BHT-206L-CR&O-3

CHAPTER 62 — MAIN ROTOR

TABLE OF CONTENTS

Paragraph Chapter/Section Page

Number Title Number Number

MAIN ROTOR SYSTEM

62-1 Main Rotor System .................................................................... 62-00-00 5

MAIN ROTOR HUB AND BLADE ASSEMBLY

62-2 Main Rotor Hub and Blade Assembly........................................ 62-00-00 7

62-3 Main Rotor Hub and Blade Assembly — Disassembly......... 62-00-00 7
62-4 Main Rotor Hub and Blade Assembly — Assembly ............. 62-00-00 7
62-5 Main Rotor Hub and Blade Assembly — Blade Alignment... 62-00-00 9
62-6 Blade Alignment — Scope Method............................... 62-00-00 9
62-7 Blade Alignment — String Method................................ 62-00-00 14
62-8 Main Rotor Hub and Blade Assembly — Static Balance ...... 62-00-00 17
62-9 Static Balance — Bell Helicopter Equipment................ 62-00-00 17
62-10 Static Balance — Marvel Equipment ............................ 62-00-00 20

MAIN ROTOR BLADE

62-11 Main Rotor Blade ....................................................................... 62-00-00 21

62-12 Main Rotor Blade — Cleaning .............................................. 62-00-00 21
62-13 Main Rotor Blade — Inspection............................................ 62-00-00 21
62-14 Main Rotor Blade — Replacement ....................................... 62-00-00 21
62-15 Main Rotor Blade — Spar Damage Inspection and Repair .. 62-00-00 22
62-16 Main Rotor Blade — Mechanical Damage Inspection and
Repair ................................................................................... 62-00-00 26
62-17 Main Rotor Blade — Void Damage Inspection and Repair .. 62-00-00 29
62-18 Main Rotor Blade — Grip Plate and Doubler
Separation/Corrosion Repair ................................................ 62-00-00 30
62-19 Main Rotor Blade — Grip Pad Replacement........................ 62-00-00 32
62-20 Main Rotor Blade — Wear Pad Replacement ...................... 62-00-00 33
62-21 Main Rotor Blade — Root End Closure Replacement.......... 62-00-00 34
62-22 Main Rotor Blade — Trim Tab Inspection and
Replacement ........................................................................ 62-00-00 35
62-23 Main Rotor Blade — Retention Bushing Inspection and
Replacement ........................................................................ 62-00-00 36
62-24 Main Rotor Blade — Tip Assembly Inspection and Repair... 62-00-00 36
62-25 Main Rotor Blade — Tip Weight Support Removal and
Installation ............................................................................ 62-00-00 37
62-26 Main Rotor Blade — Refinishing (Touch-up)........................ 62-00-00 40
62-27 Main Rotor Blade — Major Repairs...................................... 62-00-00 45

MAIN ROTOR HUB

62-28 Main Rotor Hub ......................................................................... 62-00-00 47

62-29 Main Rotor Hub — Disassembly .......................................... 62-00-00 47
62-30 Main Rotor Hub — Cleaning................................................. 62-00-00 56

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TABLE OF CONTENTS (CONT)

Paragraph Chapter/Section Page

Number Title Number Number

62-31 Main Rotor Hub — Inspection .............................................. 62-00-00 59

62-32 Main Rotor Hub — Conditional Inspection ........................... 62-00-00 59
62-33 Main Rotor Hub — Normal Inspection.................................. 62-00-00 60
62-34 Main Rotor Hub — Repair .................................................... 62-00-00 83
62-35 Main Rotor Hub — Assembly ............................................... 62-00-00 93
62-36 Main Rotor Hub — Painting.................................................. 62-00-00 113
62-37 Main Rotor Hub — Preservation .......................................... 62-00-00 114
62-38 Main Rotor Lock ........................................................................ 62-00-00 114
62-39 Main Rotor Lock — Inspection ............................................. 62-00-00 114
62-40 Main Rotor Lock — Repair ................................................... 62-00-00 114

FLAP RESTRAINT ASSEMBLY

62-41 Flap Restraint Assembly............................................................ 62-00-00 115

62-42 Flap Restraint Assembly — Disassembly ............................ 62-00-00 115
62-43 Flap Restraint Assembly — Inspection ................................ 62-00-00 115
62-44 Flap Restraint Assembly — Repair ...................................... 62-00-00 115
62-45 Flap Restraint Assembly — Assembly ................................. 62-00-00 115
62-46 Flap Restraint Assembly — Corrosion Protection ................ 62-00-00 117

ROTATING CONTROLS

62-47 Swashplate and Support ........................................................... 62-00-00 119

62-48 Swashplate and Support — Disassembly ............................ 62-00-00 119
62-49 Swashplate and Support — Cleaning .................................. 62-00-00 123
62-50 Swashplate and Support — Inspection ................................ 62-00-00 123
62-51 Swashplate and Support — Fluorescent Penetrant
Inspection ............................................................................. 62-00-00 134
62-52 Swashplate and Support — Repair ...................................... 62-00-00 137
62-53 Swashplate and Support — Assembly ................................. 62-00-00 138
62-54 Swashplate and Support — Friction Adjustment .................. 62-00-00 145
62-55 Swashplate Collar Set ............................................................... 62-00-00 149
62-56 Swashplate Collar Set — Inspection .................................... 62-00-00 149
62-57 Swashplate Collar Set — Repair .......................................... 62-00-00 151
62-58 Swashplate Idler Lever .............................................................. 62-00-00 151
62-59 Swashplate Idler Lever — Inspection ................................... 62-00-00 151
62-60 Swashplate Idler Lever — Repair......................................... 62-00-00 151
62-61 Swashplate Idler Link ................................................................ 62-00-00 156
62-62 Swashplate Idler Link — Inspection ..................................... 62-00-00 156
62-63 Swashplate Idler Link — Repair ........................................... 62-00-00 156
62-64 Swashplate Collar, Idler lever, and Idler Link — Refinish .... 62-00-00 156

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FIGURES

Figure Page
Number Title Number

62-1 Main Rotor System ......................................................................................... 6

62-2 Main Rotor Hub and Blade Assembly............................................................. 8
62-3 T-handle Workaid ........................................................................................... 10
62-4 Main Rotor Hub and Blade Alignment — Scope Method................................ 11
62-5 Main Rotor Blade Support — Fabrication ....................................................... 13
62-6 Main Rotor Hub and Blade Alignment — String Method ................................ 16
62-7 Main Rotor Hub and Blade — Static Balance................................................. 18
62-8 Main Rotor Blade ............................................................................................ 23
62-9 Spar Damage — Repair Limits ....................................................................... 25
62-10 Main Rotor Blade Patch Repair Area ............................................................. 27
62-11 Main Rotor Blade Corrosion — Removal Limits ............................................. 31
62-12 Main Rotor Blade Tip Assembly — Inspection and Repair............................. 38
62-13 Main Rotor Blade Tip Weight Support — Removal and Installation ............... 39
62-14 Main Rotor Blade — Refinishing (Touch-up) .................................................. 42
62-15 Main Rotor Hub .............................................................................................. 48
62-16 Trunnion Bearing Pressing Plate .................................................................... 51
62-17 Trunnion Bearing Pressing Plug ..................................................................... 52
62-18 Trunnion Bearing Inner Race — Removal...................................................... 53
62-19 Pillow Block Seal — Removal......................................................................... 55
62-20 Main Rotor Grip Retainer Dowel..................................................................... 57
62-21 Pitch Horn Trunnion Workaid ......................................................................... 58
62-22 Main Rotor Grip — Inspection Criteria............................................................ 62
62-23 Main Rotor Grip — Damage Limits................................................................. 63
62-24 Yoke — Inspection Criteria ............................................................................. 64
62-25 Strap Fitting — Inspection Criteria.................................................................. 66
62-26 Main Rotor Hub — Wear Limits ...................................................................... 68
62-27 Yoke — Damage Limits .................................................................................. 69
62-28 Trunnion — Damage Limits ............................................................................ 70
62-29 Strap Fitting — Damage Limits....................................................................... 71
62-30 Strap Pin — Damage Limits ........................................................................... 72
62-31 Strap Bolt and Blade Latch — Damage Limits ............................................... 73
62-32 Blade Bolt — Damage Limits.......................................................................... 74
62-33 Retainer — Damage Limits ............................................................................ 75
62-34 Radius Ring — Damage Limits....................................................................... 76
62-35 Pitch Horn — Damage Limits ......................................................................... 77
62-36 Static Stop — Damage Limits......................................................................... 78
62-37 Trunnion Pillow Block — Damage Limits........................................................ 79
62-38 Mast Nut — Damage Limits............................................................................ 80
62-39 Cone Set — Damage Limits ........................................................................... 81
62-40 Blade Bolt Plug — Damage Limits ................................................................. 82
62-41 Main Rotor Hub — Corrosion Protection ........................................................ 85
62-42 Main Rotor Hub — Painting ............................................................................ 91
62-43 Trunnion Assembly ......................................................................................... 95
62-44 Trunnion Requirements .................................................................................. 96
62-45 Trunnion Centering Workaid........................................................................... 99
62-46 Trunnion Centering ......................................................................................... 100
62-47 Yoke and Strap ............................................................................................... 102

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FIGURES (CONT)

Figure Page
Number Title Number

62-48 Wear Sleeve Installation Workaid................................................................... 104

62-49 Grip and Retainer Assembly........................................................................... 105
62-50 Main Rotor Hub Excluder Mandrel ................................................................. 108
62-51 Main Rotor Hub Assembly .............................................................................. 110
62-52 Pitch Horn and Reservoir ............................................................................... 111
62-53 Flap Restraint ................................................................................................. 116
62-54 Swashplate and Support ................................................................................ 120
62-55 Pivot Sleeve Modified with Pilot Holes ........................................................... 122
62-56 Swashplate and Support — Wear Limits ........................................................ 124
62-57 Pivot Sleeve — Damage Limits ...................................................................... 125
62-58 Inner Ring — Damage Limits ......................................................................... 126
62-59 Swashplate Support — Damage Limits .......................................................... 127
62-60 Collective Lever Link (206-010-407) — Damage Limits ................................ 128
62-60A Collective Lever Link (206-010-446) — Damage Limits ................................. 129
62-61 Collective Lever (206-010-467) — Damage Limits......................................... 130
62-61A Collective Lever (206-010-447) — Damage Limits......................................... 131
62-62 Outer Cap — Damage Limits ......................................................................... 132
62-63 Outer Ring — Damage Limits......................................................................... 133
62-64 Duplex Bearing — Damage Limits ................................................................. 135
62-65 Collective Lever/Swashplate Support Bushing — Damage Limits ................. 136
62-66 Inner and Outer Rings — Corrosion Protection.............................................. 139
62-67 Outer and Inner Ring and Pivot Sleeve .......................................................... 140
62-68 Swashplate Assembly Requirements ............................................................. 142
62-69 Collect Lever and Support .............................................................................. 146
62-70 Swashplate Support Mounting Workaid ......................................................... 147
62-71 Swashplate Friction Adjustment ..................................................................... 148
62-72 Collar Set — Damage Limits .......................................................................... 150
62-73 Idler Lever — Damage Limits ......................................................................... 152
62-74 Idler Lever Bushings — Replacement ............................................................ 153
62-75 Idler Link — Damage Limits ........................................................................... 157

TABLES

Table Page
Number Title Number

62-1 Main Rotor Blade — Refinishing of Upper Surfaces (Topcoat) ...................... 43

62-2 Swashplate Fluorescent Penetrant Overhaul Inspection Requirements ........ 137

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MAIN ROTOR SYSTEM

62-1. MAIN ROTOR SYSTEM

This chapter provides procedures for the repair and

overhaul of main rotor system components including
main rotor hub, blades, flap restraint assembly, and
rotating controls (Figure 62-1).

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Figure 62-1. Main Rotor System

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MAIN ROTOR HUB AND BLADE ASSEMBLY

62-2. MAIN ROTOR HUB AND BLADE

ASSEMBLY CAUTION

62-3. MAIN ROTOR HUB AND BLADE

ASSEMBLY — DISASSEMBLY MAKE SURE MAIN ROTOR HUB AND
O P P O S I T E B L A D E I S S U P P O R TE D
DURING REMOVAL OF BLADES. KEEP
BLADE AT NORMAL PRECONE ANGLE
SPECIAL TOOLS REQUIRED DURING REMOVAL FROM GRIP.

4. Remove bolt (1) and remove blade (8). Remove

NUMBER NOMENCLATURE opposite main rotor blade in same manner.
Workaid Blade Support
62-4. MAIN ROTOR HUB AND BLADE
Workaid T-handle ASSEMBLY — ASSEMBLY

1. Place main rotor hub and blade assembly on a MATERIALS REQUIRED

workstand. Support main rotor blades at normal
precone angle. Refer to BHT-ALL-SPM for specifications.

NUMBER NOMENCLATURE

CAUTION C-101 Corrosion Preventive

Compound

C-104 Corrosion Preventive

DO NOT CHANGE POSITION OF NUTS
(13, FIGURE 62-2) ON LEADING EDGE
SIDE OF MAIN ROTOR BLADES (8). THE
NUTS DE TERM INE ALIGNME NT OF
BLADES.
2. Loosen nut (13) on trailing edge side of main
rotor blade (8) and rotate blade latch (14) to horizontal
position.
NOTE
Identify and/or color code blade bolts (1),
grips (3), and blades (8) to ensure
installation in same location as removal.
3. Remove nut (7) and washer (6) from blade
bolt (1).
Compound
C-304 Drycleaning Solvent
1. Loosen blade latch nuts (13, Figure 62-2,
Detail A) on trailing edge side of main rotor hub and
turn blade latch (14) to horizontal position.
2. Clean blade retention bolt holes, recesses in the
inboard tang faces of the grips (3), bushings (2), and
blade bolts (1) with drycleaning solvent (C-304).
3. Apply corrosion preventive compound (C-104) to
blade bolt holes and grip pads (10) filling recesses
between grip pads and bolt hole edges. Apply a
generous coating to grip bushing (2) including bolt
holes and flanges, buffer pads (5), and shank of blade
bolt (1).

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Figure 62-2. Main Rotor Hub and Blade Assembly

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62-5. MAIN ROTOR HUB AND BLADE

ASSEMBLY — BLADE ALIGNMENT
CAUTION

62-6. Blade Alignment — Scope Method

MAKE SURE THE MAIN ROTOR HUB
AND OPPOSITE BLADE ARE
SUPPORTED DURING INSTALLATION
SPECIAL TOOLS REQUIRED
OF BLADES. KEEP BLADE AT NORMAL
PRECONE ANGLE DURING
INSTALLATION IN GRIP. NUMBER NOMENCLATURE
4. Using sufficient personnel to hold and align main T100220 Sling
rotor blade to grip, install main rotor blade (8) into grip
(3) and insert blade bolt (1). Install opposite blade in T101401 Scope Assembly
the same manner.
T101532 Support Assembly
5. Clean corrosion preventive compound from
T101576 Balance Set
threads of blade bolts (1).
T101544 Adapter
NOTE
Workaid T-handle
If blade change is being accomplished, do
not torque nuts (7 and 13). Main rotor blade Workaid Blade Support
alignment and static balance are required
first.

6. Install washers (6) and nuts (7) on blade bolts (1).
Torque nuts 274 to 340 foot-pounds (371.5 to
461.0 Nm).
7. Coat heads of blade bolts (1), nuts (7), and
washers (6) with corrosion preventive compound
(C-101).
8. Torque blade latch nuts (13) 75 to 95 foot-pounds
(101.7 to 128.8 Nm). Wipe off any excess corrosion
preventive compound using drycleaning solvent
(C-304).
9. Align main rotor blades (paragraph 62-6 or
paragraph 62-7).
10. Balance main rotor blades (paragraph 62-8).
CAUTION
DO NOT ALLOW MAIN ROTOR GRIPS
O R Y O K E T O R O TAT E O N P I T C H
CHANGE AXIS. IF GRIP OR YOKE IS
A L L O W E D T O R O TAT E O N P I T C H
CHANGE AXIS BEYOND 90°, MAIN
ROTO R GRIP RE TE NTION S TRA PS
SHALL BE REPLACED. SECURE MAIN
ROTOR BLADE GRIPS THROUGH PITCH
HORNS TO YOKE WITH LOCKWIRE OR
SUITABLE WORKAID.
1. Make sure T-handles are installed through pitch
horn trunnion bearings and yoke (Figure 62-3).
2. Remove flap restraint from main rotor hub and
blade assembly per the instructions in the applicable
Maintenance Manual (MM).

3. Position hub and blade assembly (9, Figure 62-4)

on a stable, level stand. The stand should be
positioned directly beneath a hoist in a draft free room.
The stand should have a steel top, or a piece of steel
plate thick enough to resist flexing.

