UHF communication antenna is installed on top of the fuselage.
3-1. VHF/UHF COMMUNICATION ANTENNA - REMOVAL
1. Remove the securing screws and pull the antenna away from the fuselage.
2. Disconnect the electrical connector and remove the antenna.
3-2. VHF/UHF COMMUNICATION ANTENNA - INSTALLATION
1. Connect the electrical connector and position the antenna.
2. Secure the antenna to top of fuselage by using attaching screws.
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3-3. VHF/UHF COMMUNICATION ANTENNA - INSPECTION
Visually inspect the antenna for the following defects:
1. Damage to VHF/UHF antenna.
3-4. VHF/UHF COMMUNICATION ANTENNA - REPAIR OR REPLACEMENT
Replace the antenna if warranted by the inspection criteria.
4. VHF/UHF AM-FM COMMUNICATION SYSTEM (ARC-182) SET 1 - TRANSCEIVER
The transceiver is installed a support in the lower compartment of the fuselage nose.
4-1. TRANSCEIVER - REMOVAL
1. Disconnect coaxial connectors and the electrical connector from the UHF receiver-transmitter.
2. Loosen wingnut fasteners and swivel them upwards to disengage latches on shock mount.
3. Grasp handle of the UHF receiver-transmitter and pull off shock mount.
4-2. TRANSCEIVER - INSTALLATION
1. Slide the UHF receiver-transmitter onto the shock mount.
2. Swivel the wingnut fasteners downwards to engage the latches on the mounting. Tighten the wingnuts.
3. Connect the coaxial connector and the electrical connector to the UHF receiver-transmitter.
4-3. TRANSCEIVER - INSPECTION
Inspect the receiver-transmitter for the following conditions:
1. Physical damage to case or shockmount.
4-4. TRANSCEIVER - REPAIR OR REPLACEMENT
Replace receiver-transmitter if warranted by the inspection criteria.
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Figure 1. VHF/UHF AM-FM communication system (ARC-182) equipment location SET 1
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Figure 2. VHF/UHF AM-FM communication system (ARC-182) SET 1 - block diagram
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5. VHF/UHF AM-FM COMMUNICATION SYSTEM (ARC-182) SET 1 - HOMING

ANTENNA
The homing antenna is installed on a support on the underside of the fuselage of the helicopter.
CAUTION
HANDLE THE HOMING ANTENNA WITH CARE DURING THE

MAINTENANCE PROCEDURES. DO NOT JOLT OR JAR.
5-1. HOMING ANTENNA - REMOVAL
1. Support the homing antenna and carefully remove the securing screws.
2. Still supporting the homing antenna, remove coaxial cable connector and electrical connector from rear of homing
antenna.
3. Remove the bolts, nuts and washers securing homing antenna to supporting cover and release antenna.
NOTE
For inspection and repair instructions refer to paragraph "3. VHF/UHF AM-FM
communication system (ARC-182) set 1 - VHF/UHF communication antenna".
5-2. HOMING ANTENNA - INSTALLATION
4. Install supporting cover on homing antenna using the bolts, nuts and washers.
5. Support homing antenna roughly in position on underside of fuselage to connect coaxial cable connector and electrical
connector.
6. Still supporting the homing antenna, install the securing screws to secure homing antenna to the fuselage.
6. VHF/UHF AM-FM COMMUNICATION SYSTEM (ARC-182) SET 1 - CONTROL PANEL
The control panel is installed on the RH side of the pedestal.
1. Release the four Dzus fasteners which secure the control panel to the pedestal.
2. Pull the control panel out of the pedestal and disconnect the rear electrical connector.
1. Connect the rear electrical connector to the control panel.
2. Secure the control panel to the pedestal with the four Dzus fasteners.
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E-AB412-PT6T-2
Inspect the control panel for the following defects:
2. Binding, loose or faulty switches.
97-20-04
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97-20-05
VHF/UHF AM-FM COMMUNICATION SYSTEM (ARC-182) SET 2
1. VHF/UHF AM-FM COMMUNICATION SYSTEM (ARC-182) SET 2 - DESCRIPTION
NOTE
See module 97-30-05 for VHF/UHF, Set 2 system wiring diagram. See figure 1 for
VHF/UHF system equipment location on the helicopter and figure 2 for system
block diagram.
The system consists of a control panel (on the pedestal), an antenna (on the lower skin of the tail boom), a
receiver-transmitters (in the nose compartment).
The system is interfaced with VHF/FM (low frequency) homing ”handling type” antennas and connected to CSI indicator
placed on the instrument panel (pilot). The handling antennas are installed on the cabin posts, one per side. The system is
powered by 28 DC and protected by the VHF 2 COMM circuit breaker.
2. VHF/UHF AM-FM COMMUNICATION SYSTEM (ARC-182) SET 2 - GENERAL

