Hydraulic System: BHT-206L1-MM-1

BHT-206L1-MM-1
CHAPTER 29 — HYDRAULIC SYSTEM
TABLE OF CONTENTS
Paragraph Chapter/Section Page

Number Title Number Number
HYDRAULIC SYSTEM
29-1 Hydraulic System ........................................................................... 29-00-00 5

29-2 Hydraulic System — Troubleshooting ...................................... 29-00-00 5
29-3 Hydraulic System — Leakage Limits ........................................ 29-00-00 9
29-4 Hydraulic System — Flushing................................................... 29-00-00 10
29-5 Hydraulic System — Bleeding .................................................. 29-00-00 11
29-6 Hydraulic System — Operational Check Using Test Stand...... 29-00-00 12
29-7 Hydraulic System — Operational Check Using Helicopter
System...................................................................................... 29-00-00 14
29-8 Hydraulic Pump — Operational Check ..................................... 29-00-00 14
HYDRAULIC SYSTEM COMPONENTS
29-8 Hydraulic Reservoir........................................................................ 29-00-00 15

29-9 Hydraulic Reservoir — Removal............................................... 29-00-00 15
29-10 Hydraulic Reservoir — Inspection ............................................ 29-00-00 15
29-11 Hydraulic Reservoir — Installation............................................ 29-00-00 15
29-12 Hydraulic Pump.............................................................................. 29-00-00 17
29-13 Hydraulic Pump — Removal..................................................... 29-00-00 17
29-14 Hydraulic Pump — Inspection .................................................. 29-00-00 19
29-15 Hydraulic Pump Input Driveshaft — Removal and Installation
(TB 206L-03-211) ..................................................................... 29-00-00 19
29-16 Hydraulic Pump — Installation.................................................. 29-00-00 19
29-17 Hydraulic Filters ............................................................................. 29-00-00 22
29-18 Hydraulic Filters — Differential Pressure Indicator —
Operational Check .................................................................... 29-00-00 24
29-19 Hydraulic Filters — Removal .................................................... 29-00-00 26
29-20 Hydraulic Filters — Disassembly .............................................. 29-00-00 27
29-21 Hydraulic Filters — Inspection .................................................. 29-00-00 27
29-22 Hydraulic Filters — Assembly................................................... 29-00-00 28
29-23 Hydraulic Filters — Installation ................................................. 29-00-00 29
29-24 Hydraulic Filter Element................................................................. 29-00-00 29
29-25 Hydraulic Filter Element — Removal........................................ 29-00-00 29
29-26 Hydraulic Filter Element — Inspection and Cleaning ............... 29-00-00 30
29-27 Hydraulic Filter Element — Installation..................................... 29-00-00 31
29-28 Hydraulic Solenoid Valve ............................................................... 29-00-00 31
29-29 Hydraulic Solenoid Valve — Removal ...................................... 29-00-00 31
29-30 Hydraulic Solenoid Valve — Inspection.................................... 29-00-00 32
29-31 Hydraulic Solenoid Valve — Installation ................................... 29-00-00 32
29-32 Relief Valve.................................................................................... 29-00-00 34
29-33 Relief Valve — Removal........................................................... 29-00-00 34
29-34 Relief Valve — Inspection......................................................... 29-00-00 34
29-35 Relief Valve — Installation........................................................ 29-00-00 34
29-36 Quick Disconnects ......................................................................... 29-00-00 35
29-37 Quick Disconnects — Removal ................................................ 29-00-00 35
29-00-00
Export Classification C, ECCN EAR99 10 MAR 2017 Rev. 37 Page 1
BHT-206L1-MM-1
TABLE OF CONTENTS (CONT)
Paragraph Chapter/Section Page

Number Title Number Number
29-38 Quick Disconnects — Inspection .............................................. 29-00-00 35

29-39 Quick Disconnects — Installation ............................................. 29-00-00 35
29-40 Hydraulic Hoses and Tube Assemblies ......................................... 29-00-00 35
29-41 Hydraulic Hoses and Tube Assemblies — Removal ................ 29-00-00 35
29-42 Hydraulic Hoses and Tube Assemblies — Inspection and
Cleaning.................................................................................... 29-00-00 35
29-43 Hydraulic Hoses and Tube Assemblies — Installation ............. 29-00-00 36
CYCLIC AND COLLECTIVE SERVO ACTUATORS AND SUPPORT
29-44 Cyclic and Collective Servo Actuators and Support....................... 29-00-00 37

29-45 Servo Valve .............................................................................. 29-00-00 37
29-46 Bypass Valve ............................................................................ 29-00-00 37
29-47 Check Valves............................................................................ 29-00-00 37
29-48 Sequence and Thermal Relief Valve ........................................ 29-00-00 37
29-49 Differential Relief Valve ............................................................ 29-00-00 37
29-50 Filter.......................................................................................... 29-00-00 37
29-51 Cyclic and Collective Servo Actuators — Removal .................. 29-00-00 37
29-52 Cyclic and Collective Servo Actuators — Inspection ................ 29-00-00 40
29-53 Cyclic and Collective Servo Actuators — Installation ............... 29-00-00 40
29-54 Servo Actuator Links, Bellcranks, and Idlers ................................. 29-00-00 41
29-55 Servo Actuator Links, Bellcranks, and Idlers — Removal ........ 29-00-00 41
29-56 Servo Actuator Links, Bellcranks, and Idlers — Inspection
and Repair ................................................................................ 29-00-00 42
29-57 Servo Actuator Links, Bellcranks, and Idlers — Installation ..... 29-00-00 42
29-58 Servo Actuator Support.................................................................. 29-00-00 43
29-59 Servo Actuator Support — Removal......................................... 29-00-00 43
29-60 Servo Actuator Support — Inspection and Repair.................... 29-00-00 43
29-61 Servo Actuator Support — Installation...................................... 29-00-00 45
FIGURES
Figure Page
Number Title Number
29-1 Hydraulic System Schematic .............................................................................. 7

29-2 Hydraulic System ................................................................................................ 8
29-3 Hydraulic Reservoir............................................................................................. 16
29-4 Hydraulic Pump................................................................................................... 18
29-5 Hydraulic Pump Input Driveshaft — Removal and Installation
(TB 206L-03-211)................................................................................................ 20
29-6 Hydraulic Pump Input Driveshaft — Inspection (TB 206L-03-211) ..................... 21
29-7 Hydraulic Filter and Element............................................................................... 23
29-8 Workaid No. 1 — Dummy Filter Element ............................................................ 25
29-9 Hydraulic Solenoid and Relief Valve................................................................... 33
29-10 Cyclic and Collective Servo Actuator and Bellcranks ......................................... 38
29-11 Servo Actuator Support....................................................................................... 44
29-00-00
Page 2 Rev. 37 10 MAR 2017 Export Classification C, ECCN EAR99
BHT-206L1-MM-1
TABLES
Table Page
Number Title Number
29-1 Hydraulic System Troubleshooting ..................................................................... 5

29-2 Maximum Allowable Leakage for In-service Components .................................. 10
29-00-00
Export Classification C, ECCN EAR99 10 MAR 2017 Rev. 37 Page 3/4
BHT-206L1-MM-1
HYDRAULIC SYSTEM
29-1. HYDRAULIC SYSTEM (Figure 29-1 and Figure 29-2). Refer to Chapter 98 for
the hydraulic system wiring diagram.
The hydraulic system provides power to operate the
29-2. HYDRAULIC SYSTEM —
cyclic and collective flight control servo actuators.
TROUBLESHOOTING
Operation of the hydraulic system is electrically Table 29-1 lists indication of trouble, probable cause,
controlled by the hydraulic system switch. When the and corrective action procedures to aid in hydraulic
hydraulic system solenoid valve is de-energized, the system troubleshooting. The troubleshooting table
pressurized hydraulic fluid flows to the three servo should be used with other sources of information such
actuators. When the hydraulic system solenoid valve as: hydraulic schematic, electrical wiring diagrams,
is energized, the pressurized hydraulic fluid flows to functional test, and other detailed procedures in this
the reservoir, bypassing the three servo actuators and other chapters in this manual.
Table 29-1. Hydraulic System Troubleshooting
INDICATION OF TROUBLE PROBABLE CAUSE CORRECTIVE ACTION
Red button on differential Filter element clogged or Clean and inspect filter element,
pressure indicator popped up. differential pressure indicator bleed system.
faulty.
1. Press red button down into
indicator and ground run
helicopter.
2. If red button does not pop up,

system is satisfactory.
NOTE
The differential pressure
limits across the filter is
70 PSI ±10 PSI (483
±69 kPa).
3. If red button pops up, install

new filter element.
4. If red button pops up after

installing new filter pressure,
indicator is faulty. Replace filter
assembly.
Hydraulic oil leaks. Loose connector fittings or crack Replace part if cracked. Torque
in flared portion of line under nut. fittings or nut. Bleed system.
Faulty packings. Replace packing and bleed

system.
29-00-00
BHT-206L1-MM-1
Table 29-1. Hydraulic System Troubleshooting (Cont)
INDICATION OF TROUBLE PROBABLE CAUSE CORRECTIVE ACTION
If leak is in servo actuator, replace

actuator or install seal kit.
Faulty hoses and lines. Replace hoses and bleed system.
Hydraulic system inoperative. HYDR CONTROL switch — OFF Position HYDR CONTROL switch
— ON
Solenoid valve not operating. Replace faulty valve and bleed

systems.
Relief valve stuck open. Replace faulty relief valve and

bleed system.
Pump not producing required Replace faulty pump and bleed

pressure. system.
HYD BOOST circuit breaker out. Reset HYD BOOST circuit

breaker.
Faulty wiring to CONTROL Replace faulty wiring.

BOOST switch, HYD BOOST
circuit breaker, or solenoid valve.
Leaks in system. Tighten connections. Replace

faulty hoses, lines, or
components.
Hydraulic system fails to shut off. HYD BOOST circuit breakers out. Reset HYD BOOST circuit
breaker.
Solenoid valve not operating. Replace faulty valve and bleed

system.
Faulty wiring to CONTROL Replace faulty wiring.