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Figure 62-3. T-handle Workaid

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Figure 62-4. Main Rotor Hub and Blade Alignment — Scope Method

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4. Support each main rotor blade at approximately
the preconed angle with two support stands (9,
Figure 62-5). Position support stands about 5 feet (1.5
m) inboard from blade tips.
5. Fabricate main rotor blade support stands
(Figure 62-4).
NOTE
Blade alignment may be more easily
accomplished by use of wheeled supports
between main rotor blades and blade
support stands (9, Figure 62-5). Wheeled
supports will permit main rotor blades to
move forward and aft on support stands
when sweep adjustments are made during
blade alignment.
a. Skates may be used for wheeled supports
(Figure 62-5). Remove toe and heel attaching clamps
from skates. Remove adjusting bolt from center of
skates and substitute an eye bolt (6) with the eye up.
Eye bolt should extend about 1.0 inch (25.4 mm)
above skate.
b. Fabricate two padded blocks (3) to fit airfoil
surface of blade. Blocks may be made from 2 x 3 inch
(50 x 76 mm) hardwood slightly longer than chordwise
dimension of blade. Shape blocks so the 3 inch
(76 mm) wide surface will fit the lower surface of
blade. Fasten felt padding (2) to blocks to prevent
damage.
c. Fabricate brackets (4) to adapt blocks (3) to
eye bolts (6). Use two pieces of 1.0 inch (25.4 mm)
angle for each block. Fasten brackets to lower surface
of blocks about 3.0 inches (76.2 mm) aft of forward
end so bracket will support block and blade pitch
change rotation axis. Orient brackets so bolt (5), which
attaches brackets to eye bolt, will act as a pivot point
for blade pitch change movement. Drill holes in
brackets to accept bolt of same size as hole in eye
bolt. Attach brackets to blocks with wood screws.
Attach blocks to eye bolts with bolt.
6. Attach a sling (T100220) and raise hub and blade
assembly about 12.0 inches (304 mm).
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7. Place two fabricated parallel supports on stand
beneath main rotor hub yoke (18, Figure 62-4).
Supports may be fabricated from aluminum bar stock
approximately 2 x 3 x 12 inches (51 x 76 x 304 mm)
long or other suitable substitutes.
8. Place base (14) on parallel supports under hub.
Orient base perpendicular to main rotor blades. Lower
main rotor hub and blade until hub is centered on base
and rests on supports.
9. lnstall locks (12) and adjusters (13) from adapter
set (T101544) on base (14) with screws (16) and
washers (15). Secure locks to bearings (17) with
pins (11).
NOTE
If tool requirements specified in preceding
step 6, step 7, and step 9 are not available,
allow main rotor hub and blade to rest on
stand and use machinist jack or other
means to position main rotor blade grips to
0° pitch angle and level.
10. Place a bubble protractor on flat surface of
yoke (18). Set protractor bubble to level and tighten
set screw. Reposition zeroed bubble protractor to flat
machined surface on one grip (4) adjacent to blade
bolt (7). Adjust locks (12) to set grip to 0° pitch angle.
Repeat procedure on opposite grip.
11. Position support assembly (T101532) (6,
Figure 62-4) and place scope assembly (T101401) (5)
in support as shown.
12. Check scope assembly (T101401) (5) for zero
adjustment:
a. Sight through scope at a distant surface
approximately 50 feet (15.2 m) away.
b. Draw a straight vertical mark on surface
aligned with vertical crosshair.
c. Loosen clamp screws on scope mount, rotate
scope 180° on tube axis, and tighten screws.
d. Resight to ensure vertical crosshair aligns with
target line marked in step b.
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Figure 62-5. Main Rotor Blade Support — Fabrication

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e. If vertical crosshair fails to align on target 17. Torque leading and trailing edge nuts (2 and 3) 75
mark, adjust scope as follows: to 95 foot-pounds (101.7 to 128.8 Nm).

(1) Make a second vertical mark at new

alignment of vertical crosshair.
(2) Make a third vertical mark midway
between first and second vertical marks.
(3) Adjust scope by turning screw marked L
on side of scope to align vertical crosshair on third
vertical mark.
(4) Loosen clamp screws on scope mount,
rotate scope 180° on tube axis, and tighten clamp
screws. Make sure vertical crosshair aligns with third
vertical target mark. Repeat procedures until
alignment is satisfactory.
13. Locate drive screw (10) on upper surface of blade
tip about 3.0 inches (76 mm) aft of leading edge.
NOTE
If blades are to be balanced immediately,
do not torque blade bolt nuts.
18. Torque blade bolt (7) nuts 274 to 340 foot-pounds
(371.5 to 461.0 Nm).
19. When blade alignment is complete, remove
scope assembly (T101401) (5) and support assembly
(T101532) (6).
20. Balance main rotor hub and blade assembly
(paragraph 62-8).
62-7. Blade Alignment — String Method
SPECIAL TOOLS REQUIRED

NOTE NUMBER NOMENCLATURE

Make sure each grip is positioned at 0° T100220 Sling
pitch angle in relation to yoke (step 10).
T101544 Adapter Set
14. Sight through scope to drive screw. Center of
screw head should align on vertical crosshair within T101576 Balance Set
0.0 inch (0.0 mm) forward and 0.10 inch (2.54 mm) aft.
Workaid Blade Support
15. Reverse scope on support assembly (T101532) Workaid T-handle
(6). Repeat step 14 to check alignment on opposite
blade. Blade to blade difference shall not exceed
0.020 inch (0.51 mm). MATERIALS REQUIRED

Refer to BHT-ALL-SPM for specifications.

NOTE
NUMBER NOMENCLATURE
Make sure main rotor blades are not
binding on outer support stands when C-426 Masking Tape
making blade sweep adjustments. If
wheeled supports are used, binding should C-480 Cord
not occur. If wheeled supports are not used,
raise blade tips to clear outboard support
stands and lower vertically each time
sweep adjustments are made. CAUTION

16. If main rotor blades are out of alignment as

described in step 14 and step 15, loosen nuts on blade DO NOT ALLOW MAIN ROTOR GRIPS
bolts (7). Adjust leading and trailing edge nuts (2 O R Y O K E T O R O TAT E O N P I T C H
and 3) by loosening one nut and tightening the other CHANGE AXIS. IF GRIP OR YOKE IS
until blades are aligned. ALLOWED TO ROTATE BEYOND 90°,

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R E P L A C E M A I N R O TO R G R I P
RETENTION STRAPS. USE T-HANDLE
WORKAID OR LOCKWIRE TO SECURE
GRIPS.
1. Make sure T-handle is installed through pitch
horn trunnion bearings and yoke (Figure 62-3).
2. Position hub and blade on a stable, level stand.
The stand should be positioned directly beneath a
hoist in a draft free room. Stand should have a steel
top, or a piece of steel plate thick enough to resist
flexing.
3. Support each rotor blade at approximately the
plane of preconed angle with two support stands (9,
Figure 62-5). Position support stands about 5.0 feet
(1.5 m) inboard from blade tips. Use padded support
stands or stands suitable for use with wheeled
supports (paragraph 62-6).
4. Attach a sling (T100220) and raise main rotor hub
and blade assembly about 12.0 inches (304 mm).
5. Place two fabricated parallel supports on stand
beneath hub yoke. Supports may be fabricated from
aluminum bar stock approximately 2 x 3 x 12 inches
(51 x 76 x 304 mm) or other suitable substitutes.
6. Place base (14, Figure 62-4) on parallel supports
under hub yoke. Position base perpendicular to
blades. Lower hub and blade until it rests on base.
7. Install locks (12) and adjusters (13) from adapter
set (T101544) on base (14) with screws (16) and
washers (15). Secure locks to bearings (17) with
pins (11).
8. Place a bubble protractor on flat surface of yoke
(14, Figure 62-6). Set bubble to level and tighten set
screw. Reposition zeroed protractor to flat machined
surface on one grip (8) adjacent to blade bolt (5).
Adjust locks (12, Figure 62-4) to set grip (8,
Figure 62-6) to 0° pitch angle. Repeat procedure on
opposite grip.
NOTE
If tool requirements specified in preceding
step 6 through step 8 are not available,
allow hub and blade to rest on stand and
use machinist jack or other means to
ECCN 9E991
BHT-206L-CR&O-3
position main rotor blade grips to 0° pitch
angle and level.
9. Remove caps (4, Figure 62-6) from both blade
bolts (5).
10. Locate drive screws (1) on upper surface of
blades (2) at tip end and about 3.0 inches (76.2 mm)
aft of leading edge. Attach a thin nylon cord (C-480)
between drive screws of blades. Draw cord taut and
secure in place with masking tape (C-426).
11. Make sure each grip (8) is positioned at 0° pitch
angle in relation to yoke (step 8).
12. Position two small mirrors (6) on flat machined
surface of both grips. View with one eye, cord, mirror
image of cord, and alignment point (12) on blade
bolts (5) (Detail A and View A-A). When all three
reference points are aligned, at both alignment points
on blade bolts, blades (2) are aligned.
NOTE
Make sure blades are not binding on outer
support stands when making blade sweep
adjustments. If wheeled supports are used,
binding should not occur. If wheeled
supports are not used, raise blade tips to
clear outboard support stands and lower
vertically each time sweep adjustments are
made.
13. If blades are not aligned as described in step 12,
loosen nuts and washers on bottom of blade bolts (5).
Adjust leading or trailing edge nuts (7 and 13), by
loosening one and tightening the other until main rotor
blades are aligned.
14. Torque nuts (7 and 13) 75 to 95 foot-pounds
(101.7 to 128.8 Nm).
NOTE
If blades are to be balanced immediately,
do not torque blade bolt nuts at this time.
15. Torque nuts on blade bolts (5) 274 to
340 foot-pounds (371.5 to 461.0 Nm).
16. Balance main rotor hub and blade (paragraph
62-8).
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Figure 62-6. Main Rotor Hub and Blade Alignment — String Method

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 BHT-206L-CR&O-3

62-8. MAIN ROTOR HUB AND BLADE 2. Align main rotor hub and blade (paragraph 62-6
ASSEMBLY — STATIC BALANCE or paragraph 62-7).

62-9. Static Balance — Bell Helicopter

NOTE
Equipment
Main rotor hub and blade assembly shall be
removed from stand assembly each time
sweep adjustments are made. It is
SPECIAL TOOLS REQUIRED recommended to drill three small holes
about 0.1275 inch (3.238 mm) deep in
metal covering of table to accommodate the
NUMBER NOMENCLATURE three legs of stand assembly. The legs of
stand will act as dowels to prevent shifting
T100220 Sling
of stand and possible changes in level
T101544 Adapter Set when hub and blade is removed for sweep
adjustments.
T101576 Balance Set
3. Place stand assembly (12, Figure 62-7) on level
reinforced workstand of table.

MATERIALS REQUIRED 4. Index position of stand (12) to workstand or table.

Position plate (14) on stand. Place bull’s eye level (1)
Refer to BHT-ALL-SPM for specifications. on plate and adjust screws and nuts (13) to achieve a
level condition. Remove level and plate.
NUMBER NOMENCLATURE

C-426 Masking Tape

NOTE
Do not allow stand assembly to move in
relation to supporting workstand or table
CAUTION during static balancing procedure.

5. Check mandrel assembly (11) to ensure ball and

DO NOT ALLOW MAIN ROTOR GRIPS packing are installed on balance base (8) as follows:
OR YOKE TO ROTATE ON PITCH
CHANGE AXIS. IF GRIP OR YOKE IS
ALLOWED TO ROTATE BEYOND 90°,
CAUTION
REPLACE MAIN ROTOR GRIP
RETENTION STRAPS. USE T-HANDLE
WORKAID OR LOCKWIRE TO SECURE C A R E F U L LY PLACE MANDREL
GRIPS. ASSEMBLY ON STAND TO PREVENT
DA M A G E TO B A L L A ND /O R S TA N D
ASSEMBLY.
NOTE
Main rotor hub and blade static balance a. Place base (8) on mandrel assembly (11) and
shall be accomplished in a draft free area carefully install components on stand assembly.
with adapter set (T101544) and balance set
(T101576) (Figure 62-7). Balancing is b. Place plug (4) on mandrel assembly (11). Do
required after alignment. not install screw (2) and washer (3).

1. Make sure grips and yoke are secured to prevent c. Place bull’s eye level (1) in recess on top of
rotation. plug (4) and check balance of components.

62-00-00
ECCN 9E991 10 JAN 2011 Rev. 3 Page 17
BHT-206L-CR&O-3

Figure 62-7. Main Rotor Hub and Blade — Static Balance

62-00-00
Page 18 Rev. 3 10 JAN 2011 ECCN 9E991

d. If components are in balance, index mark the
following with a pencil or ink.
(1) Bull’s eye level (1).
(2) Plug (4).
(3) Base (8).
(4) Mandrel assembly (11).
(5) Stand assembly (12).
e. If components are out of balance, lay small
washers and a small piece of masking tape (C-426) on
top surface of base (8, Figure 62-7). Attach washers
with masking tape and move to top surface of base to
attain balance. When components are balanced,
attach washer(s) to same relative position on lower
surface of base. Verify correct balance and index mark
components in accordance with step d.
f. Remove bull’s eye level (1), plug (4), base (8),
and mandrel assembly (11) from stand assembly (12).
Make sure that index marks are still visible.
6. Attach sling (T100220) through tangs of both grip
assemblies and raise approximately 12.0 inches
(304 mm) above stand assembly (12). Insert base (8)
and mandrel assembly (11) through hub trunnion from
lower side, orienting arms of base perpendicular to the
blades. Place plug (4) in trunnion and secure with
screw (2) and washer (3). Carefully lower hub and
blade and mandrel assembly on to the stand
assembly.
7. Place pins (5) through pitch change bearings and
install locks (6) and adjusters (7).
8. Place an adjustable bubble protractor on
machined chordwise surface of yoke. Adjust protractor
to center and lock.
9. Transfer protractor to outboard machined surface
on one blade grip adjacent to blade bolt.
10. Screw adjuster (7) on lock (6) until protractor is
centered. Secure lock and adjuster to base (8) with
screw (10) and washer (9). Transfer protractor to
opposite blade grip and repeat procedure.
ECCN 9E991
BHT-206L-CR&O-3
11. Verify hub is serviced with grease or oil as
applicable per the instructions in Chapter 12 of the
applicable Maintenance Manual (MM).
12. Place bull’s eye level (1) in recess on top of
plug (4). Check and align index marks applied to
components (1, 4, 8, 11, and 12).
CAUTION
DO NOT MAKE SWEEP ADJUSTMENTS
W IT H H UB A ND B LA D E A S S E M B LY
R E S T I N G O N S TA N D A S S E M B LY.
DAMAGE TO STAND ASSEMBLY MAY
RESULT.
CAUTION
DO NOT SWEEP BLADES FORWARD.
13. Check chordwise balance. Correct chordwise
imbalance by sweeping one blade aft.
CAUTION
O NLY SW EE P BL ADE W HE N M ORE
THAN EIGHT WASHERS ARE USED ON
HUB (FIGURE 62-15, DETAIL A).
NOTE
Blade sweep adjustments are sensitive.
Index mark nuts (13, Figure 62-2) and
blade latches (14) with pencil or ink before
making adjustments. Loosen leading edge
nut on blade latch bolt and tighten trailing
edge nut an equal amount. Do not exceed
a maximum of three points on nuts.
14. Raise hub and blade clear of stand assembly (12,
Figure 62-7).
15. Loosen nut (7, Figure 62-2) on blade bolt (1) of
blade to be swept and make sweep adjustments.
Torque nuts (13) 75 to 95 foot-pounds (101.7 to
128.8 Nm).
62-00-00
10 JAN 2011 Rev. 3 Page 19
BHT-206L-CR&O-3
16. Carefully lower hub and blade on stand assembly
and check chordwise balance again. Repeat step 14
and step 15 as required to obtain chordwise balance.
17. After obtaining chordwise balance, raise hub and
blade clear of stand assembly.
18. Verify nuts (13) are torqued 75 to 95 foot-pounds
(101.7 to 128.8 Nm). Torque nuts (7) 274 to
340 foot-pounds (371.5 to 461.0 Nm).
19. Carefully lower hub and blade on stand and
balance spanwise as follows:
a. Cut lockwire and remove cap (4, Figure 62-6)
with packing from blade bolt (5).
b. Inspect interior of both blade bolts (5) for
presence of lead weights. Use mechanical fingers to
remove any weights installed.
NOTE
If balance cannot be obtained, repeat
complete assembly procedure and
chordwise balance procedure.
62-00-00
Page 20 Rev. 3 10 JAN 2011
c. Add lead weights to hollow shank of high
blade bolt as indicated by bull's eye level, until
spanwise balance is achieved. Place cap (4) on blade
bolt (5) each time spanwise balance is checked.
20. Raise hub and blade clear of stand and remove
balance tools from hub and blades.
62-10. Static Balance — Marvel Equipment
CAUTION
STATIC BALANCING SHALL ONLY BE
CONDUCTED IN ACCORDANCE WITH
MARVEL OPERATION AND SERVICE
HANDBOOK. IF THERE ARE ANY
QUESTIONS CONCERNING THE USE OF
T H I S E Q U I P M E N T, C O N TA C T T H E
MANUFACTURER.
Static balancing of the main rotor hub and blade may
be accomplished with the use of equipment from
Marvel Manufacturing Company, if desired.
ECCN 9E991
 BHT-206L-CR&O-3

MAIN ROTOR BLADE

62-11. MAIN ROTOR BLADE 9. For retention bushing inspection and

replacement, refer to paragraph 62-23.
62-12. MAIN ROTOR BLADE — CLEANING
10. For tip assembly inspection and repair, refer to
paragraph 62-24.
MATERIALS REQUIRED
62-14. MAIN ROTOR BLADE — REPLACEMENT
Refer to BHT-ALL-SPM for specifications.
1. Review blade records to determine if blade has
NUMBER NOMENCLATURE been subject to an accident or incident outside the
realm of normal usage.
C-125 Preservative Oil

C-304 Drycleaning Solvent 2. Visually inspect blade for obvious damage that
would indicate blade has been subjected to an
C-318 Cleaning Compound accident or incident outside the realm of normal
usage.
1. Wash main rotor blades with a mild solution (4
parts water to 1 part detergent) of cleaning compound 3. If there is evidence of accident or incident
(C-318). Rinse with fresh water and wipe dry with damage, do the following:
clean cloths.
a. Blade may be repaired with procedures
2. Coat all surfaces of blades with preservative oil provided in the following paragraphs, if damage is
(C-125). within allowable field repair limits.