MAINTENANCE
CAUTION

3. VHF/UHF AM-FM COMMUNICATION SYSTEM (ARC-182) SET 2 - VHF/UHF

COMMUNICATION ANTENNA
The VHF/UHF communication antenna is installed on the bottom of the tailboom.
3-1. VHF/UHF COMMUNICATION ANTENNA - REMOVAL
1. Remove the securing screws and pull the antenna away from the tailboom.
2. Disconnect the electrical connector and remove the antenna.
3-2. VHF/UHF COMMUNICATION ANTENNA - INSTALLATION
1. Connect the electrical connector and position the antenna.
2. Secure the antenna to the tailboom by using attaching screws.
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E-AB412-PT6T-2
3-3. VHF/UHF COMMUNICATION ANTENNA - INSPECTION
Visually inspect the antenna for the following defects:
1. Damage to VHF/UHF antenna.
3-4. VHF/UHF COMMUNICATION ANTENNA - REPAIR OR REPLACEMENT
Replace the antenna if warranted by the inspection criteria.
4. VHF/UHF AM-FM COMMUNICATION SYSTEM (ARC-182) SET 2 - HOMING

ANTENNA
The left-hand and right-hand homing antennas are encapsuled in a T-shaped tube on either side of the Helicopter. The three
flanges of each Homing Antenna Assembly locate on the Central Support and on each end of the Main Member. The Homing
antenna cannot be removed from the Homing Antenna Assembly.
4-1. HOMING ANTENNA - REMOVAL
1. Remove the screws from the top and bottom flanges of the Homing Antenna Assembly.
2. Remove the screws from the centre flange.
3. Carefully pull the Homing Antenna Assembly away from the fuselage.
4. Disconnect the coaxial cable connector and remove the Homing Antenna Assembly.
4-2. HOMING ANTENNA - INSTALLATION
1. Clean the mounting surfaces of the Homing Antenna Assembly.
2. Connect the coaxial cable connector to the Homing Antenna Assembly.
3. Position the Homing Antenna Assembly on the fuselage; insert a piece of copper foil between top and bottom flanges
and the fuselage to ensure a good electrical connection.
4. Secure the Homing Antenna Assembly using the mounting screws.
5. Smear the attachment flanges with sealing compound (item C76).
4-3. HOMING ANTENNA - INSPECTION
Visually inspect the Homing Antenna Assembly for the following failure conditions:
2. Damaged connector or corroded connector receptacle; bent or broken connector pin.
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E-AB412-PT6T-2
4-4. HOMING ANTENNA - REPAIR OR REPLACEMENT
Replace the Homing Antenna Assembly if warranted by the inspection criteria.
5. VHF/UHF AM-FM COMMUNICATION SYSTEM (ARC-182) SET 2 -