BOOST switch, HYD BOOST
circuit breaker, or solenoid valve.
29-00-00
SYSTEM CAPACITY 65 CUBIC INCHES
RESERVOIR CAPACITY 40.0 CUBIC INCHES
RESERVE CAPACITY 24.3 CUBIC INCHES
OPERATING PRESSURE 600 PSI (206L1 AND 206L1 ENGINE UPGRADE), 1000 PSI (206L1+ IGW UPGRADE)
OPERATING TEMPERATURE -65°F TO 160°F (-54°C TO 71°C)
Export Classification C, ECCN EAR99

Figure 29-1. Hydraulic System Schematic
10 MAR 2017
Rev. 37
206L1_MM_29_0008_c01
Page 7
BHT-206L1-MM-1
29-00-00
BHT-206L1-MM-1
1. Manifold
2. Servo actuator hose assembly
3. Quick disconnect coupling - outlet
4. Quick disconnect coupling - inlet
5. Filter assembly - return
6. Filter assembly - pressure
7. Relief valve
8. Solenoid valve
9. Reservoir
10. Pump
11. Tach generator
12. Pump pressure hose
13. Return hose
206L1_MM_29_0002+
Figure 29-2. Hydraulic System
29-00-00
BHT-206L1-MM-1
may be created, or airworthiness of helicopter may be

29-3. HYDRAULIC SYSTEM — LEAKAGE
otherwise compromised.
LIMITS
b. Allowable leakage — Fluid leakage such that

The following provides guidelines for allowable
quantity lost is insignificant, will have no detrimental
external leakage of in-service hydraulic system
effect on helicopter operation, and correction does not
components and some methods of measuring such
warrant involved maintenance time.
leakage.
c. General — Leakage usually shows as a
1. Scope — Limits described are only for
seepage, stain, or wet area. It is possible for allowable
components in service in helicopter hydraulic systems.
leakage or seepage to collect in a cavity or depression
Intent is to minimize replacement of hydraulic
in adjacent structure over a period of time and falsely
components which are still serviceable.
indicate excessive leakage. Accumulation on a flat
area or a white-painted surface often appears to be
a. These limits may differ from those contained excessive, though actually is allowable. However, it is
in various specifications for components, which are also possible to have enough components with
intended to control quality, assembly, and proper allowable leakages that their combined leakage
functioning of the components for procurement. should be classified as excessive.
Components in service sometimes develop leakage
rates in excess of specification limits, without 4. Leakage checks — Measurement of leakage
necessarily becoming detrimental to the system or rates for classification according to Table 29-2 can be
failing to provide reliable operation. done as follows:
b. These limits are not to be used as a basis for a. When hydraulic systems have remained in
acceptance or rejection of components of any bench static, unpressurized conditions for an appreciable
functional test or systems on new helicopters. period of time, leakage checks should not be done
immediately after starting operation. Activate systems
c. These limits are not applicable to and operate components several times, then wipe off
self-contained, closed-compartment hydraulic units any leaked hydraulic fluid before making leakage
such as viscous dampers, liquid springs, or oleo struts. checks.
2. Causes of leakage — Some seepage is normally b. Where location of a component does not
present since static or dynamic seals are not permit direct observation, it is possible to measure
functionally perfect, due to such causes as follows: leakage on a flat surface, either using part of structure
below component or using a panel temporarily
a. A film of hydraulic fluid being retained by positioned for that purpose. Wipe the surface clean
metal surfaces, such as piston rods, and thus carried and place a drop of fluid on the area, allow to stabilize,
past seals. This film is necessary for seal lubrication. then outline the area with soft lead pencil before
wiping off fluid. Pressurize and cycle the component to
observe leakage rate, comparing the wetted surface to
b. Pressure and temperature variations affecting
marked one-drop area.
seals.
c. Where fluid dropping from a component can
c. Seals tending to take a permanent set after a
be directly observed, pressurize and cycle the
period of time.
component until a drop falls free. Continue operating,
observing time until next drop to determine leakage
3. Classification of leakage — External leakages of rate.
hydraulic fluid can be broadly classified as excessive
or allowable. d. For tests requiring long periods of time and
where fluid can drop, wipe surface clean and dry
a. Excessive leakage — Fluid leakage such that without using a solvent. Use a clean blotter or white
hydraulic reservoir level may be dangerously lowered cloth after the system has operated or has been idle
or depleted during normal operation, or a fire hazard for the required period of time.
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BHT-206L1-MM-1
Table 29-2. Maximum Allowable Leakage for In-service Components
COMPONENT FUNCTION TYPE LEAKAGE RATE
Servo Actuators (Flight Controls) Rod Seal D 1 drop/20 full cycles
Rod Seal S-D 1 drop/15 minutes
End Cap S 2 drops/day
Valve Input D 1 drop/5 cycles
Valve Input S-D 1 drop/5 minutes
Pump Output Shaft D 1 drop/minute
Output Shaft S-D 1 drop/minute
Housing S 2 drops/day
(mating surfaces)
Fittings Flared or Flareless S None
Compression Seals S 1 drop/30 minutes
NOTES:
D – Dynamic
S – Static
S-D – Static leakage through dynamic seal
29-4. HYDRAULIC SYSTEM — FLUSHING MATERIALS REQUIRED
Refer to BHT-ALL-SPM for specifications.

SPECIAL TOOLS REQUIRED
NUMBER NOMENCLATURE
NUMBER NOMENCLATURE C-002 Hydraulic Fluid
Commercial 206L1 and 206L1 C-072 Hydraulic Fluid

Engine Upgrade:
Hydraulic Test Stand, C-304 Drycleaning Solvent
1000 PSI (6895 kPa)
Pressure Maximum, C-428 Caps and/or Plugs
2 GPM (7.6 L/min),
10 Micro
(390 Micro-inch) Filter
CAUTION
Commercial 206L1+ IGW Upgrade:
Hydraulic Test Stand,
1500 PSI (10,342 kPa)
BEFORE USING THE HYDRAULIC TEST
Pressure Maximum,
STAND, MAKE SURE IT IS SERVICED
2.8 GPM (10.6 L/min),
WITH THE SAME SPECIFICATION OF
10 Micron
HYDRAULIC FLUID THAT IS USED ON
THE HELICOPTER TO PREVENT FROM
29-00-00
BHT-206L1-MM-1
MIXING THE HYDRAULIC FLUID 10. Bleed air from the system by cycling the controls
(CHAPTER 12). with the system in operation.
Use a hydraulic test stand that is equipped with a 29-5. HYDRAULIC SYSTEM — BLEEDING
10 micron filter and a calibrated pressure gauge with a
range up to 1500 PSI (10,342 kPa). The test stand
must be capable of producing 1500 PSI (10,342 kPa) SPECIAL TOOLS REQUIRED
at a minimum flow rate of 2.8 gallons per minute
(10.6 L/min). Clean the test stand and service with
hydraulic fluid (Chapter 12) prior to use. NUMBER NOMENCLATURE
When contaminated, flush the entire system to ensure Commercial 206L1 and 206L1
removal of all foreign matter as follows: Engine Upgrade:
1. Remove the following parts of the hydraulic 1000 PSI (6895 kPa)
system and clean with drycleaning solvent (C-304): Pressure Maximum,
2 GPM (7.6 L/min),
10 Micron
a. Pump and reservoir (10 and 9, Figure 29-2).
b. Pump pressure hose (12). Commercial 206L1+ IGW Upgrade:
c. Return hose (13) from reservoir (9). 1500 PSI (10,342 kPa)
Pressure Maximum,
2. Install caps and/or plugs (C-428) on all open 2.8 GPM (10.6 L/min),
ports. 10 Micron
3. Remove the filter elements from the filter
assemblies (5 and 6) and reinstall the filter bowls
(paragraph 29-24). MATERIALS REQUIRED
4. Connect the hydraulic ground test stand pressure Refer to BHT-ALL-SPM for specifications.
line to the quick disconnect coupling (4) at the filter
assembly (pressure) (6). NUMBER NOMENCLATURE
C-002 Hydraulic Fluid

5. Connect a hose to the quick disconnect coupling
(3) of sufficient length to reach an overboard container C-072 Hydraulic Fluid
for contaminated fluid.
Bleeding the hydraulic system may be done with the
6. Start the test stand and adjust to 600 PSI use of a hydraulic test stand or by operation of the
(4137 kPa). helicopter.
7. Cycle the collective stick full up to full down until 1. Bleed air from the hydraulic system with the
the fluid coming from the overboard line is clear. hydraulic test stand as follows:
8. With the collective full down, move the cyclic from

the left rear corner to the right front corner until fluid CAUTION
clears.
9. For pump failure, the pressure line filter assembly BEFORE USING THE HYDRAULIC TEST
(6) will trap all particles. When replacing a failed pump, STAND, MAKE SURE IT IS SERVICED
replace the filter elements. WITH THE SAME SPECIFICATION OF
29-00-00
BHT-206L1-MM-1
HYDRAULIC FLUID THAT IS USED ON

NOTE
THE HELICOPTER TO PREVENT FROM
MIXING THE HYDRAULIC FLUID When adding hydraulic fluid to the flight
(CHAPTER 12). control hydraulic systems, the same
specification of hydraulic fluid already used
a. Connect the hydraulic test stand to the in the hydraulic system shall be used.
helicopter (paragraph 29-6). However, in circumstances where
emergency top-off, inadvertent mixing, or
b. Set the hydraulic test stand pressure to purposeful conversion to the other specified
600 PSI (4137 kPa) (1000 PSI (6895 kPa) for 206L1+ fluid may occur, it is acceptable to use
IGW Upgrade) with 2.0 gallons per minute (2.8 gallons hydraulic fluid of the other approved
per minute for 206L1+ IGW Upgrade) flow. specification. No further maintenance
action will be required.
c. Slowly move the pilot cyclic and collective
controls through full travel, a minimum of 10 times, to c. Shut down the engine and replenish the
bleed air from the system. reservoir with hydraulic fluid (Chapter 12), if required.
29-6. HYDRAULIC SYSTEM — OPERATIONAL

NOTE
CHECK USING TEST STAND
When adding hydraulic fluid to the flight
control hydraulic systems, the same All the hydraulic system components with the
specification of hydraulic fluid already used exception of the transmission driven hydraulic pump
in the hydraulic system shall be used. may be operationally checked using the following
However, in circumstances where procedures. Refer to paragraph 29-7 for procedure to
emergency top-off, inadvertent mixing, or check the transmission driven hydraulic pump.
purposeful conversion to the other specified
fluid may occur, it is acceptable to use
hydraulic fluid of the other approved SPECIAL TOOLS REQUIRED
specification. No further maintenance
NUMBER NOMENCLATURE
d. Fill the reservoir with hydraulic fluid (C-002) or
hydraulic fluid (C-072), as required. Commercial 206L1 and 206L1
Engine Upgrade:
e. Repeat step c and step d, as required. Hydraulic Test Stand,
1000 PSI (6895 kPa)
f. Disconnect the hydraulic test stand from the Pressure Maximum,
helicopter. 2 GPM (7.6 L/min),
10 Micron
2. Bleed air from the hydraulic system by operation (390 Micro-inch) Filter
of the helicopter as follows:
Commercial 206L1+ IGW Upgrade:
a. Start the helicopter engine and operate at
1500 PSI (10,342 kPa)
flight idle.
Pressure Maximum,
2.8 GPM (10.6 L/min),
b. Slowly move the pilot cyclic and collective
10 Micron
controls to allowable limits for ground operation.
Repeat at least 10 times to bleed air from the system.
29-00-00
BHT-206L1-MM-1
6. Set the test stand to provide a minimum flow of

MATERIALS REQUIRED 2 gallons per minute (2.8 gallons per minute for
206L1+ IGW Upgrade) with pressure compensator
Refer to BHT-ALL-SPM for specifications. adjusted to 600 PSI (4137 kPa) (1000 PSI (6895 kPa)
for 206L1+ IGW Upgrade). Apply 600 PSI (4137 kPa)
NUMBER NOMENCLATURE (1000 PSI (6895 kPa) for 206L1+ IGW Upgrade) to the
hydraulic system and maintain for at least 15 minutes.
C-002 Hydraulic Fluid Do the following checks:
a. While the cyclic and collective controls are
being slowly moved, observe the hydraulic servo
actuators as they move and check for binding, chafing,
and movement of hoses, which would tend to loosen
CAUTION fittings.
b. Continue to increase the hydraulic test stand