62-13. MAIN ROTOR BLADE — INSPECTION
1. For spar damage inspection and repair, refer to
paragraph 62-15.
2. For mechanical damage inspection and repair,
refer to paragraph 62-16.
b. Blade may be sent to Bell Helicopter Textron
(BHT) or to a BHT approved repair facility for
evaluation when damage exceeds field repair limits.
4. Any damage to the main rotor blade that exceeds
the following limits or conditions requires blade be
scrapped:

3. For void damage inspection and repair, refer to
paragraph 62-17.
4. For grip plate and doubler separation and
corrosion repair, refer to paragraph 62-18.
5. For grip pad replacement, refer to paragraph
62-19.
6. For wear pad replacement, refer to paragraph
62-20.
a. Water in honeycomb core (14, Figure 62-8).
b. If a crack has developed chordwise or
spanwise on upper and/or lower skin.
c. If one or more cracks develop and extend
from a previously repaired area.
d. Holes in skin (6) larger in area than allowed
for patching. Blade may be sent to BHT or to a BHT
approved repair facility for evaluation when damage
exceeds field repair limits.

7. For root end closure replacement, refer to e. Any corrosion penetrating entirely through
paragraph 62-21. skin (6) or corrosion in core (14).

8. For trim tab inspection and replacement, refer to f. Voids between skin (6) and honeycomb core
paragraph 62-22. (14) larger than 25 square inches (161 cm2). Blade

62-00-00
ECCN 9E991 10 JAN 2011 Rev. 3 Page 21
BHT-206L-CR&O-3

may be sent to BHT or to a BHT approved repair
facility for evaluation when damage exceeds field
repair limits.
g. Any penetration through spar assembly (7),
trailing edge strip (8), doublers (5), or upper/lower grip
plates (4).
b. Using a micrometer caliper, measure chord
line dimension of blade adjacent to area of corrosion
or damage to be cleaned (Figure 62-9, Dimension A).
This measurement minus 0.125 inch (3.175 mm)
maximum clean-up at leading edge will ensure
remaining leading edge thickness is within limits (see
following example).

h. Edge voids deeper than 2.0 inches (50.8 mm) Measured Dimension A 13.009 inches
at outboard end on any root end doubler (5). (330.429 mm)

Maximum clean-up 0.125 inch

i. Edge voids in leading edges or trailing edges
allowed (3.175 mm)
of doublers (5) 0.5 inch (12.7 mm) or greater in depth
with indications of corrosion in voids. Minimum Dimension A 12.884 inch
measurement allowed (327.254 mm)
to the deepest part of
j. Obvious deformation of blade.
cleaned up area

5. Any damage to main rotor blade less than the

previous limits may be repaired.
62-15. MAIN ROTOR BLADE — SPAR DAMAGE
INSPECTION AND REPAIR
c. An alternate measurement can be made by
removing tip balance weight support (15, Figure 62-8)
and measuring thickness from aft side of spar
assembly (7) to leading edge. If chordwise
measurement is 0.6250 inch (15.8750 mm) or less,
scrap blade.

MATERIALS REQUIRED 2. If dimension calculated in step 1, substep b or

substep c is within limits, repair spar as follows:
Refer to BHT-ALL-SPM for specifications.

NUMBER NOMENCLATURE

C-323 Fairing Compound CAUTION

C-422 Aluminum Wool

SAND IN SPANWISE DIRECTION ONLY.
C-423 Abrasive Paper

1. Perform spar inspection as follows:
a. Inspect leading edge of main rotor blade spar
assembly (7, Figure 62-8) for corrosion, erosion, and
mechanical damage.
NOTE
Two squares clamped together opposing
each other and wire or feeler gauges can
be used to obtain Dimension A
(Figure 62-9) accurately.
NOTE
Do not sand skin-to-spar butt joint. A
minimum leading edge thickness of
0.625 inch (15.875 mm) shall be
maintained after clean-up.
a. Sand leading edges of spar assembly (7) with
180 to 600 grit abrasive paper (C-423) with a final
cleaning using aluminum wool (C-422). Sand using
hand pressure only and remove minimum amount of
material to remove corrosion. Blend edges of sanded
areas into adjacent areas to maintain shape of airfoil
(Figure 62-9, Dimension B and Dimension C).

62-00-00
Page 22 Rev. 3 10 JAN 2011 ECCN 9E991
 BHT-206L-CR&O-3

Bond root end closure flush to leading edge. Bond must be airtight.

Grip pads located concentric with 0.02 inch (0.5 mm) of retention bolt
bushing. Dimension over grip pads shall be 3.297 to 3.308 inches
(83.75 to 84.02 mm).

3 Not installed on -107 blade.

206L_CRO_62_0003a

Figure 62-8. Main Rotor Blade (Sheet 1 of 2)

62-00-00
ECCN 9E991 10 JAN 2011 Rev. 3 Page 23
BHT-206L-CR&O-3

1. Bushing - retention bolt

2. Grip pad
3. Modification plate and serial no. plate
4. Grip plate - upper/lower
5. Doubler
6. Skin (0.016 inch (0.41 mm) 2024 aluminum alloy, T3)
7. Spar assembly
8. Trailing edge strip
9. Decal
10. Balance weight
11. Trailing edge closure
12. Root end closure
13. Wear pad
14. Core (3/16 inch (4.76 mm) cell, 0.001 inch (0.025 mm) foil thickness)
15. Tip balance weight support
16. Alignment screw
17. Tip
18. Trim tab
19. Inboard tab

206L_CRO_62_0003b

Figure 62-8. Main Rotor Blade (Sheet 2 of 2)

62-00-00
Page 24 Rev. 3 10 JAN 2011 ECCN 9E991
 BHT-206L-CR&O-3

Figure 62-9. Spar Damage — Repair Limits

62-00-00
ECCN 9E991 10 JAN 2011 Rev. 3 Page 25
BHT-206L-CR&O-3

b. Install tip balance weight support (15,
Figure 62-8), if removed, as follows:
(1) Insert tip balance weight support (15) into
spar assembly (7). Use thin aluminum washers
(AN960JD416L) between surfaces, as required, for
contour alignment. A maximum of eight washers is
allowed. Torque retaining screws 40 inch-pounds
(4.52 Nm).
a. Any dent in the outboard 3.0 feet (0.914 m)
that does not tear skin (6, Figure 62-8), produce a
void, or affect flight characteristics is acceptable.
b. Dents in skin (6) inboard of a station 3.0 feet
(0.914 m) from blade tip, not in excess of 0.060 inch
(1.524 mm) in depth are acceptable. Dents in excess
of this limit shall be polished smooth and patched.
Refer to step 2 for polishing and step 3 for patching.

(2) Fill and fair screw heads and gaps to
mating parts with fairing compound (C-323).
(3) Touch up repaired areas and all bare
metal surfaces (paragraph 62-26).
c. If a nick or scratch exists in a sharp dent in
skin (6), the total depth of both shall not exceed
0.060 inch (1.524 mm). If the nick or scratch cannot be
polished out, it shall be cut out and patched. Refer to
step 2 for polishing and step 3 for patching.

62-16. MAIN ROTOR BLADE — MECHANICAL d. Nicks or scratches in doublers (5) or upper/
DAMAGE INSPECTION AND REPAIR lower grip plates (4), not in excess of 0.012 inch
(0.3048 mm) are acceptable if polished out (step 2).

e. Nicks and scratches anywhere on surface of

MATERIALS REQUIRED
skin (6) or trailing edge strip (8) not greater in depth
than 0.008 inch (0.203 mm) are acceptable if polished
Refer to BHT-ALL-SPM for specifications.
out (step 2).
NUMBER NOMENCLATURE
f. Nicks and scratches in skins (6) in excess of
C-309 MEK 0.008 inch (0.203 mm) in depth shall be polished out if
such damage does not touch or damage trailing edge
C-317 Adhesive strip (8) or spar assembly (7) in any manner, or does
not come within 1.0 inch (25.4 mm) of doublers (5).
C-407 Abrasive Pad Refer to step 2 for polishing and step 3 for patching.
C-422 Aluminum Wool
g. Nicks and notches in extreme trailing edge
strip (8) of blade, 0.120 inch (3.048 mm) in depth or
C-423 Abrasive Paper
less, shall be polished out over a distance of at least
C-427 Barrier Material 2.0 inches (50.8 mm.) on each side of notch. In area
outboard of trim tab (18), depth may not exceed
0.25 inch (6.35 mm). This type of damage shall be
1. Inspect mechanical damage as follows: polished out over a distance of 4.0 inches (101.6 mm)
minimum on each side. Refer to step 2 for polishing.
NOTE
h. Scratches, nicks, gouges, tears, holes, etc. in
Blade with mechanical damage greater skins (6) that exceed limits defined in step 1, and do
than the following limits or conditions, but not touch or damage trailing edge strip (8) or spar
less than replacement damage limits, may assembly (7), or do not come within 1.0 inch (25.4
be sent to Bell Helicopter Textron (BHT) or mm) of doubler (5), may be repaired by patching
to a BHT approved repair facility for provided limits set for patching in step 3 are not
evaluation. exceeded (Figure 62-10).

62-00-00
Page 26 Rev. 3 10 JAN 2011 ECCN 9E991
 BHT-206L-CR&O-3

Figure 62-10. Main Rotor Blade Patch Repair Area

62-00-00
ECCN 9E991 10 JAN 2011 Rev. 3 Page 27
BHT-206L-CR&O-3
NOTE
If a nick or scratch in skin (6, Figure 62-8),
in excess of 0.008 inch (0.2032 mm) in
depth, can be polished smooth without
leaving skin in polished area so thin it can
be dented with fingernail pressure, a patch
may be applied over the area without
cutting a hole. Refer to step 3 for patching.
2. Polish acceptable minor mechanical damage as
follows:
a. Polish out all acceptable nicks and scratches
using fine aluminum wool (C-422) or 180 to 600 grit
abrasive paper (C-423). Polish to a surface finish of
63 RHR or better, removing only enough material to
remove nicks or scratches.
b. Touch up finish to all repaired areas and bare
metal surfaces (paragraph 62-26).
CAUTION
INSPECT PATCH REPAIRS TO MAIN
ROTOR BLADE (INBOARD OF BLADE
STATION 164.0) DAILY FOR CRACKS.
NOTE
Scratches, nicks, gouges, tears, holes, etc.
in skins that touch or damage trailing edge
strip, spar, or are within 1.0 inch (25.4 mm)
of a doubler may not be repaired by
patching (Figure 62-10).
3. Proceed with patch repair as follows:
a. Apply patches to mechanical damage to skin
(6, Figure 62-8) that exceeds limits provided in step 1
and step 2.
b. Remove all paint and primer from around area
the patch will cover using clean cloths dampened with
MEK (C-309) and abrasive pad (C-407). Do not allow
MEK to enter blade. Use 180 grit abrasive paper
(C-423) to remove primer.
62-00-00
Page 28 Rev. 3 10 JAN 2011
NOTE
It is not necessary to cut a hole if damage
can be polished smooth without leaving
skin so thin it can be dented with fingernail
pressure. In this case, the area shall have a
patch applied in the same manner as
though a hole existed. The maximum
diameter of a patch of this type is 4.0
inches (101.6 mm) with at least 0.75 inch
(19.05 mm) of bonded area around the
perimeter of dent.
Orientation of oblong holes shall be within
15° of parallel to leading edge. Minimum
radius of all holes will be 0.25 inch
(6.35 mm).
c. Cut out skin around damaged area. Use hole
saw or scribe through skin with a sharp instrument.
Hole size shall not exceed 2.0 inches (50.8 mm)
diameter for round holes or 1.0 x 4.0 inches (25.4 x
101.6 mm) for oblong holes.
d. Remove skin in cutout area, disturbing core as
little as possible. It is helpful to heat cutout skin to
200°F (93°C) maximum and lift out skin while heated.
e. Deburr edges of hole, ensuring skin is free of
scratches and nicks.
f. Protect repair area with barrier material
(C-427) until preparations for bonding are complete.
CAUTION
A R E A S TO B E B O N D E D S H A L L B E
CLEAN, DRY, AND FREE OF GREASE,
OIL, WAX, ETC.
NOTE
The last two dash numbers of the Bell
Standard PN indicate length and width in
feet of stock.
If 150-021-6BX-X material is not available,
a temporary patch may be made from
2024-T3 aluminum 0.020 inch (0.508 mm)
thick. The temporary patch should be
replaced with one fabricated of
150-021-6BX-X as soon as practical.
ECCN 9E991