TRANSMITTER-RECEIVER
The Transmitter-receiver is installed on the upper compartment in the helicopter nose.
5-1. TRANSMITTER-RECEIVER - REMOVAL
1. Loosen the fasteners securing the Transmitter-receivers.
2. Carefully lift the Transmitter-receiver and disconnect the electrical connector from the rear of the Transmitter-receiver.
3. Lift and remove the Transmitter-receiver.
5-2. TRANSMITTER-RECEIVER - INSPECTION
Visually inspect the Transmitter-receiver for the following failure conditions:
1. Physical damage to case, front panel or viewing window.
2. Sticking or loose controls; loose or faulty switches.
3. Damaged connectors or corroded connector receptacle; bent or broken connector pins.
5-3. TRANSMITTER-RECEIVER - REPAIR OR REPLACEMENT
Replace the Transmitter-receiver if warranted by the inspection criteria.
5-4. TRANSMITTER-RECEIVER - INSTALLATION
1. Connect the electrical connector and place the transmitter-receiver into position.
2. Secure the Transmitter-receiver in position by tightening the fasteners.
6. VHF/UHF AM-FM COMMUNICATION SYSTEM (ARC-182) SET 2 - COURSE

SOFTENER
The course softener is located on the cabin ceiling behind the pilot's seat.
6-1. COURSE SOFTENER - REMOVAL
1. Disconnect coaxial cables from course-softener.
2. Remove mounting screws and remove course softener from helicopter.
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E-AB412-PT6T-2
6-2. COURSE SOFTENER - INSTALLATION
1. Position course softener on helicopter and secure with mounting screw.
2. Connect coaxial cables to course softener.
7. VHF/UHF AM-FM COMMUNICATION SYSTEM (ARC-182) SET 2 - CONTROL PANEL
The control panel is installed on the LH side of the pedestal.
1. Release the four Dzus fasteners which secure the control panel to the pedestal.
2. Pull the control panel out of the pedestal and disconnect the rear electric connector.
1. Connect the rear electrical connector to the control panel.
2. Secure the control panel to the pedestal with the four Dzus fasteners.
Inspect the control panel for the following defects:
2. Binding, loose or faulty switches.
8. VHF/UHF AM-FM COMMUNICATION SYSTEM (ARC-182) SET 2 - COURSE

INDICATOR
The course indicator (see figure 3) is mounted on the pilot's side of the instrument panel. The indicator is made up of a course
card, a localizer/TACAN needle, a glide slope needle, a TO/FROM indicator, an omni bearing selector, and two warning
flags.
The course card is used in conjunction with the omni bearing selector (OBS) knob to select a desired TACAN radial. The
localizer/TACAN needle indicates the relationship between the radial set by the OBS knob and the position of the helicopter.
The glide slope needle indicates corrections and an over station indication if the indicator is used during fm homing
operation. The TO/FROM indicator indicates whether the helicopter is within 180° of the inbound or outbound radial
selected. The omni bearing selector (OBS) is used to select the desired radial. The desired radial appears at the top of the
indicator under the triangular pointer. The two warning flags indicate signal reliability.
For maintenance procedures, refer to module 95-31-10 "INSTRUMENT SYSTEM".
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E-AB412-PT6T-2
G6AB0870A
Figure 1. VHF/UHF AM-FM communication system (ARC-182) equipment location SET 2
97-20-05
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E-AB412-PT6T-2
G6AB0871A
Figure 2. VHF/UHF AM-FM communication system (ARC-182) SET 2 - block diagram
97-20-05
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E-AB412-PT6T-2
G6AB0872A
Figure 3. Course indicator (5205160006)
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97-20-05
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97-20-06 HF SYSTEM ARC-174 (718U-5)
97-20-06
HF SYSTEM ARC-174 (718U-5)
1. HF SYSTEM ARC-174 (718U-5) - DESCRIPTION AND OPERATION
— The HF System consists of the following units:
— HF Communication Antenna, Type 437R-2
— HF Power Amplifier/Coupler, Type 548S-3
— HF Receiver-Exciter, Type 671U-4A
— HF Control Unit, Type 514A-4.
NOTE
See module 97-30-06 to the HF System wiring diagram. See figure 1 for the location
of the units of the HF System in the helicopter, and figure 2 for system block
diagram.
NOTE
For further information on the HF System refer to 548S-3 Power Amplifier Coupler
Instruction Books, 617U-4 Receiver-Exciter Instruction Books and 514A-4 Radio
Set Control Instruction Books of Collins Radio Company.
The HF System provides an amplitude-modulated radio communication facility. For the layout of the HF System controls,
refer to HF System Control Panel, figure 3. The HF System is energized by the HF COMM circuit breaker. The HF System
provides radio communication from 2.0000 to 29.9999 MHz in tuning increments of 100 Hz. Transmission and reception
using the HF Communication Antenna is at the carrier frequency selected by the 5 frequency con