BEFORE USING THE HYDRAULIC TEST pressure slowly while touching the relief valve (7).
STAND, MAKE SURE IT IS SERVICED Determine when the relief valve opens by feel. This
WITH THE SAME SPECIFICATION OF should occur at 670 to 770 PSI (4619 to 5309 kPa)
HYDRAULIC FLUID THAT IS USED ON (1075 to 1375 PSI (7412 to 9480 kPa) for 206L1+ IGW
THE HELICOPTER TO PREVENT FROM Upgrade). Replace or overhaul the relief valve if it
MIXING THE HYDRAULIC FLUID does not open within these limits.
(CHAPTER 12).
c. Set the hydraulic test stand pressure to 600
1. Use a hydraulic test stand which is equipped with ±25 PSI (4137 ±172 kPa) (1000 ±25 PSI (6895
a 10-micron filter and a calibrated pressure gauge with ±172 kPa) for 206L1+ IGW Upgrade) and position the
a range up to 1000 PSI (6895 kPa) (1500 PSI CONTROL BOOST switch to OFF. Move the pilot
(10,342 kPa) for 206L1+ IGW Upgrade). The test cyclic and collective controls. They will require more
stand must be capable of producing 1000 PSI force to move than they did in step a if the solenoid
(6895 kPa) (1500 PSI (10,342 kPa) for 206L1+ IGW valve (8) closed as it should have. Position the
Upgrade) at a minimum flow rate of 2 gallons per CONTROL BOOST switch to ON.
minute (2.8 gallons per minute for 206L1+ IGW
Upgrade). Clean the stand and service with hydraulic d. Reduce the hydraulic test stand pressure to
fluid (Chapter 12) prior to use. zero, then increase pressure slowly. Move the cyclic
and collective controls as pressure increases.
2. Inspect the helicopter hydraulic system visually to Changeover from mechanical to hydraulic operation
ensure that all components and lines are attached, should occur at 100 to 188 PSI (689 to 1296 kPa).
cotter pins and lockwire installed, and system appears This is a result of action of the three sequence valves
capable of satisfactory operation. (Figure 29-1, Detail B). Make sure that this
requirement is met for the collective, lateral cyclic, and
forward and aft cyclic controls.
3. Position the hydraulic test stand on the right side
of the helicopter near the transmission/engine
e. Reduce the hydraulic test stand pressure to
compartment.
zero. Grasp the rod end of each servo actuator, in turn,
and push-pull with approximately 50 pounds (222 N)
4. Remove the forward transmission fairing. force. The piston rods should not move.
Disconnect the two quick disconnect couplings (3 and
4, Figure 29-2). Connect the test stand hoses to the f. Check the hydraulic system components for
coupling half of the two quick disconnects that are evidence of leaks (paragraph 29-3).
attached to the filter assemblies (5 and 6).
g. Disconnect the hydraulic test stand and
5. Apply electrical power to the helicopter and connect the helicopter quick disconnect couplings (3
position the HYDR SYSTEM circuit breaker in and the and 4, Figure 29-2). Check the hydraulic fluid level in
HYDR SYSTEM switch to ON. the reservoir and replenish, if necessary.
29-00-00
BHT-206L1-MM-1
29-7. HYDRAULIC SYSTEM — OPERATIONAL 6. Position the pilot HYDRAULIC SYSTEM switch to
CHECK USING HELICOPTER SYSTEM ON. When the engine has been operating a total of
15 minutes, check the hydraulic system components
1. If a hydraulic test stand is not available, an for leaks (paragraph 29-3).
operational check of the hydraulic system may be
done using the transmission driven hydraulic pump 29-8. HYDRAULIC PUMP — OPERATIONAL
(10, Figure 29-2). This test is less comprehensive than CHECK
the test described in paragraph 29-6.
2. Visually inspect the helicopter hydraulic system to MATERIALS REQUIRED

ensure that all components and lines are attached,
cotter pins and lockwire installed, and system appears Refer to BHT-ALL-SPM for specifications.
capable of satisfactory operation.
NUMBER NOMENCLATURE
C-405 Lockwire
CAUTION
1. Remove the plug from the test port of one servo
A QUALIFIED PERSON MUST BE AT THE actuator and connect a calibrated pressure gauge (0
HELICOPTER CONTROLS DURING THE to 1000 PSI (0 to 6895 kPa) (0 to 1500 PSI (0 to
FOLLOWING PROCEDURE. 10,342 kPa) for 206L1+ IGW Upgrade) range).
3. Ground run the helicopter at flight idle RPM and 2. Ground run the helicopter at flight idle RPM and
position the HYDRAULIC SYSTEM switch to ON and check the indication on the calibrated pressure gauge.
the HYDR SYSTEM circuit breaker in. The hydraulic system pressure should be 600 ±25 PSI
(4137 ±172 kPa) (1000 ±25 PSI (6895 ±172 kPa) for
4. Move the cyclic and collective controls slowly to 206L1+ IGW Upgrade).
the allowable limits for ground operation with the
engine at flight idle RPM. Check the servo actuators a. If the hydraulic system pressure is not within
and hoses for binding, chafing, and movement of limits, replace or overhaul the hydraulic pump.
hoses, which would tend to loosen the fittings.
b. If the hydraulic system pressure is within
5. Position the pilot HYDRAULIC SYSTEM switch to limits, remove the gauge, install the test port plug,
OFF. A greater force should be required to move the secure with lockwire (C-405), and return the helicopter
cyclic and collective controls. to flight configuration.
29-00-00
BHT-206L1-MM-1
HYDRAULIC SYSTEM COMPONENTS
29-8. HYDRAULIC RESERVOIR 29-10. HYDRAULIC RESERVOIR — INSPECTION
The hydraulic reservoir (17, Figure 29-3) and cover (4) 1. Inspect the brace and support for security and
are constructed from magnesium alloy. The reservoir damage.
is mounted on a brace and support forward of the main
transmission and above the hydraulic pump assembly. 2. Inspect the reservoir (17, Figure 29-3) for
evidence of leakage, corrosion, and damage.
29-9. HYDRAULIC RESERVOIR — REMOVAL
3. Inspect the sight plug (8) for discoloration. The
indicator is considered serviceable if the hydraulic fluid
MATERIALS REQUIRED level in the reservoir is visible through the sight plug.

4. Inspect the strainer (6) for serviceability. No tears
NUMBER NOMENCLATURE or distortion that would permit the entry of particles
larger than the mesh of the screen wire are permitted.
C-428 Caps and/or Plugs
5. Inspect the latch (10) for distortion and wear that
1. To drain the reservoir of hydraulic fluid into a would affect function.
suitable container, remove the plug (15, Figure 29-3)
and the packing (16). 29-11. HYDRAULIC RESERVOIR —
INSTALLATION
2. Disconnect the return line from the baffle (11) on
the aft side of the reservoir.
MATERIALS REQUIRED
3. Disconnect the hose from the union (13) on the
bottom of the reservoir. Refer to BHT-ALL-SPM for specifications.
NUMBER NOMENCLATURE
4. Install caps and/or plugs (C-428) on all open
ports to prevent contamination of the hydraulic system. C-002 Hydraulic Fluid
5. Remove the three nuts, washers, and bolts from C-072 Hydraulic Fluid
the bottom of the reservoir (17) and from the brace
and support. Remove the reservoir. C-314 Adhesive
C-405 Lockwire
6. Remove the sight plug (8), baffle (11), union (13),
and plug (19). Discard the packings (9, 12, 14, 16,
and 18).
NOTE
NOTE control hydraulic systems, the same
The strainer (6) is sealed to the inside lip of specification of hydraulic fluid already used
the reservoir flange. With the aid of a in the hydraulic system shall be used.
non-sharp tool, pry the strainer from the However, in circumstances where
inside flange lip with gentle pressure to emergency top-off, inadvertent mixing, or
prevent damage. purposeful conversion to the other specified
7. Open the latch (10) and the cover (4) on the hydraulic fluid of the other approved
reservoir (17). Remove the strainer (6) and the specification. No further maintenance
gasket (7). action will be required.
29-00-00
BHT-206L1-MM-1
Figure 29-3. Hydraulic Reservoir
29-00-00
BHT-206L1-MM-1
1. Clean and flush the reservoir with hydraulic fluid in the hydraulic system shall be used.
(Chapter 12). However, in circumstances where
NOTE fluid may occur, it is acceptable to use
Lubricate all packings with hydraulic fluid hydraulic fluid of the other approved
(C-002) or hydraulic fluid (C-072) before specification. No further maintenance
installation. action will be required.
2. Install the packing (9, Figure 29-3) on the sight 11. Fill the reservoir (17) to the proper level with
plug (8) and install in the reservoir (17). Secure the hydraulic fluid (Chapter 12). Bleed the hydraulic
sight plug to the reservoir with lockwire (C-405). system (paragraph 29-5).
3. Install the packing (12) on the baffle (11) and 29-12. HYDRAULIC PUMP
install in the reservoir (17).
The hydraulic pump (6, Figure 29-4) is mounted on,
4. Install the packing (14) on the union (13) and and driven through, the rotor tachometer generator
install in the reservoir (17). (11). The pump is a variable delivery, self-lubricated
type, and is designed to operate continuously, and
provide a rated discharge pressure of 600 ±25 PSI
5. Install the packings (16 and 18) on the plugs (15
(4137 ±172 kPa) (1000 ±25 PSI (6895 ±172 kPa) for
and 19) respectively, and install in the reservoir (17).
206L1+ IGW Upgrade). The pump contains four
Secure the plugs with lockwire (C-405).
marked ports: inlet, outlet, case, and seepage drain.
6. Install the gasket (7) inside the reservoir (17) in 29-13. HYDRAULIC PUMP — REMOVAL
the groove of the flange and lip.
7. Prepare the inside flange of the reservoir (17) and MATERIALS REQUIRED
the mating surface of the strainer (6) for silicone
bonding (BHT-ALL-SPM, Chapter 7). Bonding shall be Refer to BHT-ALL-SPM for specifications.
accomplished with a 1/16 inch (1.58 mm) bead of
adhesive (C-314) to only two sides of the lip of the NUMBER NOMENCLATURE
reservoir flange. Press the strainer firmly against the
lip. C-428 Caps and/or Plugs
8. If the cover (4) was removed, reinstall and secure 1. Disconnect the hoses (1, 9, and 22, Figure 29-4)
with the pin (2), washer, (3), and cotter pin (1). Close from the hydraulic pump (6). Position a suitable
the cover and secure with the latch (10). container below the pump to hold the hydraulic fluid.
9. Position the reservoir (17) on the brace and 2. Install caps and/or plugs (C-428) on all open
support and secure with the bolts, washers, and nuts. ports to prevent contamination of the pump or the
Make sure an aluminum washer is installed under hydraulic system.
each bolt head and nut.
3. Remove the four nuts (16) and the washers (15).
10. Connect the hose assembly to the union (13) on Remove the hydraulic pump (6) and the gasket (14).
the bottom of the reservoir (17) and the tube assembly Discard the gasket.
to the baffle (11) on the aft side of the reservoir.
4. Remove the check valve (8) and discard the
packing (7).
NOTE
When adding hydraulic fluid to the flight 5. Remove the elbows (2 and 21) by loosening the
control hydraulic systems, the same nuts (3 and 20). Discard the packings (5 and 18) and
specification of hydraulic fluid already used the rings (4 and 19).
29-00-00
BHT-206L1-MM-1
1. Inlet Port Hose