Deburr and sand one side of temporary
patch until it is clean. Wipe temporary patch
with a cloth dampened with MEK (C-309)
and wipe dry.
g. Prepare a patch from sheet aluminum
(150-021-6B1-1) with adhesive precured to one side.
Cut patch large enough to overlap hole by at least
0.75 inch (19.05 mm) entirely around perimeter.
Deburr edges of patch.
h. Remove peel ply from adhesive coated patch,
lightly sand exposed adhesive, and wipe with a clean
dry cloth. Do not touch adhesive with bare hands.
i. Mix adhesive (C-317) per manufacturers
directions and apply to bond areas of patch and blade.
j. Apply patch to blade, moving patch slightly
back and forth under pressure to seat it properly and
to expel air pockets in adhesive. Blend out excessive
adhesive around edge of patch.
k. While curing, patch may be held in place with
rubber bands made from an inner tube or by other
mechanical means. Cure adhesive for 2 hours at 140
to 160°F (60 to 71°C). To accelerate cure time, apply
heat with a 200 watt lamp 12 inches from patch. Heat
should be applied until adhesive is completely firm
(resistant to fingernail penetration).
l. Touch up finish of all repaired surfaces
(paragraph 62-26).
62-17. MAIN ROTOR BLADE — VOID DAMAGE
INSPECTION AND REPAIR
MATERIALS REQUIRED
Refer to BHT-ALL-SPM for specifications.
NUMBER NOMENCLATURE
C-311 Adhesive
C-317 Adhesive
NOTE
Void damage greater than the following
limits or conditions, but less than the
replacement damage limits, may be sent to
ECCN 9E991
BHT-206L-CR&O-3
Bell Helicopter Textron (BHT) or a BHT
approved repair facility for evaluation.
1. Inspect butt end voids as follows:
a. Voids between trailing edge strip (8,
Figure 62-8) and skin (6) not in excess of 1.0 inch
(25.4 mm) deep and 0.25 inch (6.35 mm) in width are
acceptable.
b. Voids between skin (6) and trailing edge
closure (11) not deeper than 0.15 inch (3.81 mm) and
not wider than 1.0 inch (25.4 mm) are acceptable.
2. Inspect retention area voids inboard of station
60.0 as follows:
a. Edge voids not exceeding 0.06 inch
(1.524 mm) depth on any one bondline shall not
exceed 10% of total length of bondline. Single edge
voids not exceeding 0.06 inch (1.524 mm) in depth
and 2.0 inches (50.8 mm) in length are acceptable at
doublers (5) and upper/lower grip plates (4). Edge
voids in outboard 2.0 inches (50.8 mm) of each finger
of the doublers (5) and outboard 1.0 inch (25.4 mm) of
upper/lower grip plates (4), shall be repaired
(paragraph 62-16).
b. Voids between skin (6) and core (14) not wider
chordwise than 0.75 inch (19.05 mm) or not longer
spanwise than 3.0 inches (76.2 mm) are acceptable.
Total area of all voids shall not exceed 5.0 square
inches (32.26 cm2).
c. Voids between edge of skin (6) and trailing
edge strip (8), or spar assembly (7) less than 0.06 inch
(1.524 mm) wide by any length, or less than 0.12 inch
(3.048 mm) wide by 7.0 inches. (177.8 mm) long are
acceptable.
d. Voids running into area of retention bolt hole
bushings (1) in any bondline are not acceptable.
e. Other voids between skin (6) and trailing edge
strip (8), or spar assembly (7) that do not exceed
0.18 inch (4.572 mm) in width by 10.0 inches
(254.0 mm) long are acceptable.
3. Inspect voids under skin outboard of station 60.0
as follows:
a. Voids between skin (6) and trailing edge strip
(8) shall not exceed 1/3 of width of mating surface.
62-00-00
10 JAN 2011 Rev. 3 Page 29
BHT-206L-CR&O-3
b. Voids between skin (6) and core (14) shall not
exceed 1.0 inch (25.4 mm) in width chordwise by
25.0 inches (635.0 mm) long. Voids within 1.0 inch
(25.4 mm) of each other are considered one void.
c. Voids between skin (6) and spar assembly (7)
not wider than 0.25 inch (6.35 mm) are acceptable.
Voids not greater than 0.38 inch (9.652 mm) by
2.0 inches (50.8 mm) are acceptable provided spacing
between void centers exceeds 6.0 inches (152.4 mm).
Edge voids are acceptable up to 0.08 inch (2.032 mm)
in depth.
d. Edge voids between edge of skin (6) and
trailing edge strip (8), less than 0.08 inch (2.032 mm)
wide by any length, or less than 0.18 inch (4.572 mm)
wide by 10.0 inches (254 mm) long are acceptable.
4. All acceptable edge voids shall be sealed with
adhesive (C-311) or adhesive (C-317).
5. Touch up all repaired areas and bare metal
surfaces (paragraph 62-26).
62-18. MAIN ROTOR BLADE — GRIP PLATE AND
DOUBLER SEPARATION/CORROSION
REPAIR
MATERIALS REQUIRED
Refer to BHT-ALL-SPM for specifications.
NUMBER NOMENCLATURE
C-100 Chemical Film Material
C-311 Adhesive
C-426 Masking Tape
NOTE
Separation and corrosion damage greater
than the following limits or conditions, but
less than replacement damage limits may
be repaired at Bell Helicopter Textron
(BHT) or at a BHT approved repair facility.
NOTE
This repair method involves removing a
portion of tip of grip plate or doubler to
expose corroded or separated area so
62-00-00
Page 30 Rev. 3 10 JAN 2011
corrosion and separation can be removed
and arrested (Figure 62-11).
Leading edge doubler tips on upper and
lower surface of blade may be trimmed a
maximum of 2.00 inches (50.80 mm).
When one of these doublers is trimmed
more than 1.00 inch (25.40 mm), an equal
amount of that over 1.00 inch (25.40 mm)
shall be trimmed from adjacent shorter
doubler tip.
Grip plate trim limit is 1.00 inch (25.40 mm)
and will only be trimmed due to damage or
delamination. For example, if shortest
doubler is trimmed 2.00 inches (50.80 mm),
grip plate will not be trimmed unless it is
delaminated or damaged.
1. Main rotor blades with corrosion and separation
in bond line of grip plates and doublers (leading and
trailing edges) shall be repaired as follows:
a. Determine depth of tip separation by lightly
tapping grip plates and doublers with a light weight
hammer. A 0.0015 inch (0.0381 mm) feeler gauge may
be used; however, it will not give an accurate
measurement of separation depth.
b. If separation depth is less than 2.00 inches
(50.80 mm), cut off only minimum amount required to
entirely eliminate the void or separation. Use a fine
tooth hacksaw or file to cut grip plates or doublers.
c. Mask off area adjacent to grip plates or
doublers being trimmed with masking tape (C-426) to
prevent damage to adjacent blade skin or spar. File or
cut grip plates or doublers almost through, then raise
outboard end to finish breaking. Exercise care to
prevent damage to blade skin, spar, or doublers under
grip plates, or doublers being removed.
d. Remove tool marks and burrs with a smooth
sided file. It is preferred that complete end of grip
plates or doublers be trimmed on a radius 1/2 the
width of grip plates or doublers at the point where cut
(Figure 62-11).
e. Radius corners to a minimum of 0.375 inch
(9.525 mm) when grip plates or doublers are trimmed
by alternate method. Trim trailing edge of doublers to
original shape (Figure 62-11). After trimming, check
end of doublers again by tapping to ensure void no
longer exists.
ECCN 9E991
 BHT-206L-CR&O-3

Figure 62-11. Main Rotor Blade Corrosion — Removal Limits

62-00-00
ECCN 9E991 10 JAN 2011 Rev. 3 Page 31
BHT-206L-CR&O-3

f. Inspect reworked area and adhesive between
grip plates and doublers to ensure all corrosion has
been removed. Apply brush or spray application of
chemical film material (C-100) to all bare aluminum
surfaces and refinish blade as required (paragraph
62-26).
g. For additional corrosion protection, spray grip
doublers, trim tab bond lines, and trailing edge bond
lines with adhesive (C-311) (paragraph 62-26).
SHOT PEEN PITS REMAIN, SANDING
OPERATION IS ACCEPTABLE. IF ALL
EVIDENCE OF SHOT PEENING IS
REMOVED IN ANY AREA, BLADE SHALL
BE RESHOT PEENED. IT IS NOT
NECESSARY TO REMOVE ADHESIVE IN
SHOT PEEN PITS.
b. Remove adhesive from blade by sanding with
180 to 240 grit abrasive paper (C-423).

62-19. MAIN ROTOR BLADE — GRIP PAD c. Wipe surface of blade with clean cloth
REPLACEMENT dampened with MEK (C-309). Wipe dry with clean
cloth.

d. Grip pad must be concentric with retention

MATERIALS REQUIRED bolts bushing (1) within 0.02 inch (0.508 mm).

Refer to BHT-ALL-SPM for specifications. e. Distance between grip pad faces must be
3.297 to 3.308 inches (83.7438 to 84.023 mm). Set as
NUMBER NOMENCLATURE
follows:
C-305 Aliphatic Naphtha
(1) Measure distance between upper/lower
C-309 MEK grip plate surfaces in area around pads (Figure 62-8,
View A).
C-317 Adhesive
(2) Subtract this dimension from
C-423 Abrasive Paper 3.303 inches (83.896 mm) and divide result by 2. This
should result in a dimension of approximately 0.016
inch (0.406 mm). Fabricate shim of this dimension
NOTE ±0.002 inch (±0.051 mm). Cut hole in shim 0.12 inch
If corrosion has progressed beyond shot (3.048 mm) larger in diameter than grip pad.
peened surface, blade may be sent to Bell
Helicopter Textron (BHT) or a BHT NOTE
approved repair facility for evaluation and
restoration of shot peened surface. After removal of the peel ply fabric, what
remains on the surface is a thin layer of dry
1. Replace worn, damaged, or loose grip pads (2, adhesive with imprint of fabric on it.
Figure 62-8) as follows:
f. Remove peel ply fabric from inner surface of
grip pad to expose cured adhesive. Clean with a clean
a. Pry grip pad loose using a sharpened putty cloth dampened with aliphatic naphtha (C-305).
knife or equivalent. Use extreme care not to damage
blade.

CAUTION

CAUTION
THE SURFACE OF UPPER/LOWER GRIP
PLATES (4) AROUND RETENTION BOLT
BUSHINGS HAS BEEN SHOT PEENED.
DO NOT SAND THROUGH SHOT
PEENED SURFACE. IF EVIDENCE OF
DO NOT C O NTAM INAT E A DHE SI VE
SURFACE AFTER REMOVING PEEL PLY.
USE CLEAN CLOTH GLOVES WHILE
HANDLING GRIP PADS.
g. Apply adhesive (C-317) to bonded adhesive
surface of grip pad and to mating surface of blade.

62-00-00
Page 32 Rev. 3 10 JAN 2011 ECCN 9E991
 BHT-206L-CR&O-3

h. Place grip pad on blade around retention bolt

bushing (1).
CAUTION
i. Place fabricated shim around grip pad, which
has been positioned around retention bolt bushing,
THE SURFACE TO WHICH PAD HAS
and place a bar across shim and grip pads (upper and
BEEN BONDED HAS BEEN SHOT
lower surfaces).
PEENED. DO NOT SAND THROUGH
SHOT PEENED SURFACE. IF EVIDENCE
j. Install clamps over bars and tighten until bars
OF SHOT PEEN PITS REMAIN, SANDING
bottom on shim and provide 5 to 30 PSI (35 to
OPERATION IS ACCEPTABLE. IF ALL
206 kPa) contact pressure.
EVIDENCE OF SHOT PEENING IS
REMOVED IN ANY AREA, BLADE SHALL
k. Cure adhesive for 2 hours at 140 to 160°F (60
BE RESHOT PEENED (PARAGRAPH
to 71°C).
6 2- 27 ) . I T IS N O T NE C E S S A RY TO
REMOVE ADHESIVE IN SHOT PEEN
l. After cure is complete, wipe grip pad area PITS.
clean with a clean cloth dampened with MEK (C-309).
3. Wipe bonding surface on blade with a clean cloth
m. Touch up area around grip pad (paragraph dampened with MEK (C-309). Wipe dry with clean
62-26). cloth.

62-20. MAIN ROTOR BLADE — WEAR PAD

4. Removed wear pad may be reused provided
REPLACEMENT
composite bond is still attached to pad. Remove as
much old adhesive as possible by sanding without
disturbing composite bond.
MATERIALS REQUIRED
5. Remove peel ply fabric from new wear pad to
Refer to BHT-ALL-SPM for specifications.
expose adhesive coated surfaces. Use care not to
NUMBER NOMENCLATURE contaminate existing adhesive.

C-309 MEK 6. Apply adhesive (C-317) to mating surfaces of

blade and wear pad.
C-317 Adhesive

NOTE CAUTION
Any number of wear pads may be replaced
at the same time.
INSTALL LONGEST LEG OF WEAR PAD
If corrosion has progressed beyond shot INSIDE MACHINED OUT TANGS OF
peened surface, blade may be sent to Bell GRIP PLATES.
Helicopter Textron (BHT) or a BHT
approved repair facility for evaluation and
restoration. CAUTION
1. Remove wear pad by gently tapping. Be very
careful not to damage grip plates. If gentle tapping DO NO T HEA T ARE A A BO VE 20 0°F
fails to loosen pad, apply a heat gun to pad and repeat (93°C).
tapping. Do not allow surface to be heated beyond
200°F (93°C).
NOTE
2. After pad has been removed, remove as much Make sure top and bottom wear pads are in
old adhesive as possible from blade by sanding. the same plane and parallel to each other.

62-00-00
ECCN 9E991 10 JAN 2011 Rev. 3 Page 33
BHT-206L-CR&O-3

a. Bond wear pad to blade using 5 to 30 PSI (35
to 206 kPa) pressure applied with clamps. Cure at
room temperature 70 to 95°F (21 to 35°C) for 24 hours
or, as an alternate, at 175 to 195°F (79 to 90°C) for
1 hour.
7. Touch up paint wear pad area (paragraph 62-26).
62-21. MAIN ROTOR BLADE — ROOT END
CLOSURE REPLACEMENT
(4) Protect surface with barrier material
(C-427) until preparations for bonding are complete.
b. Clean new closure by lightly sanding with 180
to 240 grit abrasive paper (C-423) and wiping with
clean cloth dampened with MEK (C-309).
NOTE
After application of chemical film treatment,
do not handle new closure with bare hands.

c. Apply chemical film material (C-100), or

MATERIALS REQUIRED cleaner (C-344), or chromic acid treatment (C-103) to
bare metal surfaces of blade and new closure.
Refer to BHT-ALL-SPM for specifications.
d. Thoroughly air dry prepared surfaces.
NUMBER NOMENCLATURE

C-100 Chemical Film Material NOTE

For alternate bonding procedure, refer to
C-103 Chromic Acid
following step f.
Treatment
e. Bond root end closure to main rotor blade.
C-309 MEK

C-317 Adhesive (1) Mix adhesive (C-322) part A and part B

per manufacturers instructions.
C-322 Adhesive

C-344 Cleaner
CAUTION
C-423 Abrasive Paper

C-427 Barrier Material ADHESIVE SHALL BE USED WITHIN

2 HOURS AFTER MIXING

1. Replace unserviceable root end closure (12, (2) Apply mixed adhesive to mating surfaces
Figure 62-8). of blade and closure.

a. Remove unserviceable root end closure.
(1) Very carefully peel closure from blade by
starting at a corner using a sharpened putty knife or
equivalent, to separate bond. Use extreme care not to
damage spar, doublers, or grip plates.
(2) Remove all adhesive from blade with 180
to 240 grit abrasive paper (C-423).
(3) Clean area by wiping with a clean cloth
dampened with MEK (C-309). Continue with new
cloths until surfaces are completely clean, then dry
with clean cloths.
(3) Place closure in position on blade and
gently move it back and forth while pressing against
blade. Closure should be fitted flush to leading edge
surface (Figure 62-8, View A and View B). Remove
excess adhesive by wiping with clean cloth.
(4) Allow adhesive to cure 24 hours at 70 to
80°F (21 to 27°C) or for 2 hours at 145 to 155°F (63 to
68°C).
(5) Touch up repaired area and all bare
metal surfaces (paragraph 62-26).
f. Alternate bonding procedure for root end
closure.

62-00-00
Page 34 Rev. 3 10 JAN 2011 ECCN 9E991
 BHT-206L-CR&O-3

(1) Mix adhesive (C-317) per manufacturers a. Edge voids between trim tab and blade less
instructions. than 0.12 inch (3.048 mm) deep are acceptable and
shall be sealed with adhesive (C-311) or adhesive
(2) Apply adhesive per step e. (C-317).

b. If corrosion exists, replace trim tab (18)

(3) Allow adhesive to cure 24 hours at 70 to
80°F (21 to 27°C) or for 1 hour at 175 to 190°F (79 to
88°C). Allow 5 to 6 days for full cure.
(4) Touch up repaired area and all bare
metal surfaces (paragraph 62-26).
62-22. MAIN ROTOR BLADE — TRIM TAB
INSPECTION AND REPLACEMENT
MATERIALS REQUIRED
(step 3).
3. Replace unserviceable trim tab (18) as follows:
a. Cut off portion of trim tab leaving 0.12 inch
(3.048 mm) beyond trailing edge of blade.
b. Very carefully peel trim tab from blade by
starting at a corner using a sharpened putty knife, or
equivalent, to separate bond. Use extreme care not to
damage blade skin or pull blade skin loose from core
or trailing edge strip.

Refer to BHT-ALL-SPM for specifications. c. Remove all adhesive from blade by sanding in
a spanwise direction, starting with 200 grit abrasive
NUMBER NOMENCLATURE paper (C-423), and finishing with 400 grit abrasive
paper (C-423). If any evidence of corrosion exists on
C-100 Chemical Film Material
skin (6) or trailing edge strip (8) it shall be polished out.
C-305 Aliphatic Naphtha Do not polish more than 0.008 inch (0.203 mm) deep
in skin or more than 0.030 inch (0.762 mm) deep in
C-309 MEK trailing edge strip.

C-311 Adhesive d. Remove paint finish for a distance of 0.25 to

0.50 inch (6.35 to 12.7 mm) around perimeter of area
C-317 Adhesive where new trim tab (18) will be bonded, sanding
spanwise starting with 200 grit abrasive paper (C-423),
C-323 Fairing Compound and finishing with 400 grit abrasive paper (C-423).
C-423 Abrasive Paper
e. Clean area by wiping with clean cloth
C-426 Masking Tape dampened with MEK (C-309). Continue with new
clean cloths until surfaces are completely clean.
C-427 Barrier Material
f. Protect surfaces with barrier material (C-427)
and masking tape (C-426) until preparations for
1. Perform trim tab inspection as follows: bonding are complete.

a. Inspect trim tabs (18, Figure 62-8) for g. Bond new trim tab (18) to main rotor blade.
evidence of bending, bond separation, corrosion, and
cracks.
CAUTION
b. Straighten bent trim tab (18) with a mallet and
back-up block.
D O N O T C O N TA M I N AT E I N S I D E
2. If trim tab (18) is cracked, bent to the extent it ADHESIVE S U R FA C E AFTER
cannot be straightened, or if edge voids exist that are RE MO V ING P EE L P LY. US E CLE A N
0.12 inch (3.048 mm) deep between trim tab and W H I T E C O T TO N G L O V E S W H I L E
blade, replace trim tab (step 3). HANDLING TRIM TAB.