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THIS PUBLICATION IS ISSUED BY AGUSTAWESTLAND S.P.A.

ISSUE: 6 DECEMBER 2011

LIST OF EFFECTIVE MODULES

Insert latest revision pages and dispose of superseded ones.

Issue - 27 June 1997

Frontispiece ...................................3 CHAPTER 11 CHAPTER 25

LOG OF MODULES (CONT.D)

LOG OF MODULES (CONT.D)

LOG OF MODULES (CONT.D)

LOG OF MODULES (CONT.D)

LOG OF MODULES (CONT.D)

REVISION NUMBER ISSUE DATE DATE INSERTED BY

PAGE INTENTIONALLY LEFT BLANK

RECORD OF TEMPORARY REVISION

Temporary Revision Interested Pages Incorporated

PAGE INTENTIONALLY LEFT BLANK

CHAPTER CHAPTER NO.

AIR VEHICLE GENERAL 00

DIMENSIONS AND CHARTS 06

LIFTING, SHORING, RECOVERING AND TRANSPORTING 07

LEVELING AND WEIGHING 08

HANDLING AND TAXIING 09

PARKING, MOORING AND STORING 10

PLACARDS AND MARKINGS 11

VIBRATION AND NOISE ANALYSIS AND ATTENUATION 18

ICE AND RAIN PROTECTION 30

MAIN ROTOR DRIVE 63

TAIL ROTOR DRIVE 65

ROTORS FLIGHT CONTROL 67

CHAPTER CHAPTER NO.

ENGINE OIL SYSTEM 79

APPENDIX APPENDIX NO.

POWER PLANT BUILD-UP II

CORROSION CONTROL GUIDE III

WIRING HARNESSES AND CABLE IV

PAGE INTENTIONALLY LEFT BLANK

CONTENTS — MAINTENANCE PROCEDURES

1. Introduction - general .............................................................................................................................. 1

00-00-40 THE MANUAL

1. The manual - use of the manual .............................................................................................................. 1

00-00-40 THE MANUAL

Figure 1. Maintenance hoist .........................................................................................................................................21

00-00-40 THE MANUAL

Table 1. Consumable materials list............................................................................................................................... 2

PAGE INTENTIONALLY LEFT BLANK

The content of this manual is subject to updating.

TECHNICAL PUBLICATIONS DISCREPANCY FORM

SUBMITTED TO: SUBMITTED BY:

AgustaWestland S.p.A. Customer name and address:

PUBLICATION AFFECTED: PUBLICATION TITLE:

ISSUE DATE: CHANGE/REVISION DATE:

AFFECTED PAGE N.: AFFECTED FIGURE:

DISCREPANCY OR DEFICIENCY (DESCRIBE DISCREPANCY WITH TEXT AND/OR SKETCH).

0 -0 -40 THE MANUAL

1. THE MANUAL - USE OF THE MANUAL

ALL MAINTENANCE PROCEDURES LISTED IN THE MANUAL ARE

2. THE MANUAL - NUMBERING SYSTEM

The numbering of the modules is in accordance with SPEC 1000D criteria.