2. Elbow
3. Nut
4. Ring
5. Packing
6. Hydraulic Pump
7. Packing
8. Check Valve
9. Case Port Hose
10. Gasket
11. Rotor Tachometer Generator
12. Washer
13. Nut
14. Gasket
15. Washer
16. Nut
17. Seepage Drain Port Plug
18. Packing
19. Ring
20. Nut
21. Elbow
22. Outlet Port Hose
206L_MM_29_0004
Figure 29-4. Hydraulic Pump
29-00-00
BHT-206L1-MM-1
29-14. HYDRAULIC PUMP — INSPECTION (plastic type) to separate the input shaft from the
hydraulic pump (2).
1. When the hydraulic pump (6, Figure 29-4) is
installed, inspect for secure mounting on the rotor b. Discard the retainer ring (3) and the retaining
tachometer generator (11). spring (4).
2. Inspect the port hoses (1, 9, and 22) for damage 2. Inspect the hydraulic pump internal driveshaft to
and leakage. make sure it has no flat spots, is chipped, or has
uneven wear of splines (Figure 29-6). If the internal
driveshaft is damaged, send the pump for overhaul.
3. Inspect the packings at the check valve (8) and
the elbows (2 and 21) for leakage or damage.
3. Install the input driveshaft (1, Figure 29-5) in the
4. When the hydraulic pump (6) is removed, inspect hydraulic pump (2) as follows:
for the following:
a. Install the retainer ring (3) on the input
a. Damaged threads in the pump ports. driveshaft (1).
b. Damaged driveshaft splines. Refer to b. Apply a light coating of grease (C-525) or

paragraph 29-15 for the removal and installation of the grease (C-561) to the input shaft splines and use a
input driveshaft. small amount of grease (C-525) or grease (C-561) to
hold the spring (4) in the input driveshaft end.
c. Damage, corrosion, or distorted threads on
the fittings and the hoses. c. Invert the hydraulic pump (2) and insert the
input driveshaft (1) with the assembled retainer ring (3)
and the spring (4) into the internal driveshaft and press
29-15. HYDRAULIC PUMP INPUT DRIVESHAFT
in until the retainer ring snaps into the groove of the
— REMOVAL AND INSTALLATION
internal driveshaft.
(TB 206L-03-211)
29-16. HYDRAULIC PUMP — INSTALLATION

MATERIALS REQUIRED

MATERIALS REQUIRED
NUMBER NOMENCLATURE
C-525 Grease
NUMBER NOMENCLATURE
C-561 Grease
NOTE C-012 Lubricant

The force needed to remove the external C-072 Hydraulic Fluid
shaft can vary due to differences in retainer
ring spring load. C-525 Grease
1. Remove the hydraulic input driveshaft (1, C-561 Grease

Figure 29-5) from the hydraulic pump (2) as follows:
1. If a new pump is being installed, remove the
a. Clamp the input driveshaft (1) in a vise with shipping plugs and allow preservative fluid to drain
soft jaws and tap the housing lightly with a small mallet from the pump.
29-00-00
BHT-206L1-MM-1
1 4
1 2 3
2 4
1. Input driveshaft (67541)

2. Hydraulic pump (206-076-030-003/-101)
3. Retainer ring (25399)
4. Spring (67588)
NOTES
1 Use grease (C-525) or grease (C-561) to hold spring.
2 Apply a light coating of grease (C-525) or grease (C-561).
3 Use input driveshaft (20546) for 206L1+ IGW upgrade helicopters.
4 Use hydraulic pump (206-076-030-117) for 206L1+ IGW upgrade helicopters.
206L1_MM_29_0005
Figure 29-5. Hydraulic Pump Input Driveshaft — Removal and Installation (TB 206L-03-211)
29-00-00
BHT-206L1-MM-1
Figure 29-6. Hydraulic Pump Input Driveshaft — Inspection (TB 206L-03-211)
29-00-00
BHT-206L1-MM-1
NOTE NOTE
When adding hydraulic fluid to the flight When adding hydraulic fluid to the flight
control hydraulic systems, the same control hydraulic systems, the same
specification of hydraulic fluid already used specification of hydraulic fluid already used
in the hydraulic system shall be used. in the hydraulic system shall be used.
However, in circumstances where However, in circumstances where
emergency top-off, inadvertent mixing, or emergency top-off, inadvertent mixing, or
purposeful conversion to the other specified purposeful conversion to the other specified
fluid may occur, it is acceptable to use fluid may occur, it is acceptable to use
hydraulic fluid of the other approved hydraulic fluid of the other approved
specification. No further maintenance specification. No further maintenance
action will be required. action will be required.
NOTE 8. Fill the reservoir to proper level with hydraulic

fluid (C-002) or hydraulic fluid (C-072). Bleed the
All packings must be lubricated with
hydraulic system (paragraph 29-5).
hydraulic fluid (C-002) or hydraulic fluid
(C-072) prior to installation.
29-17. HYDRAULIC FILTERS
2. Fill the pump case with hydraulic fluid
(Chapter 12). Install the new packing (7, Figure 29-4) Two hydraulic filters are installed on a bracket on the
on the check valve (8) and install in the hydraulic forward right side of the cabin roof near the
pump (6). Make sure that the arrow embossed on the transmission. One filter is installed in the pressure line
check valve is pointed away from the pump. and one in the return line. The return line filter
incorporates a differential pressure indicator (4,
3. Install the elbows (2 and 21) with the nuts (3 and Figure 29-7) with a red indicator button (5).
20), new rings (4 and 19), and new packings (5 and
18) in the hydraulic pump (6). Before torquing the nuts, The bypass valve, located internally in the return line
position the elbows to align with the hose assemblies filters, serves to prevent over-pressurization of the
(1 and 22). return system if the filter element in the return line
becomes clogged. The bypass valve will open when
4. Remove the seepage drain port plug (17), if the pressure drop across the filter element increases
installed. to 100 ±10 PSI (689 ±69 kPa). When pressure
decreases to 65 PSI (450 kPa) minimum, the bypass
valve will close. Therefore, if the filter element in the
5. Apply grease (C-525), grease (C-561), or
return line becomes clogged, the bypass valve will
lubricant (C-012) to the splines of the hydraulic pump
open and allow fluid to bypass the filter and return to
(6) and to the mating splines of the rotor tachometer
the reservoir. The hydraulic pump has an internal
generator (11).
pressure compensator that prevents application of
excessive pressure to the filter in the pressure line.
6. Position the hydraulic pump (6) and the new Therefore, no bypass valve is required in the pressure
gasket (14) on the rotor tachometer generator (11) line filter.
with the check valve (8) up, as shown. Secure with the
four thin aluminum washers (15) and the nuts (16).
NOTE
7. Connect the hoses (1, 9, and 22) to the pump Removal, installation, inspection, and
fittings as shown. cleaning procedures for hydraulic filter
elements are identical for both the pressure
and return line filters.
29-00-00
BHT-206L1-MM-1
6 5
1
4
18
20 9
11
7 10
12
21
22
2 3
13
14
OIL 15
1 FLOW
IN OUT
19 23
16
17
2
1. Coupling half 19. Hose assembly
2. Coupling half 20. Bolt
3. Preformed packing 21. Washer
4. Differential pressure indicator 22. Nut
5. Red indicator button 23. Filter bracket assembly
6. Bolt
7. Retainer
8. Preformed packing
10. Preformed packing FILTER ASSEMBLY
11. Union (TYPICAL)
12. Filter body
14. Retainer
16. Element
LOCKWIRE (C-508)
17. Filter bowl 1
18. Tube assembly 20 TO 60 IN-LBS
LOCKWIRE (C-405) (2.86 TO 6.78 Nm)
2
206L4_MM_29_0008+
Figure 29-7. Hydraulic Filter and Element
29-00-00
BHT-206L1-MM-1
29-18. HYDRAULIC FILTERS — DIFFERENTIAL 1. Open the forward fairing (Chapter 71).
PRESSURE INDICATOR —
OPERATIONAL CHECK 2. Remove the transmission fairing (Chapter 71).
3. Remove the pressure filter element (16,

SPECIAL TOOLS REQUIRED Figure 29-7).
4. Install the dummy filter element (Workaid No. 1,

NUMBER NOMENCLATURE Figure 29-8) instead of the pressure filter.
Workaid No. 1 Dummy Filter Element
5. Connect the hydraulic test stand to the helicopter
Commercial 206L1 and 206L1 Engine (paragraph 29-6).
Upgrade: Hydraulic Test
Stand, 1000 PSI (6895 kPa) 6. Set the hydraulic test stand pressure to 600
Pressure Maximum, 2 GPM ±25 PSI ((4137 ±172 kPa) (1000 ±25 PSI (6895
(7.6 L/min), 10 Micron ±172 kPa) for 206L1+ IGW Upgrade).
Commercial 206L1+ IGW Upgrade: NOTE

Hydraulic Test Stand, When the controls are moved with the
1500 PSI (10,342 kPa) dummy filter installed on the pressure side,
Pressure Maximum, 2.8 GPM a hydraulic OFF condition is felt. Additional
(10.6 L/min), 10 Micron force is required to move the controls.
7. With the hydraulic system on, move the controls
to their limits of motion several times.
MATERIALS REQUIRED 8. Inspect for extension of the red button on the

pressure filter housing assembly. If the button is not
Refer to BHT-ALL-SPM for specifications. extended, disassemble, clean, reassemble, and retest
the red indicator button. If the button still does not
NUMBER NOMENCLATURE extend, replace the filter housing assembly (paragraph
29-19).
C-405 Lockwire
9. If the red indicator button extends during the test,
the test is complete. Remove the dummy filter element
Do an operational check of the red indicator buttons (Workaid No. 1), reset the red indicator button, and
on the pressure line filter assembly and on the return install a serviceable filter element (paragraph 29-24).
line filter assembly as follows: Install safety lockwire (C-405).
10. Remove the return filter element.

CAUTION
11. Install the dummy filter element instead of the
return filter.
SET HYDRAULIC TEST STAND
PRESSURE BACK TO ZERO BEFORE 12. Set the hydraulic test stand pressure to 600
REMOVING ANY FILTER ELEMENT OF ±25 PSI (4137 ±172 kPa) (1000 ±25 PSI (6895
THE HYDRAULIC SYSTEM. ±172 kPa) for 206L1+ IGW Upgrade).
29-00-00
BHT-206L1-MM-1
2.500 IN. (63.5 mm)
0.625 IN. (15.87 mm)
0.315 IN. (8.0 mm)
0.055 IN. (1.39 mm)
0.625 IN.
(15.87 mm) 0.430 IN.
(10.9 mm)
0.463 IN. 0.3125 IN.

(11.76 mm) (7.93 mm)
1
0.075 IN. (1.90 mm)
MATERIAL: ALUMINUM
NOTE
1 Install preformed packing into groove on inside diameter of workaid. Preformed
packing - 7/16 O.D. x 5/16 I.D. (Part number M83461/1-011 or MS28775-011).
NO OBJECT BEYOND THIS POINT 407_MM_29_0012+
Figure 29-8. Workaid No. 1 — Dummy Filter Element
29-00-00
BHT-206L1-MM-1
29-19. HYDRAULIC FILTERS — REMOVAL