62-00-00
ECCN 9E991 10 JAN 2011 Rev. 3 Page 35
BHT-206L-CR&O-3
(1) Remove peel ply fabric from inner
surface of trim tab to expose cured adhesive. Lightly
abrade adhesive with 180 grit abrasive paper (C-423)
and wipe clean with clean cloth dampened with
aliphatic naphtha (C-305).
(2) Mix adhesive (C-317) per manufacturers
instructions and apply to inside surface of trim tab and
to clean mating surface of blade.
(3) Bond trim tab to blade using 5 to 30 PSI
(34.5 to 206.8 kPa) pressure and cure for 2 hours at
140 to 160°F (60 to 71°C). C-clamps and wooden
blocks approximately the size of tab may be used as
pressure devices. A rubber pad approximately 0.062
to 0.125 inch (1.574 to 3.175 mm) thick of
approximately 40 durometer hardness should be used
between wood blocks and tab to evenly distribute
pressure.
(4) Remove C-clamps and clean excess
adhesive. Wipe tab and surrounding area of blade with
clean cloths dampened with MEK (C-309), then wipe
dry with clean cloth. Fair around edges of tab with
fairing compound (C-323).
h. Apply chemical film material (C-100) or
cleaner (C-344) to all bare aluminum surfaces.
i. Touch up repaired areas and new trim tab
(paragraph 62-26).
62-23. MAIN ROTOR BLADE — RETENTION
BUSHING INSPECTION AND
REPLACEMENT
MATERIALS REQUIRED
Refer to BHT-ALL-SPM for specifications.
NUMBER NOMENCLATURE
C-101 Corrosion Preventive
Compound
CAUTION
REPLACEMENT OF BLADE RETENTION
B O LT B U S H I N G M AY O N LY B E
ACCOMPLISHED BY BELL HELICOPTER
62-00-00
Page 36 Rev. 3 10 JAN 2011
TEXTRON (BHT) OR A BHT APPROVED
REPAIR FACILITY.
1. lnspect main rotor blade retention bolt bushing (1,
Figure 62-8) as follows:
a. lnspect retention bolt bushing (1) for
corrosion, pitting, elongation, and size.
b. Main rotor blade bushing shall be replaced if
inner diameter exceeds 1.524 inches (38.709 mm).
c. Any corrosion or pitting in bushing inner
diameter exceeding replacement dimension after
polishing is cause for rejection.
d. Immediately after retention bolt bushing
clean-up, apply a coat of corrosion preventive
compound (C-101) to inner diameter.
62-24. MAIN ROTOR BLADE — TIP ASSEMBLY
INSPECTION AND REPAIR
MATERIALS REQUIRED
Refer to BHT-ALL-SPM for specifications.
NUMBER NOMENCLATURE
C-305 Aliphatic Naphtha
C-317 Adhesive
C-423 Abrasive Paper
C-426 Masking Tape
NOTE
Blade with tip debonding exceeding
following limits may be sent to Bell
Helicopter Textron (BHT) or a BHT
approved repair facility for evaluation.
1. lnspect tip (17, Figure 62-8) for debonding by
tapping both upper and lower surfaces.
a. The lower side of tip may be debonded from
blade skin for complete chord length (tip weight
support to trailing edge strip, approximately 7.3 inches
(185.4 mm) provided no debonding exists on upper
surface or along trailing edge strip (Figure 62-12,
Note 3).
ECCN 9E991
 BHT-206L-CR&O-3

b. Small areas of skin debonding on both upper (4) Cover only debonding line with a thin
and lower surfaces are allowed until one side has layer of adhesive (C-317) between masking tape strips
debonded to a length of 4.0 inches (101.6 mm) and index marks. Remove tape. Make sure adhesive
(Note 4). seals void areas.

c. Spanwise tip skin debonding, tip skin cracks,
or damage along trailing edge extrusion are not
allowed.
d. Debonding, cracks, or other damage are not
allowed between trailing edge extrusion and tip
assembly (Note 5).
(5) Blades shall be inspected daily prior to
each start to monitor and record any additional
debonding. Repeat step (1) through step (4), as
required, until debonding exceeds limits set in step 1.
62-25. MAIN ROTOR BLADE — TIP WEIGHT
SUPPORT REMOVAL AND INSTALLATION

2. Seal debonded blade tip as follows:

MATERIALS REQUIRED
a. Blade tips with allowable tip debonding shall
be marked and sealed to prevent entrance of air and Refer to BHT-ALL-SPM for specifications.
moisture and to allow monitoring for additional
NUMBER NOMENCLATURE
debonding.
C-245 Polyurethane Coating
(1) Tap blade skin surfaces to determine
actual amount of debonding along blade tip chord line. C-246 Epoxy Primer Coating
Mark area of debonding with a permanent marker.
Marks are required for personnel to monitor amount of C-305 Aliphatic Naphtha
debonding that may occur from one flight to the next.
C-323 Fairing Compound
(2) Clean blade and tip skin on both sides of C-406 Abrasive Cloth
chord line with clean cloths dampened with aliphatic
naphtha (C-305).
1. Remove the tip weight support assembly (1,
(3) Apply masking tape (C-426) 0.25 inch Figure 62-13) from the main rotor blade (5) as follows:
(6.35 mm) on each side of bonding line, chordwise.
Lightly sand surfaces between tape with 400 grit or a. Remove the screws (2 and 4).
finer abrasive paper (C-423). Remove sanding residue
with clean cloths dampened with aliphatic naphtha b. Remove fairing compound around the tip
(C-305). weight support assembly (1) with a plastic scraper.

62-00-00
ECCN 9E991 10 JAN 2011 Rev. 3 Page 37
BHT-206L-CR&O-3

206L_CRO_62_0007

Figure 62-12. Main Rotor Blade Tip Assembly — Inspection and Repair

62-00-00
Page 38 Rev. 3 10 JAN 2011 ECCN 9E991
 BHT-206L-CR&O-3

4 T

(4 PL) 1 3

BLADE SPAR

1
T 2

1. Tip weight support assembly

2. Screw
3. Washer
4. Screw
5. Main rotor blade

T 40 IN-LBS (4.5 Nm)

NOTE
1 Washer(s) (3) are used to align the contour of the tip weight support assembly (1) with
the contour of the blade spar. If installed, record location and quantity of washers.

206_CRO_62_0075

Figure 62-13. Main Rotor Blade Tip Weight Support — Removal and Installation

62-00-00
ECCN 9E991 10 JAN 2011 Rev. 3 Page 39
BHT-206L-CR&O-3

62-26. MAIN ROTOR BLADE — REFINISHING

(TOUCH-UP)
CAUTION

MATERIALS REQUIRED
RECORD LOCATION AND QUANTITY OF
WASHER(S), IF INSTALLED, WHEN YOU Refer to BHT-ALL-SPM for specifications.
REMOVE THE TIP WEIGHT SUPPORT
ASSEMBLY. WASHERS ARE USED TO NUMBER NOMENCLATURE
A LI G N T HE CO N T O UR O F T HE T IP
C-100 Chemical Film Material
WEIGHT SUPPORT WITH THE SPAR OF
THE MAIN ROTOR BLADE. IF WASHERS C-165 Tape
ARE NOT CORRECTLY INSTALLED,
CONTOURS OF TIP WEIGHT SUPPORT C-245 Polyurethane Coating
AND SPAR MAY NOT BE ALIGNED.
C-246 Epoxy Polyamide
c. Remove the tip weight support assembly (1) Primer
and record the location and quantity of washer(s) (3), if
installed. C-265 Polyurethane Coating

C-305 Aliphatic Naphtha

2. Install the tip weight support assembly (1) on the
main rotor blade (5) as follows: C-318 Cleaning Compound

C-331 Adhesive
a. Remove the remaining fairing compound with
a plastic scraper and a 240 grit abrasive cloth (C-406). C-407 Abrasive Pad

b. Clean the mating surfaces of the tip weight C-423 Abrasive Paper
support assembly (5) and the main rotor blade with
aliphatic naphtha (C-305). C-426 Masking Tape

C-486 Cheesecloth
c. Put the tip weight support assembly (1) in
position in the recess of the main rotor blade (5) with C-516 Clean Cloth
the previously recorded quantity of washer(s) (3), if
installed, and at the correct location. C-594 Lacquer

d. Install and torque the screws (2 and 4) T .

NOTE

e. Clean the tip weight support assembly (1) and
the surrounding area on the main rotor blade (5) with
aliphatic naphtha (C-305).
f. Fill and fair the area with a necessary quantity
of fairing compound (C-323) to maintain the contour of
the blade.
g. As required, apply epoxy primer coating
(C-246) and polyurethane coating (C-245) to areas of
bare metal (BHT-ALL-SPM, Chapter 4).
This procedure provides instructions for the
refinishing (touch-up) of small repaired
areas and bare metal surfaces on main
rotor blades. For a major rework of the
topcoat or a complete refinishing, send the
blade to Bell Helicopter Textron (BHT) or a
BHT approved repair facility.
Refer to General Information Letter (IL)
GEN-04-98 for the applicable shipping
information and to obtain a Return Material
Authorization (RMA) number.

62-00-00
Page 40 Rev. 3 10 JAN 2011 ECCN 9E991

1. Prepare the area to be refinished as follows:
a. If the area has primer, sealer, or topcoat,
thoroughly sand the surface with 120 grit or finer
abrasive paper (C-423). Remove sanding residue with
cheesecloth (C-486) moistened with aliphatic naphtha
(C-305).
b. Clean the area of the blade with an abrasive
pad (C-407) and a solution of cleaning compound
(C-318).
NOTE
Surface is water-break free when the film of
water on the surface is continuous.
c. Rinse the area until the surface is water-break
free.
d. Fully dry the area with a clean cloth (C-516).
e. If the area has bare metal surfaces, apply
chemical film material (C-100) to the surfaces in
accordance with the BHT-ALL-SPM, Chapter 3.
f. Mask areas not to be painted with masking
tape (C-426) and protective sheeting, as applicable.
CAUTION
DO NOT TOUCH THE AREA WITH BARE
HANDS AFTER PREPARATION. USE
CLEAN AND DRY GLOVES TO PREVENT
SURFACE CONTAMINATION.
CAUTION
ALWAYS OVERCOAT PRIMER, SEALER,
OR TOPCOAT, AS APPLICABLE, WITHIN
8 HOURS AFTER APPLICATION. IF NOT
POSSIBLE, YOU MUST SAND AND
PRIME THE SURFACE AGAIN BEFORE
OVERCOATING. FAILURE TO DO SO
COULD RESULT IN LOSS OF PAINT
ADHESION.
ECCN 9E991
BHT-206L-CR&O-3
NOTE
If filler material is applied to the area after
priming or sealing, apply one coat of epoxy
primer coating (C-246) before application of
the next coat, as applicable.
2. Apply the primer and sealer coats to the area as
follows:
a. Apply one coat of epoxy primer coating
(C-246) (BHT-ALL-SPM, Chapter 4). Thickness of the
primer coating to be 0.0006 to 0.0009 inch (0.016 to
0.022 mm). Let the primer dry at ambient temperature
a minimum of 30 minutes.
b. Apply two coats of coating (C-265)
(BHT-ALL-SPM, Chapter 4) as a sealer. Thickness of
the sealer coating to be 0.0016 to 0.0024 inch (0.041
to 0.061 mm).
CAUTION
ALWAYS OVERCOAT PRIMER, SEALER,
OR TOPCOAT, AS APPLICABLE, WITHIN
8 HOURS AFTER APPLICATION. IF NOT
POSSIBLE, YOU MUST SAND AND
PRIME THE SURFACE AGAIN BEFORE
OVERCOATING. FAILURE TO DO SO
COULD RESULT IN LOSS OF PAINT
ADHESION.
3. Depending on the location of the area to be
refinished (Figure 62-14) and the paint scheme of the
blade (Table 62-1), apply the topcoat as follows:
a. If the area to be refinished is located on the
lower surface or root end closure of the blade, apply
two coats of coating (C-265), lusterless black, color
code 37038 per FED-STD-595 (BHT-ALL-SPM,
Chapter 4). Thickness of the top coating to be 0.0016
to 0.0024 inch (0.041 to 0.061 mm).
b. If the area to be refinished is located on the
upper surface of the blade, apply the topcoat in
accordance with the information in Table 62-1 and the
instructions in the BHT-ALL-SPM, Chapter 4.
62-00-00
10 JAN 2011 Rev. 3 Page 41
BHT-206L-CR&O-3

STANDARD

6.0 IN.
(152 mm)

35.0 IN. 70 IN. 35.0 IN. 35.0 IN.

(889 mm) (1778 mm) (889 mm) (889 mm)
LEADING EDGE

PAD GRIP DATA PLATES STRIPE STRIPE TIP

HIGH-VISIBILITY (I)

HIGH-VISIBILITY (II)

HIGH-VISIBILITY (III)

NO ORGANIC FINISH

NOTES
1. Only upper surface of blades is shown.
2. Refer to the procedure for instructions and paint requirements.

206L_CRO_62_0076

Figure 62-14. Main Rotor Blade — Refinishing (Touch-up)

62-00-00
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 BHT-206L-CR&O-3

4. Depending on the location of the area to be WAS OMITTED FROM THE LEADING
refinished (Figure 62-14) and/or the paint scheme of EDGE. FAILURE TO DO SO WILL CAUSE
the blade (Table 62-1), add a stripe color coating to the AN EARLY EROSION OF THE BLADE
upper surface of the blade or a tip color coating to the
FINISH.
top and bottom surfaces of the blade tip as follows:

(1) Mask areas not to be painted with 5. If paint was omitted from the leading edge, as
masking tape (C-426) and protective sheeting shown in Figure 62-14, feather the forward edge of the
(Figure 62-14). paint coat as follows:

(2) Thoroughly sand the topcoated area with

a 120 grit or finer abrasive paper (C-423).
(3) Remove sanding residue with
cheesecloth (C-486) moistened with aliphatic naphtha
(C-305).
(4) Apply one coat of epoxy primer coating
(C-246) (BHT-ALL-SPM, Chapter 4). Thickness of the
primer coating to be 0.0006 to 0.0009 inch (0.016 to
0.022 mm). Let the primer dry at ambient temperature
a minimum of 30 minutes.
(5) Apply the color coating in accordance
with the information in Table 62-1 and the instructions
in the BHT-ALL-SPM, Chapter 4.
a. Mask approximately 0.25 inch (6.3 mm) back
from the forward edge with 2 inch wide tape (C-165).
b. Sand the forward edge, overlapping the tape,
with a power sander and 120 grit or finer abrasive
paper (C-423) until the edge shows a constant line of
primer approximately 0.06 inch (1.5 mm) wide.
6. If applicable, bond modification plate and serial
number plates to blade using adhesive (C-331)
(Figure 62-8). Apply firm contact pressure to plates
and cure adhesive for 72 hours at 70 to 90°F (21 to
32°C) (handling strength in 24 hours), or cure for 60
minutes at 175 to 185°F (79 to 85°C).

CAUTION 7. If applicable, install decal (9, Figure 62-8) to

lower side of blade to dimensions shown.
YOU MUST FEATHER THE FORWARD
EDGE OF THE PAINT COAT IF PAINT

Table 62-1. Main Rotor Blade — Refinishing of Upper Surfaces (Topcoat)

FINISH AND COLOR NUMBER COATING

FINISH COATING
(CODE PER FED-STD-595) OF COATS THICKNESS

STANDARD

Topcoat coating (C-265) semi-gloss white 2 0.0016 to 0.0024 inch

(27925) (0.041 to 0.061 mm)

Tip polyurethane lusterless yellow 2 0.0012 to 0.0015 inch

coating (C-245) (33538) (0.031 to 0.038 mm)
or
lacquer (C-594)

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BHT-206L-CR&O-3

Table 62-1. Main Rotor Blade — Refinishing of Upper Surfaces (Topcoat) (Cont)

FINISH AND COLOR NUMBER COATING

FINISH COATING
(CODE PER FED-STD-595) OF COATS THICKNESS

HIGH-VISIBILITY (I)

Topcoat coating (C-265) semi-gloss white 2 0.0012 to 0.0015 inch

(27925) (0.031 to 0.038 mm)
Stripes polyurethane lusterless black 2 0.0012 to 0.0015 inch
coating (C-245) (37038) (0.031 to 0.038 mm)
or
coating (C-265)
or
lacquer (C-594)
Tip polyurethane lusterless yellow 2 0.0012 to 0.0015 inch
coating (C-245) (33538) (0.031 to 0.038 mm)
or
lacquer (C-594)

HIGH-VISIBILITY (II)

Topcoat coating (C-265) semi-gloss white 2 0.0012 to 0.0015 inch

(27925) (0.031 to 0.038 mm)

Stripes polyurethane gloss orange 2 0.0012 to 0.0015 inch

coating (C-245) (12197) (0.031 to 0.038 mm)
or
lacquer (C-594)

Tip polyurethane lusterless yellow 2 0.0012 to 0.0015 inch

coating (C-245) (33538) (0.031 to 0.038 mm)
or
lacquer (C-594)

HIGH-VISIBILITY (III)

Topcoat coating (C-265) lusterless black 2 0.0016 to 0.0024 inch

(37038) (0.041 to 0.061 mm)

Tip polyurethane lusterless yellow 2 0.0012 to 0.0015 inch

coating (C-245) (33538) (0.031 to 0.038 mm)
or
lacquer (C-594)

NOTE:

Requirements for the color coating of the tip apply to the upper and lower surfaces of the blade.

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 BHT-206L-CR&O-3

62-27. MAIN ROTOR BLADE — MAJOR REPAIRS d. Shot peening.

1. Main rotor blades with damage greater than limits
stated previously, but not requiring replacement, may
be sent to Bell Helicopter Textron (BHT) or a BHT
approved repair facility for evaluation. Repair facilities
are capable of accomplishing the following repairs:
a. Patching damaged skin (6, Figure 62-8).
b. Trim tab (18) and root end closure (12)
replacement.
e. Complete refinishing of blade.
f. Tip (17) and tip balance weight support (15)
replacement.
g. Inspection after major overspeed, sudden
stoppage, and hard landing.
h. Grip pad (2) and wear pad (13) replacement.

c. Retention bolt hole bushing (1) replacement. i. Main rotor blade master balance and sweep.

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 BHT-206L-CR&O-3

MAIN ROTOR HUB

62-28. MAIN ROTOR HUB 2. Place main rotor hub on workbench supporting
yoke (12, Figure 62-15) and grips (54) with three
62-29. MAIN ROTOR HUB — DISASSEMBLY pieces of wood, approximately 2 x 4 x 10 inches (51 x
102 x 254 mm). Place wood pieces under grip and
yoke.
SPECIAL TOOLS REQUIRED
3. On oil lubricated hubs, remove plugs (83) and
sight glasses (86). Discard packings (84 and 85).
NUMBER NOMENCLATURE

OTC No.1124 1 Bearing Splitter 4. Remove nuts (5) and washers (6) from inboard
side of yoke (12). Remove bolts (32), washers (6 and
T101491 Bearing Puller 31), shims (88), and bushings (30) from each pillow
block (28). Using a soft faced plastic mallet, tap pillow
T101554 Socket Wrench blacks from yoke and trunnion (20).
Workaid Main Rotor Grip
Retainer Dowel 5. Remove trunnion from yoke. Using a 1/4 inch
hexagon wrench, turn adjusting screws (21) clockwise
Workaid Pitch Horn Trunnion to drive wear disc (19) and thrust washers (22) from
journal ends of trunnion (20). Continue turning
Workaid Trunnion Bearing adjusting screws until threads clear trunnion. Discard
Pressing Plate packings (23) from thrust washers.
Workaid Trunnion Bearing
Pressing Plug 6. On yoke (206-011-149), remove nuts (66),
washer (67), retainer (68), and balance washers (69,
NOTE: 70, and 71),

1 SPX/OTC Service Solutions,

655 Eisenhower Dr., 7. Remove bearing inner races (25) from spindles of
Owatonna, MN 55060. trunnion (20) as follows:

a. Fabricate trunnion bearing pressing plate and

NOTE
Review Mandatory Retirement Schedule in
Chapter 4 of the applicable Maintenance
Manual (MM). Components that are
scheduled for retirement shall be removed
from service.
If main rotor hub is being disassembled for
replacement of defective component(s)
instead of overhaul, disassemble only to
the extent necessary to replace defective
parts.
1. If accompanying records and/or physical
appearance of hub indicate components have been
subject to an accident or incident such as overspeed,
overtorque, or sudden stoppage, accomplish
paragraph 62-32, step 1 prior to disassembly.
pressing plug (Figure 62-16 and Figure 62-17). As an
alternate, bearing splitter (OTC No. 1124) may be
used (Figure 62-18).
b. Using a sharp plastic scraper, remove sealant
from radius groove around trunnion (20, Figure 62-15)
and inboard end of bearing race (25).
c. Position fabricated bearing pressing plate
around trunnion at inboard end of bearing inner race.
Make sure pressing plate fits snug to bearing inner
race and sufficient clearance is available to allow plate
to clear spindle of trunnion.
d. Position trunnion (20) in hydraulic press and
support bearing press plate with support blocks across
parting line of pressing plate.

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BHT-206L-CR&O-3

206L_CRO_62_0013a

Figure 62-15. Main Rotor Hub (Sheet 1 of 3)

62-00-00
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 BHT-206L-CR&O-3

DETAIL A

DETAIL B

206L_CRO_62_0013b

Figure 62-15. Main Rotor Hub (Sheet 2 of 3)

62-00-00
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BHT-206L-CR&O-3

1. Packing 24. Seal 46. Nut 68. Retainer

2. Retainer 25. Bearing innner race 47. Latch 69. Hub balance washer
3. Excluder 26. Bearing 48. Spring 70. Hub balance washer
4. Packing 27. Grease fitting 49. Nut 71. Hub balance washer
5. Nut 28. Pillow block 50. Washer 72. Nut
6. Washer 29. Pillow block pad 51. Nut 73. Lockwasher
7. Laminated shim 30. Bushing 52. Washer 74. Thin steel washer
8. Rubber stop 31. Washer 53. Buffer pad 75. Stat-o-seal
9. Static stop 32. Bolt 54. Grip 76. Grip reservoir
10. Bolt 33. Relief valve 55. Pin 77. Lubrication fitting
11. Washer 34. Washer 56. Strap bolt 78. Packing
12. Yoke 35. Bolt 57. Blade bolt 79. Sight glass
13. Identification plate 36. Bolt 58. Packing 80. Bolt
14. Radius ring 37. Washer 59. Blade bolt cap 81. Packing
15. Strap fitting 38. Pitch horn trunnion 60. Grease fitting 82. Washer
16. Strap pin 39. Nut 61. Spot decal 83. Plug
17. Insert 40. Pitch horn 62. Nut 84. Packing
18. Deleted 41. Identification plate 63. Seal 85. Packing
19. Wear disc 42. Packing 64. Wearsleeve 86. Sight glass
20. Trunnion 43. Bearing 65. Tension - torsion strap 87. Plug
21. Adjusting screw 44. Spacer 66. Nut 88. Shim
22. Thrust washer 45. Closure 67. Washer 89. Pillow block pad
23. Packing

NOTES
1 Springs (48) are no longer required and may be removed.

2 Retainer (68) and balance washers (69, 70 and 71) are used only on 206-011-149 yoke.

206L_CRO_62_0013c

Figure 62-15. Main Rotor Hub (Sheet 3 of 3)

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 BHT-206L-CR&O-3

206L_CRO_62_0014

Figure 62-16. Trunnion Bearing Pressing Plate

62-00-00
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BHT-206L-CR&O-3

206L_CRO_62_0015

Figure 62-17. Trunnion Bearing Pressing Plug

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 BHT-206L-CR&O-3

PRESSING PLUG

PRESSING PLATE
OR OTC NO. 1124
BEARING SPLITTER

206L_CRO_62_0016

Figure 62-18. Trunnion Bearing Inner Race — Removal

62-00-00
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BHT-206L-CR&O-3
e. Insert pressing plug into journal end of
trunnion and press trunnion from bearing inner race
(25). During pressing operation, make sure pressing
plate does not damage spindle of trunnion. Do not
permit trunnion to drop when trunnion spindle clears
inner race.
8. Remove seal (24) from pillow blocks (28) using
bearing puller (T101491) (Figure 62-19).
a. Fabricate a pressure block from 0.25 to
0.50 inch (6.35 to 12.7 mm) phenolic, approximately
1.50 to 1.75 inches (38.1 to 44.5 mm) in diameter.
Place pressure block in bottom of pillow block.
b. Insert bearing puller (T101491) into pillow
block with jaws contacting inside surface of seal by
use of adjusting screw. Tighten pulling screw until seal
clears pillow block.
9. Invert pillow blocks (28, Figure 62-15) on
workbench and apply heat lamp. When pillow blocks
are heated, tap face of pillow blocks on a hard wood
surface to remove bearings (26).
10. Remove and discard pillow block pads (29
and 89).
11. For grease lubricated hubs, remove grease
fittings (27) from pillow blocks (28).
12. Remove nuts (51), washers (52), and blade bolts
(57) from each grip (54).
13. Remove caps (59) from blade bolts and remove
balance weights. Retain weights for future use during
rebalancing of hub and blade assembly. Discard
packings (58).
CAUTION
DO NOT EXCEED THE MAXIMUM
ALLOWABLE TEMPERATURE WHEN
YOU HEAT A PART OR DAMAGE TO THE
PART MAY OCCUR.
14. Heat the blade bolt (57) in the area of the plug
(87) to a maximum of 200°F (93°C) and remove the
plug with an aluminum or wood drift.
62-00-00
Page 54 Rev. 3 10 JAN 2011
15. Remove and disassemble both grips (54).
CAUTION
DO NOT ALLOW GRIPS OR YOKE TO
ROTATE ON PITCH CHANGE AXIS. IF
GRIP OR YOKE IS ALLOWED TO
ROTATE ON THE PITCH CHANGE AXIS
BEYOND 90°, REPLACE MAIN ROTOR
GRIP RETENTION STRAPIS. USE
T-HANDLE WORKAID OR LOCKWIRE TO
SECURE GRIPS.
a. Make sure grips and yoke are secured to
prevent rotation.
b. Remove nuts (46), latches (47), and springs
(48), if used.
c. Remove nuts (49) with socket wrench
(T101554) then remove washers (50) and strap bolts
(56). Refer to Chapter 4 of the applicable Maintenance
Manual (MM) and discard the strap bolts if these have
reached their retirement life.
d. Remove nuts (62), washers (34), and
bolts (35).
e. Pull grips (54) outboard. Allow oil to drain, if
applicable.
f. Remove grips (54) and pitch horns (40) from
yoke (12). Do not allow hub weight to rest on wear
sleeves (64). Support yoke with pieces of wood.
g. Remove bolts (10), washers (11), static stops
(9), rubber stops (8), and laminated shims (7).
h. Using a sharp plastic scraper, trim sealant
from around inboard end of strap fitting (15) and
surface of yoke (12).
i. With hand pressure, push tension-torsion
straps (65) inboard in yoke to break sealant bond. If
bond cannot be broken with hand pressure, insert a
0.50 inch (12.7 mm) wooden dowel into yoke journal
against strap fitting and lightly tap from yoke.
j. Remove strap pins (16), radius rings (14),
strap fittings (15), and tension-torsion straps (65).
ECCN 9E991
 BHT-206L-CR&O-3

Figure 62-19. Pillow Block Seal — Removal

62-00-00
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BHT-206L-CR&O-3

k. Fabricate grip retainer dowel workaid
(Figure 62-20). Insert grip retainer dowel workaid into
retainer (2, Figure 62-15). Rock dowel to break
sealant around retainers. Remove retainers from
grips (54).
l. Remove excluders (3) and packings (1 and 4)
from retainers.
m. Thoroughly heat grips with a heat lamp.
Remove bearings (43) and spacers (44) from each
grip.
pitch horn slot and tighten screw until trunnion (38,
Figure 62-15) can just be pulled out. Immediately
release screw tension and remove trunnion workaid.
As an alternate method, insert a phenolic wedge in
pitch horn slot just far enough to remove pitch horn
trunnion.
e. Using care to prevent damage to pitch horns
(40), press seals (63) from horns.
62-30. MAIN ROTOR HUB — CLEANING

n. Remove closures (45), two buffer pads (53),

and spot decals (61) from each grip (54). Do not MATERIALS REQUIRED
remove blade bolt bushings or pin (55).
Refer to BHT-ALL-SPM for specifications.
o. Trim sealant around wear sleeve (64) on
spindles of yoke (12). NUMBER NOMENCLATURE

p. Press wear sleeves (64) off yoke (12). Inspect C-304 Drycleaning Solvent
yoke for possible damage resulting from wear sleeve
C-309 MEK
removal.
C-407 Abrasive Pad
q. For grease lubricated hubs, remove grease
fittings (60) from grips (54). C-436 Paint Remover

16. Disassemble both pitch horns (40) as follows: C-563 Vapor Degreaser

a. For oil lubricated hubs, remove the oil

1. Clean all main rotor hub parts with drycleaning
lubrication peculiar hardware from pitch horns (40).
solvent (C-304).
(1) Remove nuts (72), lockwashers (73), thin
steel washers (74), stat-o-seals (75), packings (78),
and grip reservoirs (76) from outboard side of pitch
CAUTION
horns (40).

(2) Remove bolts (80), packing (81), washer

MAKE SURE YOU DON’T EXCEED THE
(82), and sight glass (79) from the inboard side.
MAXIMUM TEMPERATURE WHEN YOU
HEAT THE PART OR DAMAGE TO THE
(3) Remove lubrication fittings (77) from grip
PART MAY OCCUR.
reservoirs (76).
2. Heat the blade bolts (57, Figure 62-15) and the
(4) Discard all packings and stat-o-seals.
plugs (87) to a maximum of 200°F (93°C) and remove
adhesive from the parts using a plastic scrapper.
b. For grease lubricated hubs, remove relief
Clean the surfaces with MEK (C-309).
valves (33) from pitch horns (40).

c. Remove retaining nuts (39), washers (37),
and bolts (36) from pitch horn trunnions (38) and pitch
horn (40).
d. Fabricate pitch horn trunnion workaid
(Figure 62-20). Insert tangs of trunnion workaid into
3. Vapor degrease grip using vapor degreaser
(C-563) at 188 to 193°F (87 to 89°C) and abrasive pad
(C-407). After cleaning, apply a film of water to surface
and check for break free surface. If a flashout occurs
within 25 seconds after water flow stops, repeat
cleaning and retest.

62-00-00
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 BHT-206L-CR&O-3

ALUMINUM TUBE OR WOODEN DOWEL

MATERIAL: Aluminum alloy tube or hardwood dowel 2.093 inches (53.16 mm) outside diameter by 14 inches
(356 mm) in length. No paint finish required.

USE: Removal of outboard seal retainer from main rotor grips.

206L_CRO_62_0018

Figure 62-20. Main Rotor Grip Retainer Dowel

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BHT-206L-CR&O-3

206L_CRO_62_0019

Figure 62-21. Pitch Horn Trunnion Workaid

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 BHT-206L-CR&O-3

1. Carefully inspect all detail parts visually for any

apparent damage or abnormal appearance. Visual
CAUTION
defects that are cause for replacing the entire hub
include the following:
DO NOT SPIN BEARINGS WHILE AIR
DRYING. a. Pitch horn pulled from grip.

4. Dry parts with filtered, compressed air and clean, b. A segment of sheared mast attached to
lint-free cloths. trunnion.

5. Strip paint from components as required using
paint remover (C-436).
62-31. MAIN ROTOR HUB — INSPECTION
c. Obvious deformation of any other detail part
within the hub would cause only the part that is
deformed to be replaced along with both
tension-torsion straps, both strap pins, and both strap
bolts.

2. Any detail part within the hub that has sustained

surface damage shall also be subject to normal
CAUTION
inspection procedures (paragraph 62-33). Surface
damage in excess of overhaul limits will require
replacing only the damaged part along with both
DO NOT REMOVE CADMIUM PLATING
tension-torsion straps, both strap pins, and both strap
FROM COMPONENTS EXCEPT FOR
bolts.
REPAIRS.

If records or physical appearance of main rotor hub
indicate the assembly has been subjected to an
accident or incident outside the realm of normal
usage, perform conditional inspection (paragraph
62-32). If the main rotor hub does not require
conditional inspection, proceed with normal inspection
(paragraph 62-33).
3. Dimensionally check for indications of permanent
deformation or damage to parts specified in step a
through step f. A dimensional discrepancy of any part
will cause only that part to be replaced along with both
tension-torsion straps, both strap pins, and both strap
bolts, unless stated otherwise in the following detailed
evaluation procedure.

62-32. MAIN ROTOR HUB — CONDITIONAL a. lnspect yoke (12, Figure 62-15) as follows:
INSPECTION
(1) Check straightness as follows:

MATERIALS REQUIRED (a) Check yoke precone angle and

spanwise straightness by inspecting machined
Refer to BHT-ALL-SPM for specifications. surfaces of yoke with a straight edge. Yoke lower
surface is not to be included in this inspection.
NUMBER NOMENCLATURE Replace hub assembly if there is a deviation of more
than 0.001 inch (0.025 mm) per 1.0 inch (25 mm).
C-309 MEK
(b) lnspect pillow block bolts (32) for
C-407 Abrasive Pad shear offset (straightness). Replace hub assembly if
any evidence of bolt yielding is found.