NOTE
When the controls are moved with the
dummy filter installed on the right side, a
MATERIALS REQUIRED
hydraulic ON condition is felt due to the
bypass capability of the return filter housing
assembly. The controls are easily moved
throughout their entire range. NUMBER NOMENCLATURE
13. With the hydraulic system on, move the controls C-428 Caps and/or Plug
to their limits of motion several times.
14. Inspect for extension at the red button on the CAUTION

return filter housing assembly. If the button is not
extended, disassemble, clean, reassemble, and retest
the red indicator button. If the button still does not CLOSE ALL PORTS, TUBES, AND
extend, replace the filter housing assembly. HOSES WITH CAPS AND/OR PLUGS
(C-428) AS YOU REMOVE THEM. THIS
15. If the red indicator button extends during the test, WILL PREVENT CONTAMINATION OF
the test is complete. Remove the dummy filter UNWANTED MATERIALS INTO THE
element, reset the red indicator button, and install a HYDRAULIC SYSTEM.
serviceable filter element. Install safety lockwire
(C-405). NOTE
This procedure is for the hydraulic filter on
16. Remove the hydraulic test stand (paragraph the return system (Figure 29-7). The
29-6). procedure is the same for the hydraulic
filter on the pressure system except where
indicated.
NOTE
When adding hydraulic fluid to the flight 1. Open the forward fairing (Chapter 71).
control hydraulic systems, the same
specification of hydraulic fluid already used 2. Remove the transmission fairing (Chapter 71).
in the hydraulic system shall be used.
However, in circumstances where
3. Disconnect the coupling half (1, Figure 29-7) from
the coupling half (2).
hydraulic fluid of the other approved 4. Disconnect the tube assembly (18) from the
specification. No further maintenance union (11).
5. Remove the two bolts (20) with the attaching nuts
17. Fill the hydraulic system (Chapter 12). (22) and the washers (21) that secure the filter body
(12) to the filter bracket assembly (23) mounted on the
cabin roof. Remove the filter body.
18. Bleed air from the hydraulic system (paragraph
29-5).
6. Remove the coupling half (2) and discard the
preformed packing (3).
19. Install the transmission fairing (Chapter 71).
7. Remove the union (11) and discard the
20. Close the forward fairing (Chapter 71). preformed packing (10).
29-00-00
BHT-206L1-MM-1
8. For removal of the element (16), refer to 8. Remove the preformed packing (15) from the
paragraph 29-25. element (16). Discard the preformed packing.
29-20. HYDRAULIC FILTERS — DISASSEMBLY 29-21. HYDRAULIC FILTERS — INSPECTION
NOTE
MATERIALS REQUIRED
This procedure is for the hydraulic filter on
the return system (Figure 29-7). The Refer to BHT-ALL-SPM for specifications.
procedure is the same for the hydraulic
filter on the pressure system except where NUMBER NOMENCLATURE
indicated.
C-304 Drycleaning Solvent
1. Remove the coupling half (2, Figure 29-7) and
the preformed packing (3).
WARNING
2. Remove the union (11) and the preformed
packing (10). Discard the preformed packing.
USAGE OF ISOPROPYL ALCOHOL IS
3. Carefully cut and remove the lockwire from the PROHIBITED ON EITHER INTERNAL OR
bolts (6) on the differential pressure indicator (4). EXTERNAL SURFACES OF HYDRAULIC
COMPONENTS.
4. Remove the differential pressure indicator (4),
preformed packing (9), preformed packing (8), and
NOTE
retainer (7). Discard the preformed packings and the
retainer. This procedure is for the hydraulic filter on
the return system (Figure 29-7). The
5. Carefully cut and remove the lockwire from the procedure is the same for the hydraulic
filter bowl (17) and from the filter body (12). Make sure filter on the pressure system except where
not to damage the lockwire holes in the filter bowl or in indicated.
the filter body.
1. Clean the filter body with drycleaning solvent
(C-304). For inspection and cleaning of the element,
6. Remove the filter bowl (17), element (16),
refer to paragraph 29-26.
preformed packing (13), and retainer (14). Discard the
preformed packing and the retainer.
2. Examine the filter body for scratches, nicks, and
dents.
NOTE
If the element (16) will be used again, put it 3. Examine the threaded ports, coupling, coupling
in a new clean plastic bag to prevent half, and union for damaged threads and fluid leakage.
contamination.
4. Examine the red indicator button (5, Figure 29-7)
7. Remove the element (16) from the filter of the differential pressure indicator (4) for proper
bowl (17). operation.
29-00-00
BHT-206L1-MM-1
29-22. HYDRAULIC FILTERS — ASSEMBLY 3. Install the retainer (7) in the filter body (12).
4. Install the differential pressure indicator (4) on the

MATERIALS REQUIRED filter body (12) with the bolts (6). Tighten the bolts.
Refer to BHT-ALL-SPM for specifications. 5. Safety the bolts (6) on the differential pressure
indicator (4) with lockwire (C-508).
NUMBER NOMENCLATURE
C-002 Hydraulic Fluid 6. Install the preformed packing (15) in the

element (16).
7. Install the element (16) in the filter bowl (17).
C-405 Lockwire Make sure the element retention springs engage in the
retention groove in the filter bowl.
C-508 Lockwire
8. Install the preformed packing (13) in the filter

body (12).
NOTE
This procedure is for the hydraulic filter on 9. Install the retainer (14) in the filter body (12).
the return system (Figure 29-7). The
procedure is the same for the hydraulic
filter on the pressure system except where NOTE
indicated. When adding hydraulic fluid to the flight
NOTE specification of hydraulic fluid already used
When adding hydraulic fluid to the flight However, in circumstances where
control hydraulic systems, the same emergency top-off, inadvertent mixing, or
specification of hydraulic fluid already used purposeful conversion to the other specified
in the hydraulic system shall be used. fluid may occur, it is acceptable to use
However, in circumstances where hydraulic fluid of the other approved
emergency top-off, inadvertent mixing, or specification. No further maintenance
purposeful conversion to the other specified action will be required.
hydraulic fluid of the other approved 10. Fill the filter bowl (17) half full with hydraulic fluid
specification. No further maintenance (Chapter 12).
11. Install the filter bowl (17) in the filter body (12).
NOTE Torque the filter bowl T .
Lubricate all preformed packings and
retainers with hydraulic fluid (C-002) or 12. Install the preformed packing (10) on the
hydraulic fluid (C-072) before installation. union (11).
Apply a layer of hydraulic fluid (C-002) or
hydraulic fluid (C-072) to the threads of all 13. Install the union (11) on the filter body (12).
the fittings before installation. Tighten the union.
1. Install the preformed packing (9, Figure 29-7) in 14. Install the preformed packing (3) on the coupling
the differential pressure indicator (4). half (2).
2. Install the preformed packing (8) in the filter 15. Install the coupling half (2) on the filter body (12).
body (12). Tighten the coupling half.
29-00-00
BHT-206L1-MM-1
assembly (5) incorporates an internal

bypass valve. Also, the hole pattern for the
CAUTION
mounting bolt holes is different. In addition,
coupling halves (1 and 2, Figure 29-7) are
of different sizes to minimize the possibility
DO NOT TIGHTEN THE LOCKWIRE ON
of assembling quick disconnects
FILTER BODY AND FILTER BOWL TOO
incorrectly.
TIGHT. IF YOU TIGHTEN THE
LOCKWIRE TOO TIGHT, THE LOCKWIRE
HOLES CAN GET DAMAGED. 5. Attach the coupling half (1, Figure 29-7) to the
mating coupling half (2) and secure.
16. Carefully safety the filter body (12) to the filter
bowl (17) with lockwire (C-405).
NOTE
17. Repeat step 1 through step 16 to assemble the When adding hydraulic fluid to the flight
hydraulic filter on the pressure system. control hydraulic systems, the same
29-23. HYDRAULIC FILTERS — INSTALLATION in the hydraulic system shall be used.
MATERIALS REQUIRED purposeful conversion to the other specified
Refer to BHT-ALL-SPM for specifications. hydraulic fluid of the other approved
NUMBER NOMENCLATURE action will be required.
C-002 Hydraulic Fluid 6. Fill the hydraulic reservoir (9, Figure 29-2) with
hydraulic fluid (Chapter 12) to the correct level.
7. Bleed the hydraulic system (paragraph 29-5).

1. Lubricate the new preformed packings (3 and 10,
Figure 29-7) with hydraulic fluid (C-002) or hydraulic
fluid (C-072). 29-24. HYDRAULIC FILTER ELEMENT
2. Install the new preformed packing (3) on the The filter element removes the particles from the
coupling half (2) and install in the inlet port of the filter hydraulic fluid. These particles come from the usual
body (12). Tighten the coupling half. wear of hydraulic components. The filtration rate is
590.6 micro-inches (15 microns) absolute. The filter
element operates at high pressure on a large
3. Install the new preformed packing (10) on the
temperature range. Examine, clean, or replace the
union (11) and install in the outlet of the filter body
filter element when the red indicator button extends
(12). Tighten the union.
and at the recommended inspection intervals
(Chapter 5).
4. Position the return line filter body on the outboard
side of the bracket and secure with the two bolts (20),
29-25. HYDRAULIC FILTER ELEMENT —
aluminum washers (21), and nuts (22). Position the
REMOVAL
pressure line filter body on the inboard side of the
bracket and secure with the two bolts, aluminum
washers, and nuts. Tighten the nuts. 1. Remove the transmission fairing (Chapter 71).
2. Carefully cut and remove the lockwire from the

NOTE
filter bowl (17, Figure 29-7) and from the filter body
The filter assemblies (5 and 6, Figure 29-2) (12). Make sure that you do not damage the lockwire
are different in that the return line filter holes in the filter bowl or in the filter body.
29-00-00
BHT-206L1-MM-1
3. Remove the filter bowl (17), element (16), contamination is found and flush the hydraulic system
preformed packing (13), and retainer (14). Discard the as per paragraph 29-4.
packing and the retainer.
3. The element (16) can be cleaned by vigorous
4. Remove the element (16) from the filter bowl (17). agitation in one of the following solutions:
5. Remove the preformed packing (15) from the • Hydraulic fluid (C-002) or hydraulic fluid
element (16). Discard the packing. (C-072).
29-26. HYDRAULIC FILTER ELEMENT — • Safety solvent (C-319) or equivalent

INSPECTION AND CLEANING
• Turbine fuel (C-003)
MATERIALS REQUIRED • Solvent (C-389)
Refer to BHT-ALL-SPM for specifications. • 0.5% of cleaning compound (C-318) in filtered

water. Backflush with water.
NUMBER NOMENCLATURE
C-002 Hydraulic Fluid NOTE
C-003 Turbine Fuel Install caps and/or plugs (C-428) on both

ends of the filter element to prevent
C-072 Hydraulic Fluid contaminant migration into the element.
C-318 Cleaning Compound
C-319 Safety Solvent CAUTION

C-389 Solvent
C-428 Caps and/or Plugs DO NOT PUT THE FILTER ELEMENT

INTO AN ULTRASONIC CLEANER. THIS
WILL DAMAGE THE ELEMENT.
CAUTION 4. Submerge and agitate the element vigorously by

hand in one of the approved solutions.
DO NOT USE ALCOHOL ON THE 5. Backflush the element (16) with the same type of
HYDRAULIC COMPONENTS. ALCOHOL solution used in step 4. Solvent/air mixture can be
CAN CAUSE DAMAGE TO THE utilized. Backflush pressure to be 10 to 15 PSIG (69 to
COMPONENTS. 103 ΔkPa)
NOTE 6. Repeat step 1. If the element (16) is undamaged,

go to step 7.
The filter element can be cleaned a
maximum of three times.
7. Dry the element (16) with dry filtered air at 50 to
1. Visually inspect the element (16, Figure 29-7) for 60 PSI (345 to 414 kPa).
damage. If any defects on or near the filtering
surfaces, or sealaing area are noted, do not clean the
element, replace it with a new element. NOTE
Lubricate the preformed packing (15) and
2. Inspect the filtering core for metal, brass, and the retainer (14) with hydraulic fluid (C-002)
aluminum contamination. Replace the element if or hydraulic fluid (C-072) before installation.
29-00-00
BHT-206L1-MM-1
8. Replace the preformed packing (15). in the hydraulic system shall be used.
9. Verify the retention spring on the element (16) for emergency top-off, inadvertent mixing, or
serviceability. purposeful conversion to the other specified
hydraulic fluid of the other approved
10. Scribe an X on the element (16) bottom end to
indicate each cleaning event.
29-27. HYDRAULIC FILTER ELEMENT — 5. Fill the hydraulic reservoir (9, Figure 29-2) with
INSTALLATION hydraulic fluid (Chapter 12) to the correct level.
6. Bleed the hydraulic system (paragraph 29-5).

MATERIALS REQUIRED
Refer to BHT-ALL-SPM for specifications. 29-28. HYDRAULIC SOLENOID VALVE
NUMBER NOMENCLATURE The solenoid valve (31, Figure 29-9) is incorporated in

the hydraulic system for turning the system on and off.
The solenoid valve is installed forward of the
C-072 Hydraulic Fluid transmission in the center work deck area. The
solenoid valve is normally open, and when the HYDR
C-405 Lockwire SYSTEM circuit breaker is in and the HYDRAULIC
SYSTEM switch is OFF, electrical power is applied to
the solenoid which closes the valve and removes
hydraulic pressure from the three servo actuators
NOTE
(Figure 29-1).
hydraulic fluid (C-002) or hydraulic fluid 29-29. HYDRAULIC SOLENOID VALVE —
(C-072) before installation. Preformed REMOVAL
packing (15, Figure 29-7) is furnished with
each new element (16).
1. Make sure that a serviceable preformed packing MATERIALS REQUIRED

(15) is installed in the element (16) and is seated in the
groove. Refer to BHT-ALL-SPM for specifications.
NUMBER NOMENCLATURE
2. Press the ends of the springs on the element (16)
and insert in the filter bowl (17) until the springs C-428 Caps and/or Plugs
engage in the retention groove.
3. Install the preformed packing (13) and the 1. Position the battery switch to OFF and disconnect
retainer (14) in the filter body (12). the external power if it is connected.
4. Thread the filter bowl (17) into the filter body (12) 2. Disconnect the electrical connector from the
and torque T . Secure the filter bowl to the filter body solenoid valve (31, Figure 29-9).
with lockwire (C-405).
3. Drain the hydraulic fluid from the reservoir. Place
cloths around the solenoid valve (31) to absorb the
NOTE hydraulic fluid during removal.
control hydraulic systems, the same 4. Disconnect the tube assemblies from the reducer
specification of hydraulic fluid already used (30) on the forward end of the solenoid valve (31).
29-00-00
BHT-206L1-MM-1
5. Disconnect the tube assemblies from the tee (1),

unions (21 and 39), and reducer (27). Disconnect the NOTE
hose assembly from the elbow (15). All packings must be lubricated with
6. Remove the two bolts (32) and the aluminum (C-072) before installation.
washers (33) from the solenoid valve (31) and remove
the assembly from the helicopter. 1. Install the packing (29, Figure 29-9) on the
reducer (30) and install on the solenoid valve (31).
ports to prevent system contamination. 2. Install the packing (34) on the bolt (35) and on the
solenoid valve (31). Torque the bolt 110 to
170 inch-pounds (12 to 19 Nm).
8. Remove the bolt (23) from the fitting (25) and the
solenoid valve (31). Discard the packings (24 and 28).
3. Install the packing (36) on the bolt (35) and
position against the inboard flat. Slide the body (37)
9. Remove the nut (41) and the body (37) from the
onto the bolt and install the packing (40) and the nut
bolt (35). Discard the packings (36 and 40).
(41). Torque the nut 110 to 170 inch-pounds (12 to
19 Nm) after positioning the body with the union (39)
10. Remove the bolt (35) and the reducer (30). forward, and the plugs (43 and 45) to the top and aft
Discard the packings (29 and 34). positions.
29-30. HYDRAULIC SOLENOID VALVE — 4. Install the packing (24) on the bolt (23) and in the
INSPECTION fitting (25). Install the packing (28) on the inboard end
of the fitting on the bolt. Torque the bolt 110 to 170
1. Inspect the installed solenoid valve (31, inch-pounds (12 to 19 Nm).
Figure 29-9) for secure mounting, damage, and
leakage. 5. Secure the bolt (23) to the fitting (25) and the nut
(41) to the body (37) with lockwire (C-405).
2. Inspect the electrical connector for tightness and
security. Inspect the electrical wiring for chafing and 6. Position the solenoid valve (31) and the attached
condition. part on the work deck at the mounting location and
secure with the two bolts (32) and the aluminum
washers (33).
3. Inspect the removed solenoid valve (31) for
damaged thread parts, corrosion, and operation of
solenoid. 7. Connect the mating hose and the tube
assemblies to their respective fittings. Connect the
electrical connector to the solenoid valve (31).
29-31. HYDRAULIC SOLENOID VALVE —
INSTALLATION
NOTE
MATERIALS REQUIRED When adding hydraulic fluid to the flight
Refer to BHT-ALL-SPM for specifications. specification of hydraulic fluid already used
NUMBER NOMENCLATURE However, in circumstances where
C-002 Hydraulic Fluid purposeful conversion to the other specified
C-072 Hydraulic Fluid hydraulic fluid of the other approved
C-405 Lockwire
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BHT-206L1-MM-1
Figure 29-9. Hydraulic Solenoid and Relief Valve
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BHT-206L1-MM-1
8. Fill the reservoir to the correct level with hydraulic 3. Perform a functional test of the relief valve
fluid (Chapter 12). Bleed the hydraulic system (paragraph 29-6).
(paragraph 29-5).
29-35. RELIEF VALVE — INSTALLATION
9. Do an operational check of the solenoid valve
(Chapter 96).
29-32. RELIEF VALVE MATERIALS REQUIRED

The relief valve (5, Figure 29-9) is incorporated in the
hydraulic system for controlling system pressure. The NUMBER NOMENCLATURE
relief valve is installed forward of the transmission in
the center work deck area. The relief valve is normally C-002 Hydraulic Fluid
closed, but if system pressure should exceed the
normal pressure range of 600 PSI (4137 kPa) C-072 Hydraulic Fluid
(1000 PSI (6985 kPa) for 206L1+ IGW Upgrade) and
rise to 670 to 750 PSI (4620 to 5170 kPa) (1075 to
1375 PSI (7412 to 9480 kPa) for 206L1+ IGW
Upgrade), the relief valve will open to protect the NOTE
system from damage.
29-33. RELIEF VALVE — REMOVAL
(C-072) prior to installation.
1. Install the packing (6, Figure 29-9) on the union

MATERIALS REQUIRED
(7) and install the RET end of the relief valve (5) to the
union.
NUMBER NOMENCLATURE 2. Connect the tube assemblies to the tee (1). The
tube assembly from the bottom of the tee is connected
to the solenoid valve (31), and the tube assembly from
the pressure filter assembly (6, Figure 29-2) is
1. Drain the hydraulic fluid from the reservoir. Place connected to the top of the tee (1, Figure 29-9).
cloths around the relief valve (5, Figure 29-9) to
absorb the hydraulic fluid.
NOTE
2. Disconnect the tube assemblies from the tee (1).
3. Remove the relief valve (5) from the union (7). control hydraulic systems, the same
Discard the packing (6). specification of hydraulic fluid already used
ports to prevent system contamination.
29-34. RELIEF VALVE — INSPECTION hydraulic fluid of the other approved
1. Inspect the installed relief valve (5, Figure 29-9) action will be required.
for secure mounting, damage, and leakage.
3. Fill the reservoir to the correct level with hydraulic
2. Inspect the removed relief valve (5) for damaged fluid (Chapter 12). Bleed the hydraulic system
threads in the ports, corrosion, and operation. (paragraph 29-5).
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BHT-206L1-MM-1
29-36. QUICK DISCONNECTS 29-40. HYDRAULIC HOSES AND TUBE

ASSEMBLIES
Two quick disconnect fittings are installed on the
helicopter to provide a convenient means of The hydraulic hoses and the tube assemblies
connecting a hydraulic test stand to the helicopter. illustrated in Figure 29-1 are used to connect the
Each quick disconnect is made up of two coupling components of the hydraulic system. The tube
halves (1 and 2, Figure 29-7). When disconnected, assemblies have sleeve end fittings that are retained
each coupling automatically closes to prevent loss of by flared ends of tubes.
fluid and/or entry of foreign matter.
29-41. HYDRAULIC HOSES AND TUBE
29-37. QUICK DISCONNECTS — REMOVAL ASSEMBLIES — REMOVAL
MATERIALS REQUIRED MATERIALS REQUIRED
Refer to BHT-ALL-SPM for specifications. Refer to BHT-ALL-SPM for specifications.
NUMBER NOMENCLATURE NUMBER NOMENCLATURE
C-428 Caps and/or Plugs C-428 Caps and/or Plugs
1. Grasp the coupling half (1, Figure 29-7) of the 1. Disconnect the hose or tube assembly at the
quick disconnect. Push toward the filter assembly and connecting fittings.
turn counterclockwise to disconnect the quick
disconnect. 2. Remove the attaching clamps that secure the
hose or the tube assembly to the helicopter and
2. Remove the coupling half (1) from the hose remove the hose or the tube assembly.
assembly (19) and the coupling half (2) from the filter
body (12). Be prepared to catch the hydraulic fluid 3. Install caps and/or plugs (C-428) on all open
when the couplings are removed from the hose ports to prevent system contamination.
assembly and the filter body.
29-42. HYDRAULIC HOSES AND TUBE
3. Install caps and/or plugs (C-428) on all open ASSEMBLIES — INSPECTION AND
ports to prevent system contamination. CLEANING
29-38. QUICK DISCONNECTS — INSPECTION

MATERIALS REQUIRED
Inspect the coupling halves (1 and 2, Figure 29-7) for
cracks, distortion, and proper locking when the two Refer to BHT-ALL-SPM for specifications.
couplings are joined.
NUMBER NOMENCLATURE
29-39. QUICK DISCONNECTS — INSTALLATION
1. Install the preformed packing (3, Figure 29-7) on
the coupling half (2) and install on the filter body (12). 1. Inspect the hose and the tube assemblies for
Tighten the coupling half. evidence of chafing, crimping, and damaged threads.
2. Connect the hose assembly (19) to the coupling 2. Inspect the hose and the tube assemblies for
half (1). Tighten the coupling nut. leakage (Table 29-2).
3. Assemble the quick disconnects and bleed the 3. Clean the hose and the tube assemblies prior to
hydraulic system (paragraph 29-5). installation with drycleaning solvent (C-304).
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BHT-206L1-MM-1
29-43. HYDRAULIC HOSES AND TUBE sure that there is no chafing between the hose or the
ASSEMBLIES — INSTALLATION tube assemblies and the helicopter components.
NOTE
MATERIALS REQUIRED
Refer to BHT-ALL-SPM for specifications. control hydraulic systems, the same
NUMBER NOMENCLATURE in the hydraulic system shall be used.
C-002 Hydraulic Fluid emergency top-off, inadvertent mixing, or
C-072 Hydraulic Fluid fluid may occur, it is acceptable to use
hydraulic fluid of the other approved
NOTE action will be required.
When torquing the hose nuts, use a backup 2. Fill the hydraulic reservoir (9, Figure 29-2) with
wrench on the hose end fitting to prevent hydraulic fluid (Chapter 12) to the correct level. Bleed
twisting of the hose. hydraulic system (paragraph 29-5).
1. Install the hose or the tube assemblies and 3. Inspect for hydraulic fluid leaks while system is
secure with clamps and supports, as required. Make pressurized.
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BHT-206L1-MM-1
CYCLIC AND COLLECTIVE SERVO ACTUATORS AND SUPPORT
29-44. CYCLIC AND COLLECTIVE SERVO reseat pressure within 120 PSI (827 kPa) of cracking
ACTUATORS AND SUPPORT pressure.
The cyclic and collective servo actuator support is 29-50. FILTER

installed on the cabin roof forward of the transmission.
The support serves as a mount for the three servo The inlet port of the servo valve contains a 150 micron
actuators and associated bellcranks. The collective absolute filter.
servo actuator is mounted in the center position of the
support and two cyclic servo actuators are mounted on
29-51. CYCLIC AND COLLECTIVE SERVO
the outboard positions.
ACTUATORS — REMOVAL
29-45. SERVO VALVE
The servo valve is a closed-center, four-way valve. MATERIALS REQUIRED