NOTE (2) lnspect retainer (68) for alignment and

If the following evaluation requires the damaged threads.
replacement of any part, also replace both
tension-torsion straps, both strap pins, and (3) lnspect hub balance washers (69, 70,
both strap bolts. and 71) for damage and straightness.

62-00-00
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BHT-206L-CR&O-3
(4) lnspect attaching nuts (66) for damaged
threads.
(5) lnspect balance washer attachment holes
for cracks on outer and inner surfaces of yoke (12).
(6) lnspect pillow block (28) bore diameter
for out-of-round condition. If out-of-round condition
exceeds 0.001 inch. (0.025 mm), remove primer and
cadmium plate and remeasure. If bore is still
out-of-round in excess of 0.001 inch (0.025 mm),
replace pillow block.
(7) Inspect pillow block (28) for wear where
thrust washer (22) abrades it. lnspect wear disc (19)
for looseness if installed.
b. lnspect grips (54) and pitch horns (40).
(1) lnspect holes for blade bolts (57), blade
bolt bushings, and bolt holes for strap bolts (56) to
ensure roundness within 0.001 inch (0.025 mm).
Elongation of grip bushings in excess of 0.002 inch
(0.050 mm) is cause to replace entire hub.
(2) Inspect mating surfaces between grips
(54) and pitch horns (40) for deformation. Surface
deformation greater than 0.0015 inch (0.038 mm) is
cause to replace grips and pitch horns.
(3) lnspect surface of pitch horns (40) for
deformation on a surface plate. Horn deformation
greater than 0.002 inch (0.050 mm) is cause to
replace the horns.
(4) lnspect inboard lug surfaces of pitch horn
trunnion (38) for deformation. Lug surfaces must be
parallel to pitch horn (40) and to grip (54) surfaces.
Deformation greater than 0.0025 inch (0.063 mm) per
1.0 inch (25 mm) of surface length being inspected is
cause to replace pitch horn.
c. Inspect blade bolts (57).
(1) Remove dry film lubricant from shank of
blade bolts (57) by scrubbing with abrasive pad
(C-407) and MEK (C-309).
(2) Measure shank diameter of blade bolts in
at least six locations. If diameters vary more than
0.0007 inch (0.017 mm), replace blade bolts.
62-00-00
Page 60 Rev. 3 10 JAN 2011
(3) Roll blade bolts on a surface plate. A
deviation greater than 0.0015 inch (0.038 mm) is
cause to replace blade bolts.
d. lnspect strap bolts (56).
(1) Measure shank diameter of strap bolts
(56) in at least six locations. If diameters vary more
than 0.0008 inch (0.020 mm), remove cadmium
plating and remeasure. If diameters vary more than
0.0005 inch (0.012 mm), replace straps bolts.
(2) Roll strap bolts (56) on a surface plate. A
deviation greater than 0.0015 inch (0.038 mm) is
cause to replace strap bolts.
e. lnspect static stops (9) for cracks or
deformation. Replace stops if damage is evident.
f. lnspect trunnion (20).
(1) Dimensionally check for indications of
permanent deformation or damage to parts. If a
dimensional discrepancy is found on any part, replace
only that part unless otherwise stated.
(2) Place one spindle of trunnion in a
V-block. Mount a dial indicator on opposite spindle.
Rotate trunnion. Indicator reading should not exceed
0.004 inch (0.10 mm).
4. Perform normal inspection (paragraph 62-33).
62-33. MAIN ROTOR HUB — NORMAL
INSPECTION
MATERIALS REQUIRED
Refer to BHT-ALL-SPM for specifications.
NUMBER NOMENCLATURE
C-001 Grease
C-108 Cadmium Plating
Solution
C-204 Epoxy Polyamide
Primer
1. If any main rotor hub part shows indications of
excessive wear or is not within tolerance, check
mating part for abnormal wear.
ECCN 9E991
 BHT-206L-CR&O-3

2. Perform a Fluorescent Penetrant Inspection (FPI)

NOTE
on the following parts, as applicable (BHT-ALL-SPM,
Chapter 6). The general formula to determine electrical
current is amp-turns divided by number of
coil-turns (on coil nameplate) = number of
FIGURE AND amps. EXAMPLE: for a five turn coil,
NOMENCLATURE
INDEX NUMBER 11,000 amp-turns ÷ five coils = 2,200 amps.

Figure 62-15, 4 Ring

NOTE
Figure 62-15, 9 Static Stop
If AC magnetic equipment is used, use 60%
Figure 62-15, 28 Pillow Block of specified DC current.

Figure 62-15, 40 Pitch Horn

NOTE
Figure 62-15, 49 Nut Magnetic particle indications interpreted as
Figure 62-15, 54 Grip cracks, seams, laps, or shuts are cause
for replacement. Contact the nearest
Bell Helicopter Textron (BHT) Customer
a. Closely inspect grips for defects in Area A, as
Support Representative.
shown in Figure 62-22.
a. Thoroughly demagnetize all parts after
b. There may be a decrease in the brightness of inspection. Check parts with a field indicator to ensure
indications on surfaces that have been shot peened. demagnetization.
c. Thoroughly clean components that have been
4. Inspect yoke (12, Figure 62-15) as follows:
fluorescent penetrant inspected.

d. lnspect grips for damage (Figure 62-23).
3. Perform a Magnetic Particle Inspection (MPI) on
the following parts (BHT-ALL-SPM, Chapter 6).
FIGURE AND
NOMENCLATURE
INDEX NUMBER
a. Place a 1.0 inch (25.4 mm) control conductor
through yoke and place conductor and yoke between
contact heads of machine. Pass 2500 amps through
conductor. Examine yoke 100% for indications
interpreted as cracks, seams, laps, or shuts. Special
attention shall be given to fillet radii, wear sleeve
journal, inboard bearing journal, tooling holes, and
mating surfaces (Figure 62-24).

Figure 62-15, 12 Yoke b. Rotate yoke 120° and repeat step a.

Figure 62-15, 15 Strap Fitting

c. Rotate yoke an additional 120° and repeat
Figure 62-15, 16 Pin step a.

Figure 62-15, 20 Trunnion d. Place yoke in coil so axis of yoke is 90° to

direction of current flow through coil. Magnetize yoke
Figure 62-15, 47 Latches
using 9000 amp-turns. lnspect yoke completely for
Figure 62-15, 56 Strap Bolt indications from two directions.

Figure 62-15, 57 Blade Bolt e. Replace yoke if indications are found.

62-00-00
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BHT-206L-CR&O-3

Figure 62-22. Main Rotor Grip — Inspection Criteria

62-00-00
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 BHT-206L-CR&O-3

Figure 62-23. Main Rotor Grip — Damage Limits

62-00-00
ECCN 9E991 10 JAN 2011 Rev. 3 Page 63
BHT-206L-CR&O-3

Figure 62-24. Yoke — Inspection Criteria

62-00-00
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 BHT-206L-CR&O-3

a. Place a 1.0 inch (25.4 mm) diameter central

conductor through strap fitting and place conductor
CAUTION
and strap fitting between contact heads of machine.
Pass 1500 amps through central conductor and
inspect strap fitting completely for indications.
DURING ACCOMPLISHMENT OF
MAGNETIC PARTICLE INSPECTION,
GIV E PA RTICULA R ATTENTION TO b. Place strap fitting in coil so axis of strap fitting
E AC H T R UNN IO N S P IN DL E F IL LE T is 90° to direction of current flow through coil
RADIUS. (Figure 62-25). Magnetize strap fitting using 9000 amp
turns of magnetizing force. lnspect strap fitting
5. Perform a MPI on trunnion (20, Figure 62-15) as completely for indications on both inner and outer
follows: diameters.

c. Replace strap fitting if indications are found.

CAUTION 7. lnspect strap pins (16, Figure 62-15) as follows:

a. Place pins between contact heads of

MAKE SURE ALL TRACES OF SEALANT
machine. Pass 600 amps through pin. lnspect
ARE REMOVED FROM TRUNNION
completely for indications.
AFTER REMOVAL OF BEARING INNER
RACES.
b. Place pin in coil so axis of pin is 90° to
a. Thoroughly degrease trunnion. direction of current flow through coil. Magnetize pin
using 15,000 amp turns magnetizing force. lnspect for
indications.
b. Place trunnion longitudinally between contact
heads of machine. Pass 2000 amps through trunnion.
c. Replace pins if indications are found.
c. lnspect for indications interpreted as cracks,
seams, laps, or shuts. 8. lnspect strap bolts (56) as follows:

d. Place a 1.0 inch (25.4 mm) central conductor a. Place strap bolt between contact heads of
through internal spline of trunnion and place conductor machine. Pass 900 amps through strap bolt and
and trunnion between contact heads of machine. Pass inspect completely for indications interpreted as
1000 amps through central conductor. cracks, seams, laps, or shuts.

e. Inspect for indications. b. Place strap bolt in coil so axis of strap bolt is
90° to direction of current flow through coil. Magnetize
f. Rotate trunnion 180° around central conductor strap bolt using 9000 amp turns of magnetizing force.
and pass 1000 amps through central conductor. lnspect strap bolt completely for indications.

g. lnspect for indications. c. Replace strap bolts if any indications are

found.
h. Place trunnion longitudinally in coil. Magnetize
trunnion with 15,000 amp turns. 9. lnspect blade bolts (57) as follows:

i. lnspect for indications. a. Thoroughly degrease blade bolt.

j. Replace trunnion if indications are found. b. Place blade bolt between contact heads of
machine and pass 1800 amps through blade bolt.
6. Perform a MPI on strap fittings (15, Figure 62-15)
as follows: c. Inspect blade bolt completely for indications.

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BHT-206L-CR&O-3

Figure 62-25. Strap Fitting — Inspection Criteria

62-00-00
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d. Place blade bolt in coil with longitudinal axis of
blade bolt perpendicular to plane of coil. Magnetize
blade bolt using 10,000 amp turns.
e. Inspect blade bolt completely for indications.
NOTE
Limit charts are provided to show required
fit between mating parts and provide
dimensions as a guide for replacement of
worn parts. It is not intended all dimensions
listed on limits charts be checked as a
prescribed overhaul procedure; however,
parts showing evidence of wear or physical
damage shall be checked dimensionally.
10. lnspect main rotor hub parts dimensionally for
wear and damage (Figure 62-26). Replace parts that
exceed limits.
a. lnspect yoke (12, Figure 62-15) for evidence
of corrosion and mechanical damage (Figure 62-27).
Special attention shall be given to pillow block bores,
inboard bearing journals, wear sleeve journals, and
mating fillet radii.
b. lnspect interior of yoke for damage to primed
surfaces. Touch up as required with epoxy polyamide
primer (C-204).
c. lnspect cadmium plated surfaces of yoke for
condition. Apply cadmium plating solution (C-108) as
required (BHT-ALL-SPM, Chapter 3).
d. lnspect yoke for mark from flap restraint arms.
Marked area shall not exceed limits shown in
Figure 62-27, View A.
NOTE
A main rotor yoke, which would be rejected
solely due to excessive corrosion damage
in outboard bore of spindle, may be
repaired by Bell Helicopter Textron (BHT).
Repair consists of machining and
installation of a special insert in bore. Once
installed, the insert cannot be removed or
replaced except by BHT.
(1) If yoke has excessive corrosion damage
in outboard bore of spindle, but is otherwise
repairable, review historical records to determine if
ECCN 9E991
BHT-206L-CR&O-3
yoke is acceptable for special repair by BHT. Yoke
shall be considered unacceptable for repair if it has
indeterminable history or a conditional inspection for
overspeed, overtorque, hard landing, or sudden
stoppage.
NOTE
Refer to General Information Letter (IL)
GEN-04-98 for the applicable shipping
information and to obtain a Return Material
Authorization (RMA) number.
(2) If yoke is determined to be acceptable for
special repair, the following information is required by
BHT along with the yoke:
(a) Complete historical records of yoke.
(b) A repair order attesting yoke has no
history, which would render it unacceptable as defined
in step (1).
NOTE
Roller bearings in trunnions normally have
a feel of ratcheting and drag during rotation
due to preload.
11. lnspect pitch horn trunnion bearings (38,
Figure 62-15) for axial looseness not to exceed
0.020 inch (0.51 mm). No radial play permitted. Purge
lubricate trunnion with grease (C-001).
12. lnspect trunnion (20), strap fitting (15), strap pins
(16), strap bolts (56), latches (47), blade bolts (57),
retainers (2), radius rings (14), pitch horns (40), static
stops (9), pillow blocks (28), plug (87), mast nut (3,
Figure 62-1), and cone set (7) for cracks, mechanical
damage, and corrosion (Figure 62-28 through
Figure 62-40). Replace parts that are cracked and/or
exceed limits.
13. Inspect tension-torsion straps (65, Figure 62-15)
for wire strand failures and for damage as follows:
a. A total of 25 broken wires (50 loose ends)
protruding through urethane coating of any one of the
eight outside corners is cause for rejection. A total of
400 loose ends found over the entire strap surface is
cause for rejection.
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BHT-206L-CR&O-3

206L_CRO_62_0024

Figure 62-26. Main Rotor Hub — Wear Limits

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 BHT-206L-CR&O-3

BRINELLING DEPTH INSPECTION

If yoke was previously modified with a special insert in outboard bore, corrosion damage limits for bore
and insert shall be 0.005 inch (0.127 mm) before repair and 0.010 inch (0.254 mm) after repair. Insert is
not field replaceable.
206L_CRO_62_0025

Figure 62-27. Yoke — Damage Limits

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BHT-206L-CR&O-3

No damage allowed in fillet radius.

206L_CRO_62_0026

Figure 62-28. Trunnion — Damage Limits

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 BHT-206L-CR&O-3

Figure 62-29. Strap Fitting — Damage Limits

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BHT-206L-CR&O-3

Figure 62-30. Strap Pin — Damage Limits

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 BHT-206L-CR&O-3

Figure 62-31. Strap Bolt and Blade Latch — Damage Limits

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BHT-206L-CR&O-3

Figure 62-32. Blade Bolt — Damage Limits

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 BHT-206L-CR&O-3

Figure 62-33. Retainer — Damage Limits

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BHT-206L-CR&O-3

Figure 62-34. Radius Ring — Damage Limits

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 BHT-206L-CR&O-3

Figure 62-35. Pitch Horn — Damage Limits

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BHT-206L-CR&O-3

Figure 62-36. Static Stop — Damage Limits

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 BHT-206L-CR&O-3

Figure 62-37. Trunnion Pillow Block — Damage Limits

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BHT-206L-CR&O-3

MAST NUT MAST NUT

(206-010-198) (206-011-152)

DAMAGE LOCATION SYMBOLS

TYPE OF DAMAGE MAXIMUM DAMAGE AND REPAIR DEPTH

MECHANICAL 0.010 In. (0.25 mm) 0.030 In. (0.76 mm)

BEFORE AND AFTER REPAIR

CORROSION 0.010 In. (0.25 mm) 0.030 In. (0.76 mm)

BEFORE AND AFTER REPAIR
2
MAXIMUM AREA PER 0.10 sq. In. (64 mm) Not critical
FULL DEPTH REPAIR

NUMBER OF REPAIR AREAS Not critical Not Critical

EDGE CHAMFER 0.030 In. (0.76 mm) 0.060 In. (1.52 mm)
BEFORE AND AFTER REPAIR

THREAD:
Depth: 1/3 thread
Length: 0.50 In. (12.7 mm)
Number: Two

206L_CRO_62_0067

Figure 62-38. Mast Nut — Damage Limits

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 BHT-206L-CR&O-3

0.270 TO 0.280 IN.

(6.86 TO 7.11 mm)
A

3 B
A SECTION A-A

CONE SET

DAMAGE LOCATION SYMBOLS

1 2 3

TYPE OF DAMAGE MAXIMUM DAMAGE AND REPAIR DEPTH

MECHANICAL 0.010 In. (0.25 mm) 0.010 In. (0.25 mm) 0.005 In. (0.13 mm)
BEFORE AND AFTER REPAIR

CORROSION 0.010 In. (0.25 mm) 0.010 In. (0.25 mm) 0.005 In. (0.13 mm)
BEFORE AND AFTER REPAIR

EDGE CHAMFER 0.030 In (0.76 mm) 0.030 In (0.76 mm) 0.030 In (0.76 mm)

NOTES
1 Damage may be considered negligible and not requiring repair if the depth does not exceed the limit
and the minimum radii observed in the damage area are not less than 0.025 inch (0.64 mm).

2 Surface must not have any protrusions above the surrounding surface. Dents and scratches not
exceeding the limit may be polished out.

3 Use a surface plate to repair damage. Both halves of the cone set must be surfaced exactly the same
amount so that the distance from surface A to B is identical for both halves.