With the valve in neutral, there shall be no hydraulic
fluid flow out the return port except the leakage Refer to BHT-ALL-SPM for specifications.
specified in paragraph 29-3 and Table 29-2. The valve
operating load shall not exceed 8 ounces (237 ml) with NUMBER NOMENCLATURE
600 PSI (4137 kPa) pressure.
29-46. BYPASS VALVE
Removal procedures for the cyclic and collective servo
The bypass valve is a closed-centered, three-way actuators are similar except for the bellcrank and idler
valve. With the valve in neutral, there shall be no installation (Figure 29-10 and View A-A).
hydraulic fluid flow to the servo ports. The valve is
preloaded to the center position, and a force of 15 to 1. Disconnect the two screws (2) attached to the two
30 pounds (67 to 133 N) shall be required to override unions (3 and 5) on each servo actuator (15).
the preload force throughout its stroke in each
direction.
29-47. CHECK VALVES ports to prevent system contamination.
Check valves have a cracking pressure of 2 to 5 PSI 3. Disconnect the cyclic and collective control tubes
(14 to 34 kPa) and shall reseat with 1 PSI (7 kPa) of attached to the aft end of the servo actuators (15).
cracking pressure.
4. To disconnect the aft end of the servo actuators
29-48. SEQUENCE AND THERMAL RELIEF (15) from the cyclic idlers (21) and the collective idler
VALVE (43), remove the cotter pins (20), nuts (19), aluminum
washers (18), and bolts (17).
The sequence valve will open the return port at 100 to
188 PSI (689 to 1296 kPa) and shall provide full fluid
flow at a pressure not to exceed 275 PSI (1896 kPa). 5. To disconnect the two links (7) from each servo
The sequence valve also functions as a thermal relief actuator (15), remove the cotter pins (14), nuts (13),
valve at a static pressure of 125 to 200 PSI (862 to and bearing washers (12). Pull the links (7) from the
1379 kPa). The valve shall reseat after both functions studs on the servo valve trunnions (16).
at approximately 65% of the cracking pressure.
6. To disconnect the rod end bearings (11) from the
29-49. DIFFERENTIAL RELIEF VALVE actuator support (34), remove the cotter pins (33), nuts
(32), aluminum washers (30), bushings (31), and bolts
The differential relief valve has a cracking pressure (29). Remove the cyclic and collective servo actuators
between 825 and 895 PSI (5688 to 6171 kPa) and a (15) from the actuator support (34).
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BHT-206L1-MM-1
Figure 29-10. Cyclic and Collective Servo Actuator and Bellcranks (Sheet 1 of 2)
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BHT-206L1-MM-1
Figure 29-10. Cyclic and Collective Servo Actuator and Bellcranks (Sheet 2 of 2)
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BHT-206L1-MM-1

ACTUATORS — INSPECTION
CAUTION
1. Visually inspect the cyclic and collective servo
actuators (15, Figure 29-10) for cracks, corrosion, and DO NOT INSTALL CLAMPS ON SERVO
other signs of damage. ACTUATOR BARRELS.
2. Inspect the exposed portion of the servo actuator 1. When a new or overhauled cyclic or collective
pistons for evidence of scoring and corrosion. servo actuator (15) is to be installed, the following
adjustment should be accomplished prior to
installation.
3. Inspect the cyclic and collective bellcranks (1 and
39), links (7), and cyclic and collective idlers (21 or
21A and 43) for cracks, corrosion, or other signs of a. Set the servo actuator piston to its midstroke
damage. Inspect the staked bearings in the cyclic and position with the servo valve in the neutral position
collective idlers for serviceability. Refer to the with the aid of a servo actuator rigging tool (T102019).
BHT-206L-CR&O, Chapter 29 for replacement of
bearings and bushings. b. Adjust the servo actuator rod end bearing (11)
to obtain an overall dimension of 11.69 ±0.03 inch
4. Inspect the hoses and attaching fittings for (296.9 ±0.8 mm) between the centerline of the rod end
leakage, chafing, and security. bolt hole and the centerline of the servo valve trunnion
(16). This is accomplished by cutting the lockwire and
backing off the jam nut until the locking key is
5. Inspect all threaded parts and ports for damaged disengaged with the slot in the piston rod. Turn the rod
threads and cracks. until dimension is obtained, engage the locking key,
and retighten the jam nut.
ACTUATORS — INSTALLATION c. Secure the key to the jam nut with lockwire
(C-405). Remove the rigging tool.
SPECIAL TOOLS REQUIRED 2. Position the cyclic and collective servo actuators
(15) to the cyclic and collective bellcranks (1 and 39).
Install the two links (7) to the servo valve trunnion (16)
NUMBER NOMENCLATURE and secure with the bearing washers (12) and the nuts
(13). Torque the nuts 30 to 40 inch-pounds (3 to
T102019 Rigging Tool 5 Nm). Secure the nuts with the cotter pins (14).
3. Position the rod end bearings (11) of each servo

MATERIALS REQUIRED actuator (15) to the forward end of the actuator
support (34). Secure the rod end bearings with the
Refer to BHT-ALL-SPM for specifications. bolts (29), aluminum washers (30), bushings (31), and
nuts (32). Install the bolts for the cyclic servo actuators
NUMBER NOMENCLATURE with the heads outboard and the collective servo
actuator bolt head shall be to the right side of the
C-002 Hydraulic Fluid helicopter. Torque the nuts 60 to 85 inch-pounds (7 to
10 Nm). Secure the nuts with the cotter pins (33).
C-405 Lockwire 4. Position the aft end of the cyclic and collective
actuators (15) into the cyclic or collective idler (21 or
21A or 43). Install the bolts (17), aluminum washers
Installation procedures for the cyclic and collective (18), and nuts (19). Torque the nuts 60 to
servo actuators are similar except for bellcrank and 85 inch-pounds (7 to 10 Nm). Secure the nuts with the
idler installation (Figure 29-10, View A-A). cotter pins (20).
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BHT-206L1-MM-1
5. Connect the droop compensator control tube to 10. Rig the collective and cyclic flight control systems
the bearing on the collective idler (43) (Chapter 76). (Chapter 27).
6. To ensure hydraulic actuator bypass valve will 11. Perform a functional test of the hydraulic system
open, do the following checks with the hydraulic boost (paragraph 29-6 and paragraph 29-7).
off:
29-54. SERVO ACTUATOR LINKS,
BELLCRANKS, AND IDLERS
a. Check for approximately 0.016 inch (0.41 mm)
free travel, each way from neutral, of the servo valve.
BELLCRANKS, AND IDLERS — REMOVAL
b. Check for additional travel of 0.016 inch
(0.41 mm) of the bypass valve by applying a maximum
1. Remove the cyclic and collective idlers (21 or 21A
of 35 pounds (156 N) to the pilot’s input. Gradually
and 43, Figure 29-10) as follows:
release the 35 pound (156 N) load and when the valve
has moved 0.016 inch (0.41 mm), there should still be
8 pounds (36 N) remaining. a. Disconnect the droop compensator control
tube from the collective idler (43).
c. If the servo actuator does not meet the above

b. Disconnect the servo actuators (15) from the
checks, it must be replaced.
cyclic and collective idlers (21 or 21A and 43) by
removing the cotter pins (20), nuts (19), aluminum
7. Connect the cyclic and collective control tubes at washers (18), and bolts (17).
the aft end of the servo actuators (15) (Chapter 27).
c. To remove the cyclic idlers (21 or 21A) from
the actuator support (34), remove the cotter pins (26),
8. Lubricate the new packings (4 and 6) with nuts (25), aluminum washers (23), bushings (24), and
hydraulic fluid (C-002) or hydraulic fluid (C-072) and bolts (22).
insert on the unions (3 and 5). Install the unions in
each servo actuator (15) and connect the hydraulic d. To remove the collective idler (43) from the
hoses (paragraph 29-43). Do not allow the hoses to actuator support (34), remove the cotter pin (45), nut
twist while torquing the hose fittings to the unions. (44), aluminum washers (41), bushing (42), and
bolt (40).
2. Remove the cyclic and collective bellcranks (1

NOTE and 39) and the link (7) as follows:
control hydraulic systems, the same a. Remove the cyclic and collective servo
specification of hydraulic fluid already used actuators (15) (paragraph 29-51).
However, in circumstances where b. To remove the links (7) from the cyclic and
emergency top-off, inadvertent mixing, or collective bellcranks (1 and 39), remove the cotter pins
purposeful conversion to the other specified (10), nuts (9), aluminum washers (8), and screws (2).
hydraulic fluid of the other approved c. To remove the cyclic bellcranks (1), remove
specification. No further maintenance the cotter pins (35), nuts (36), aluminum washers (28),
action will be required. and bolt (27).
9. Fill the hydraulic reservoir to the correct fluid level d. To remove the collective bellcrank (39),
with hydraulic fluid (Chapter 12). Bleed the hydraulic remove the cotter pin (46), nut (47), aluminum
system (paragraph 29-5). washers (38), and bolt (49).
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BHT-206L1-MM-1
29-56. SERVO ACTUATOR LINKS, b. Corrosion damage to the clevis area of the
BELLCRANKS, AND IDLERS — bellcranks and idlers shall not exceed 0.005 inch
INSPECTION AND REPAIR (0.13 mm) in depth and 0.010 inch (0.25 mm) in all
other areas.
MATERIALS REQUIRED c. Maximum area per full depth repair is

0.10 square inch (0.6 cm2) in clevis areas and only
Refer to BHT-ALL-SPM for specifications. one repair permitted per clevis. Repairs to other areas
are not critical.
NUMBER NOMENCLATURE
d. Edge chamfer repairs on the bellcranks in the
C-100 Chemical Film Material clevis areas are limited to 45° by 0.040 inch (1.02 mm)
and 0.060 inch (1.52 mm) in all other areas. Edge
C-204 Epoxy Polyamide chamfer repairs on the idlers in the clevis areas are
Primer limited to 45° by 0.020 inch (0.51 mm) and 0.040 inch
(1.02 mm) in all other areas.
5. Polish out acceptable damage, removing no more
C-317 Adhesive
material than necessary to blend the repair smoothly
C-423 Abrasive Cloth or into the surrounding surface. Mechanical damage
Paper shall be polished out only deep enough to remove
traces of damage not exceeding maximum limits.
Corrosion damage shall be polished out to twice the
depth of the deepest pit, provided the maximum limit is
NOTE
not exceeded.
Refer to the BHT-206L-CR&O for detailed
inspection and repair procedures. a. Use 400 to 600-grit abrasive cloth or paper
(C-423) to remove damage to a scratch free surface.
1. Clean parts with cloths moistened with Do not attempt repairs with the use of a grinding
drycleaning solvent (C-304). Do not allow solvent to wheel.
enter the bearings.
b. Apply chemical film material (C-100) to the
2. Inspect the bearings for axial and radial wear. repaired or bare areas and a protective coating of
Refer to Chapter 20 for allowable bearing wear. epoxy polyamide primer (C-204) (Chapter 20).
6. For replacement of the bearings or bushings,

3. Inspect for elongated holes and wear in contact refer to the BHT-206L-CR&O.
areas. Elongation of the bolt or bushing holes must not
exceed 0.005 inch (0.13 mm).
BELLCRANKS, AND IDLERS —
4. Inspect the cyclic and collective bellcranks (1 and INSTALLATION
39, Figure 29-10) and the cyclic and collective idlers
(21 or 21A and 43) for mechanical and corrosion 1. Install the collective idler (43, Figure 29-10) as
damage. If chafing strips (21B) are worn on the cyclic follows:
idler (21A), replace with new chafing strips. Bond the
chafing strips to the cyclic idler (21A) with adhesive a. Position the collective idler (43) to the actuator
(C-317). Smooth and fair edges around the chafing support (34) and install the bolt (40), aluminum washer
strips. (41), bushing (42), and nut (44). Torque the nut 60 to
85 inch-pounds (7 to 10 Nm). Secure the nut with the
a. Mechanical damage to the clevis area of the cotter pin (45).
bellcranks and idlers shall not exceed 0.010 inch
(0.25 mm) in depth and 0.020 inch (0.51 mm) in all b. Connect the droop compensator control tube
other areas. to the collective idler (43).
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BHT-206L1-MM-1
c. Position the collective servo actuator (15) to screws (2) through the aluminum washers (8) and the
the collective idler (43) and install the bolt (17), nuts (9). Torque the nuts 30 to 40 inch-pounds (3 to
aluminum washers (18), and nut (19). Torque the nut 5 Nm). Secure the nuts with the cotter pins (10).
60 to 85 inch-pounds (7 to 10 Nm). Secure the nut with
the cotter pin (20). 5. Install the cyclic and collective servo actuators
(15) (paragraph 29-53).
2. Install the cyclic idlers (21) as follows:
29-58. SERVO ACTUATOR SUPPORT
a. Position the cyclic idler (21) to the actuator
support (34) and install the bolt (22), bushings (24), The cyclic and collective control servo actuator
aluminum washers (23), and nut (25). Install the bolt support is mounted on the cabin roof forward of the
with the head outboard. Torque the nuts 60 to transmission. The support serves as a mount for the
85 inch-pounds (7 to 10 Nm). Secure the nuts with the three servo actuators and associated bellcranks and
cotter pins (26). idlers.
b. Position the cyclic servo actuators (15) to the 29-59. SERVO ACTUATOR SUPPORT —
cyclic idlers (21) and install the bolts (17), aluminum REMOVAL
washers (18), and nuts (19). Torque the nuts 60 to
85 inch-pounds (7 to 10 Nm). Secure the nuts with the
1. Remove the servo actuator (paragraph 29-51).
cotter pins (20).
3. Install the collective bellcrank (39) as follows: 2. Remove the cyclic and collective bellcranks and
idlers (paragraph 29-55).
a. Position the collective bellcrank (39) to the

actuator support (34) with the double arms up and the 3. Remove the elevator bellcrank and anti-torque
single arm pointing forward. bellcrank (Chapter 27).
b. Insert one aluminum washer (38) on the bolt 4. Remove the nuts (12, 16, and 18, Figure 29-11)
(49) and install into the actuator support (34) through from the bolts that secure the actuator support (3) to
the bushing (48) and access the holes of the actuator the upper cabin roof shell and beam. Remove the
support and the bearings of the collective bellcrank. bolts (7, 9, and 13) and the aluminum washers (8, 10,
Install the opposite aluminum washer and the nut (47). 11, 14, 15, and 17) and remove the actuator support.
Torque the nut 60 to 85 inch-pounds (7 to 10 Nm).
Secure the nut with the cotter pin (46). 29-60. SERVO ACTUATOR SUPPORT —
INSPECTION AND REPAIR
4. Install the cyclic bellcranks (1) and the link (7) as
follows:
MATERIALS REQUIRED
a. Position the cyclic bellcrank (1) to the actuator
support (34) with the double arms up and the single Refer to BHT-ALL-SPM for specifications.
arm pointing forward.
NUMBER NOMENCLATURE
b. Install the bolts (27) with the aluminum washer C-100 Chemical Film Material
(28) under the bolt heads through the bushing (37)
and the actuator support (34) with the bolt heads C-204 Epoxy Polyamide
outboard. Install the opposite aluminum washers and Primer
the nuts. Torque the nuts 30 to 40 inch-pounds (3 to
5 Nm). Secure the nuts with the cotter pins (35). C-304 Drycleaning Solvent
C-423 Abrasive Cloth or

c. Position the link (7) in the double arms of the
Paper
cyclic and collective bellcranks (1 and 39). Install the
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BHT-206L1-MM-1
6
5
7
9
4
1 2
3
10
11
D 12
FW
15
13 16
UPPER CABIN
ROOF SHELL 1. Bushing
AND BEAM 14 17
2. Bushing
3. Actuator support
18 4. Bearing
5. Bushing
6. Bushing
7. Bolt
8. Thin aluminum washer
9. Bolt
11. Aluminum washer
12. Nut
13. Bolt
15. Aluminum washer
16. Nut
17. Aluminum washer
18. Nut
206L1_MM_29_0011
Figure 29-11. Servo Actuator Support
29-00-00
BHT-206L1-MM-1
depth of the deepest pit, provided the maximum limit is

NOTE
not exceeded.
Refer to the BHT-206L-CR&O for detailed
inspection and repair procedures. a. Use 400 to 600-grit abrasive cloth or paper
(C-423) to remove damage to a scratch free surface.
1. Clean the actuator support (3, Figure 29-11) with Do not attempt repairs with the use of a grinding
drycleaning solvent (C-304) and dry with filtered wheel.
compressed air. Do not allow solvent to enter the
bearings. b. Apply chemical film material (C-100) to
repaired or bare areas and a protective coating of
2. Inspect for elongation of holes and wear in epoxy polyamide primer (C-204) (Chapter 20).
contact areas. Elongation of the bolt or bushing holes
shall not exceed 0.005 inch (0.13 mm). Bore damage 5. For replacement of the bushings (1, 2, 5, and 6)
shall not exceed 0.002 inch (0.05 mm) for and bearings (4), refer to the BHT-206L-CR&O.
1/4 circumference.
29-61. SERVO ACTUATOR SUPPORT —
3. Inspect the actuator support (3) for mechanical INSTALLATION
and corrosion damage.
a. Mechanical damage to the boss areas for the MATERIALS REQUIRED

bushings (1, 2, 5, and 6), bearings (4), and bolt holes
shall not exceed 0.010 inch (0.25 mm). Mechanical Refer to BHT-ALL-SPM for specifications.
damage to all other areas shall not exceed 0.020 inch
NUMBER NOMENCLATURE
(0.51 mm) except for the center lateral rib and bottom
surface which shall not exceed 0.040 inch (1.02 mm). C-308 Sealant
b. Corrosion damage to the boss areas for the

bushings (1, 2, 5, and 6), bearings (4), and bolt holes 1. Position the actuator support (3, Figure 29-11) to
shall not exceed 0.005 inch (0.13 mm). Corrosion the upper cabin roof shell and beam. Align the
damage to all other areas shall not exceed 0.010 inch mounting holes.
(0.25 mm) except for the center lateral rib and bottom
surface which shall not exceed 0.020 inch (0.51 mm). 2. At the forward end of the actuator support (3),
install the two bolts (13) with thin aluminum washers
c. Maximum area per full depth repair shall not (14) under the bolt heads. Install the aluminum washer
exceed 0.010 square inch (0.6 cm2) to the bushing (17) and the nut (18) from inside passenger
and bearing bosses and only one repair permitted by compartment on the bolt (13).
bearing and bushing clevis area. Repairs to other
areas are not critical. 3. At the center of the actuator support (3), install
the two bolts (7) with thin aluminum washers (8) under
d. Edge chamfer repairs to boss areas for the the bolt heads. Install the aluminum washers (15) and
bushings and bearings shall not exceed 0.030 inch the nuts (16) from inside passenger compartment on
(0.76 mm) by 45°; all other areas shall not exceed the bolts (7).
0.060 inch (1.52 mm), except that the center lateral rib
and bottom surface shall not exceed 0.150 inch 4. At the aft end of the actuator support (3), install
(3.81 mm). the two bolts (9) with thin aluminum washers (10)
under the bolt heads. Install the aluminum washers
4. Polish out acceptable damage removing no more (11) and the nuts (12) from inside passenger
material than necessary to blend the repair smoothly compartment on the bolts (9).
into the surrounding surface. Mechanical damage
shall be polished out only deep enough to remove 5. Torque the nuts (12, 16, and 18) 120 to
traces of damage not exceeding maximum limits. 160 inch-pounds (14 to 18 Nm). Apply a bead of
Corrosion damage shall be polished out to twice the sealant (C-308) around the support.
29-00-00
BHT-206L1-MM-1
6. Install the cyclic and collective bellcranks and the 8. Install the elevator and anti-torque bellcranks
idlers (paragraph 29-57). (Chapter 27).
7. Install the servo actuators (paragraph 29-53).
29-00-00

Hydraulic System: BHT-206L1-MM-1

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CHAPTER 29 — HYDRAULIC SYSTEM

Paragraph Chapter/Section Page

29-1 Hydraulic System ........................................................................... 29-00-00 5

HYDRAULIC SYSTEM COMPONENTS

29-8 Hydraulic Reservoir........................................................................ 29-00-00 15

TABLE OF CONTENTS (CONT)

Paragraph Chapter/Section Page

29-38 Quick Disconnects — Inspection .............................................. 29-00-00 35

CYCLIC AND COLLECTIVE SERVO ACTUATORS AND SUPPORT

29-44 Cyclic and Collective Servo Actuators and Support....................... 29-00-00 37

29-1 Hydraulic System Schematic .............................................................................. 7

29-1 Hydraulic System Troubleshooting ..................................................................... 5

Table 29-1. Hydraulic System Troubleshooting

INDICATION OF TROUBLE PROBABLE CAUSE CORRECTIVE ACTION

2. If red button does not pop up,

3. If red button pops up, install

4. If red button pops up after

Faulty packings. Replace packing and bleed

Table 29-1. Hydraulic System Troubleshooting (Cont)

INDICATION OF TROUBLE PROBABLE CAUSE CORRECTIVE ACTION

If leak is in servo actuator, replace

Faulty hoses and lines. Replace hoses and bleed system.

Solenoid valve not operating. Replace faulty valve and bleed

Relief valve stuck open. Replace faulty relief valve and

Pump not producing required Replace faulty pump and bleed

HYD BOOST circuit breaker out. Reset HYD BOOST circuit

Faulty wiring to CONTROL Replace faulty wiring.

Leaks in system. Tighten connections. Replace

Solenoid valve not operating. Replace faulty valve and bleed

Faulty wiring to CONTROL Replace faulty wiring.

Export Classification C, ECCN EAR99

Figure 29-2. Hydraulic System

may be created, or airworthiness of helicopter may be

b. Allowable leakage — Fluid leakage such that

Table 29-2. Maximum Allowable Leakage for In-service Components

COMPONENT FUNCTION TYPE LEAKAGE RATE

Servo Actuators (Flight Controls) Rod Seal D 1 drop/20 full cycles

Rod Seal S-D 1 drop/15 minutes

End Cap S 2 drops/day

Valve Input D 1 drop/5 cycles

Valve Input S-D 1 drop/5 minutes

Pump Output Shaft D 1 drop/minute

Output Shaft S-D 1 drop/minute

Fittings Flared or Flareless S None

Compression Seals S 1 drop/30 minutes

29-4. HYDRAULIC SYSTEM — FLUSHING MATERIALS REQUIRED

Refer to BHT-ALL-SPM for specifications.

NUMBER NOMENCLATURE C-002 Hydraulic Fluid

Commercial 206L1 and 206L1 C-072 Hydraulic Fluid

C-002 Hydraulic Fluid

8. With the collective full down, move the cyclic from

HYDRAULIC FLUID THAT IS USED ON

29-6. HYDRAULIC SYSTEM — OPERATIONAL

6. Set the test stand to provide a minimum flow of

b. Continue to increase the hydraulic test stand

2. Visually inspect the helicopter hydraulic system to MATERIALS REQUIRED

HYDRAULIC SYSTEM COMPONENTS

29-8. HYDRAULIC RESERVOIR 29-10. HYDRAULIC RESERVOIR — INSPECTION

Refer to BHT-ALL-SPM for specifications.

Figure 29-3. Hydraulic Reservoir

1. Inlet Port Hose