206L_CRO_62_0068

Figure 62-39. Cone Set — Damage Limits

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BHT-206L-CR&O-3

SHANK

BLADE BOLT PLUG

INSPECTION
NUMBER CHARACTERISTIC METHOD LIMIT

1 Mechanical/corrosion Measure 0.010 inch (0.25 mm) maximum depth.

damage

2 Maximum area per Measure 0.150 square inch (96.7 mm2).

full depth repair

3 Number of repairs Visual One per surface.

4 Edge chamfer to Measure 0.015 inch (0.38 mm)

remove damage

5 Wear Measure 0.850 inch (21.59 mm) minimum

diameter.

6 Cracks Visual None permitted.

206L_CRO_62_0073

Figure 62-40. Blade Bolt Plug — Damage Limits

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 BHT-206L-CR&O-3

b. Strap bulge in excess of 0.06 inch (1.5 mm) 17. On oil lubricated hubs, inspect sight glasses (79
outside the normal straight contour is cause for and 86) for cracks, crazing, discoloration, and
rejection. A bulging of strap cross-section in any area damage.
from ends of strap to 3.5 inches (89 mm) inboard is
normal and not cause for rejection.
18. Inspect buffer pads (53) for condition. Replace if
loose or if severe fretting has occurred.
c. Cracks in urethane coating are acceptable
providing wires are not exposed.
62-34. MAIN ROTOR HUB — REPAIR
d. Delamination of urethane coating from the
bushings is acceptable. Delamination in any other
area is cause for rejection.
MATERIALS REQUIRED
e. A permanent set in twist may occur and is not
cause for rejection. Refer to BHT-ALL-SPM for specifications.

NUMBER NOMENCLATURE
f. Strap stiffness can vary when flexed in an
unloaded condition and is not cause for rejection. C-005 Solid Film Lubricant
g. Displacement of urethane wedges between C-021 Solid Film Lubricant
bushings and inner surfaces of wire bundle is cause
for rejection. C-100 Chemical Film Material

h. Cracks in strap bushings are cause for C-104 Corrosion Preventive

rejection. lnspect using a 10X magnifying glass. Compound

i. lnspect bushings for fretting corrosion. A C-108 Cadmium Plating

maximum of 0.005 inch (0.127 mm) in depth for 25% Solution
total area is allowed on bushing flange surfaces. A
C-202 Epoxy Primer
maximum of 0.002 inch (0.050 mm) axial scoring in
depth is allowed for 1/4 of total bushing bore surfaces. C-204 Epoxy Polyamide
No circumferential scoring is allowed. Primer
j. Replace tension-torsion straps exceeding C-245 Polyurethane Coating
previous limits.
C-305 Aliphatic Naphtha
14. Visually inspect bearing journals on yoke (12) for
roughness, spalling, scoring, pitting, flaking, etc. C-309 MEK

C-331 Adhesive
NOTE
C-363 Adhesive
Springs are no longer required and may be
removed. C-407 Abrasive Pad
15. Inspect springs (48), if installed, for condition. C-423 Abrasive Paper
Apply compression load of 3.5 pounds (15.57 N) and
check for a length of 0.69 to 0.81 inch (17.53 to C-464 India Stone
20.57 mm).
C-500 Crocus Cloth
16. On oil lubricated hubs, inspect grip reservoir (76)
C-516 Clean Cloth
for cracks and damage.

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BHT-206L-CR&O-3

11. Repair yoke (12) as follows:

NOTE
Self-locking nuts are unserviceable when a. Polish out minor scratches and damage on
tare torque is not present. noncritical areas with crocus cloth (C-500)
(Figure 62-27).
1. Replace all packings, seals, washers,
unserviceable self-locking nuts, and attaching
hardware. b. Longitudinal scratches on spindle, not in
excess of 0.002 inch (0.050 mm) deep, do not need to
be completely removed. Surface burrs should be
2. Replace shims that have curled or damaged
removed using crocus cloth (C-500). Clean up minor
laminations.
damage to threads.
3. Repair allowable mechanical and corrosion
c. Pillow block bore damage shall be removed
damage to trunnion (20, Figure 62-15), strap fittings
by sanding in a circular motion using 400 grit abrasive
(15), trap pins (16), strap bolts (56), latches (47), blade
paper (C-423). Final polish surface until scratch free
bolts (57), retainers (2), radius rings (14), pitch horns
using fine abrasive pad (C-407). Make sure that all
(40), static stops (9), pillow blocks (28), plug (87), mast
nicks, scratches, and tool marks are removed.
nut (3, Figure 62-1), and cone set (7) (Figure 62-28
through Figure 62-40).
d. Damage to bearing and spacer journals and
mating fillet radii shall be removed by sanding with 400
4. Polish out acceptable damage using fine India
grit abrasive paper (C-423) and abrasive pad (C-407).
stone (C-464) on steel parts and 400 to 600 grit
abrasive paper (C-423) on aluminum parts.
e. Damage to other surfaces shall be removed
5. Apply cadmium plating solution (C-108) to all by sanding using 400 grit abrasive paper (C-423) and
previously plated and repaired steel surfaces abrasive pad (C-407). Make sure that all nicks,
(BHT-ALL-SPM, Chapter 3). Do not cadmium plate scratches, tool marks, and corrosion pitting are
threaded areas. removed. Touch up surfaces where plating has been
damaged or where repairs were accomplished. Apply
cadmium plating solution (C-108) where required
6. Apply chemical film material (C-100) to all (Figure 62-41) (BHT-ALL-SPM, Chapter 3).
repaired and bare aluminum surfaces (BHT-ALL-SPM,
Chapter 3).
f. Mask the areas of yoke (12, Figure 62-15) that
do not require prime or paint (Figure 62-42).
7. Refinish parts in accordance with paragraph
62-36, as required.
g. Apply epoxy polyamide primer (C-204) to yoke
as required.
8. Replace cracked, broken, or distorted parts, or
parts that have damaged threads.
h. After primer has cured, check yoke pillow
block bores with inside micrometer for minimum I.D. of
9. Replace parts that exceed allowable wear or
2.6242 inches (66.6546 mm). Sand as required
damage limits (Figure 62-27 through Figure 62-40).
without penetrating primer to achieve set dimension.

10. Surface damage to retainer (2, Figure 62-15)

i. Within 8 hours of primer application, apply two
does not require repair if function of seals is not
coats of light gull gray polyurethane coating (C-245),
impaired.
color code 36440 per FED-STD-595, to yoke center
section (Figure 62-41).

CAUTION 12. Apply epoxy primer (C-202) or epoxy polyamide

primer (C-204) and light gull gray polyurethane coating
(C-245), color code 36440 per FED-STD-595, where
REPAIRS TO SHOT PEENED YOKE ARE removed from parts during inspection and repair, to
LIMITED TO DAMAGED AREAS. areas shown in Figure 62-42.

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 BHT-206L-CR&O-3

1 Apply cadmium plating solution (C-108) to repaired areas.

2 Prime center section, except threads, with one coat of epoxy polyamide primer (C-204).

3 Paint center section, except as noted, with two coats of light gull gray polyurethane
coating (C-245).

4 Do not cadmium plate, prime, or paint this area.

5 Do not paint. After primer has cured, pillow block bore shall accept a 2.6242 inch
(66.655 mm) diameter gauge.

6 Do not prime or paint this area.

7 Touch up repaired areas with epoxy polyamide primer (C-204).

8 Swab holes with epoxy polyamide primer (C-204).

9 Do not prime or paint threads.

10 Swab unprimed inside diameter with corrosion preventive compound (C-104).

206L_CRO_62_0036a

Figure 62-41. Main Rotor Hub — Corrosion Protection (Sheet 1 of 6)

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BHT-206L-CR&O-3

NOTES

1 Coat repaired and bare areas with solid film lubricant (C-005 or C-021).

2 Apply corrosion preventive compound (C-101) to inner diameter of bolt.

3 Apply cadmium plating solution (C-108) to repaired areas.

206L_CRO_62_0036b

Figure 62-41. Main Rotor Hub — Corrosion Protection (Sheet 2 of 6)

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 BHT-206L-CR&O-3

NOTES

1 Do not brush cadmium plate, prime or paint bores, splines, cone seat, or threads.

2 Apply cadmium plating solution (C-108) to all repaired and bare areas, except Note 1 areas.

3 Do not prime or paint threads.

4 One coat of epoxy polyamide primer (C-204) and two coats of polyurethane coating (C-245),
color 36440 on exterior surfaces except threads.

206L_CRO_62_0036c

Figure 62-41. Main Rotor Hub — Corrosion Protection (Sheet 3 of 6)

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BHT-206L-CR&O-3

RETAINER SPACER
RADIUS RING

ADJUSTING SCREW
PLUG

BLADE BOLT WASHER

STRAP BOLT

STRAP PIN

NOTES

1 Apply chemical film material (C-100) to repaired areas. Do not prime or paint.

2 Apply cadmium plating solution (C-108) to repaired and bare areas.

206L_CRO_62_0036d

Figure 62-41. Main Rotor Hub — Corrosion Protection (Sheet 4 of 6)

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 BHT-206L-CR&O-3

NOTES

1 Do not prime or paint.

2 Apply chemical film material (C-100) to repaired areas.

3 Apply one spray coat of epoxy polyamide primer (C-204) and two coats of polyurethane
coating (C-245), color 36440, on all exterior surfaces except Note 1 areas.

206L_CRO_62_0036e

Figure 62-41. Main Rotor Hub — Corrosion Protection (Sheet 5 of 6)

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BHT-206L-CR&O-3

NOTES

1 Do not prime or paint.

2 Coat bore of grip with solid film lubricant (C-005 or C-021); minimum diameter after
coating shall be 3.9995 inches (101.588 mm).

3. Apply chemical film material (C-100) to repaired areas.

4. Apply one spray coat of epoxy polyamide primer (C-204) and two spray coats of
polyurethane coating (C-245), color 36440, on all exterior surfaces except Note 1 areas.

206L_CRO_62_0036f

Figure 62-41. Main Rotor Hub — Corrosion Protection (Sheet 6 of 6)

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 BHT-206L-CR&O-3

UNPAINTED

EPOXY POLYAMIDE PRIMER (C-204)

AND POLYURETHANE COATING (C-245),
COLOR NO. 36440

206L_CRO_62_0037

Figure 62-42. Main Rotor Hub — Painting

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BHT-206L-CR&O-3
13. Dress out minor damage to nuts (46 and 51,
Figure 62-15). Replace if cracked, damaged, or
corroded.
14. Repair grips (54).
a. Polish out nicks, dents, and corrosion on outer
surface of grip using 400 to 600 grit abrasive paper
(C-423) (Figure 62-23). Treat repaired areas with
chemical film material (C-100) (BHT-ALL-SPM,
Chapter 3).
NOTE
Thickness of cured lubricant shall be
0.0002 to 0.0004 inch (0.0051 to
0.0101 mm.
b. Coat grip bore with solid film lubricant (C-021)
if required. Damaged solid film lubricant coating (up to
10% of area) may be touched up with solid film
lubricant (C-021).
15. Replace bearings (43, Figure 62-15) if any of the
following conditions is found:
a. Broken or rough rollers.
b. Spalling, scoring, flaking, brinelling, or
discoloration.
c. Pits larger than 0.008 inch (0.20 mm).
d. Cluster of three pits or more within an area of
0.25 inch (6.3 mm) diameter with any one pit larger
than 0.004 inch (0.10 mm).
16. Repair trunnion (20) as follows:.
a. Polish out allowable nicks and scratches on
surface of trunnion with crocus cloth (C-500)
(Figure 62-28).
b. Coat repaired areas with cadmium plating
solution (C-108) (BHT-ALLSPM, Chapter 3).
c. Dress out nicks, burrs, and scratches on
splines with a fine India stone (C-464).
d. Replace trunnion if cracked or if mechanical
and corrosion damage limits are exceeded
(Figure 62-28).
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e. Apply corrosion preventive compound (C-104)
to trunnion spindle inner diameter.
17. Replace bearing inner race (25, Figure 62-15) if
spalled, brinnelled, or discolored due to overheating.
Replace inner race and trunnion if damaged due to
race turning on spindle of trunnion.
18. On oil lubricated hub, replace grip reservoir (76)
and sight glasses (79 and 86) if cracked, crazed, or
damaged.
19. Repair pillow block (28) as follows (Figure 62-37):
a. Polish out repairable minor nicks and
scratches in pillow block with 180 to 400 grit abrasive
paper (C-423).
b. Coat repaired areas with chemical film
material (C-100).
c. Replace pillow block if cracked or if damaged
beyond limits.
d. On helicopters modified by TB 206L-81-67,
replace wear discs (19, Figure 62-15) if loose.
(1) Clean bore of pillow block thoroughly with
MEK (C-309).
(2) Bond wear disc in pillow block bore using
adhesive (C-331) centering disc in wear area.
20. Replace pillow block pads (29 and 89) as follows:
a. Lightly abrade bonding surfaces on the pillow
block (28) with a 400 grit abrasive paper (C-423).
Clean with MEK (C-309) and dry with a clean cloth
(C-516).
b. Abrade the light brown side of new pillow bloc
pads (29 and 89) with a 100 or 150 grit abrasive paper
(C-423). Clean with aliphatic naphtha (C-305) and let
the pads air dry.
c. Apply a 0.003 to 0.008 inch (0.08 to 0.20 mm)
thick layer of adhesive (C-363) to the bonding surfaces
of the pillow block (28) or pillow block pads (29
and 89), as applicable.
d. Locate the pillow block pads (29 and 89) on
the inboard and outboard sides of the pillow block
ECCN 9E991
 BHT-206L-CR&O-3

(28), respectively, and within 0.030 inch (0.76 mm) of SPECIAL TOOLS REQUIRED (Cont)
the hole center.

NUMBER NOMENCLATURE
NOTE
Refer to the manufacturer instructions for Workaid Trunnion Centering
the mixing ratio, pot life, and curing time of Dowel
the adhesive.
Workaid Wear Sleeve
e. Bond the pillow block pads (29 and 89) to the Installation
pillow block (28) and remove excess adhesive before
Workaid Pitch Horn Trunnion
complete cure.

f. Refinish the pillow block (28) in accordance

with paragraph 62-36, as required. MATERIALS REQUIRED

21. Visually inspect bushings (30), thrust washers Refer to BHT-ALL-SPM for specifications.
(22), and adjusting screws (21) for damage that would
render parts unserviceable. NUMBER NOMENCLATURE

C-001 Grease
22. Replace bearings (26) if spalled or discolored due
to overheating, roller is broken, or operation is rough. C-013 Lubricating Oil

23. Replace any part with defects for which no C-100 Chemical Film Material
damage limits are specified.
C-101 Corrosion Preventive
Compound
24. Install new insert (17) in strap pin (16), if required.
C-104 Corrosion Preventive
25. Inspect blade bolts (57) for corrosion and Compound
mechanical damage (Figure 62-32). If blade bolt cap
(59, Figure 62-15) is damaged, replace. C-125 Preservative Oil

26. Inspect blade bolt solid film lubricant coating. C-204 Epoxy Polyamide
Primer
a. If less than 10% of coating area is damaged, C-245 Polyurethane Coating
1
touch up coating with solid film lubricant (C-021).
C-304 Drycleaning Solvent
b. If more than 10% of coating area is damaged,
recoat blade bolt with solid film lubricant (C-005). C-305 Aliphatic Naphtha

62-35. MAIN ROTOR HUB — ASSEMBLY C-308 Sealant

C-309 MEK

SPECIAL TOOLS REQUIRED C-313 2 Adhesive

C-319 Safety Solvent

NUMBER NOMENCLATURE
C-320 3 Sealant
T101554 Socket Wrench
C-331 Adhesive
Commercial Feeler Gauge
C-405 Lockwire
Workaid Excluder Mandrel

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BHT-206L-CR&O-3
MATERIALS REQUIRED (Cont)
Refer to BHT-ALL-SPM for specifications.
NUMBER NOMENCLATURE
C-423 Abrasive Paper
C-427 Barrier Material
NOTES:
1 Use color code 37925 per FED-STD-595.
2 Use Metalset A-4 only.
Use an ASTM D5363, Group 01, Class 5,
3
Grade 1 anaerobic sealant, equivalent to
MIL-S-22473, Grade E, and use a
MIL-S-22473, Grade T, Form R activator for
the sealant.
NOTE
The following procedure is for one side.
Opposite side is identical and should be
assembled at the same time.
NOTE
Lubricate all seals and packings with
appropriate lubricant prior to installation per
the instructions in Chapter 12 of the
applicable Maintenance Manual (MM).
1. Assemble main rotor trunnion as follows:
a. Apply corrosion preventive compound (C-104)
to trunnion (4, Figure 62-43) splines and inner
diameter of spindles.
b. Clean trunnion (4) and bearing inner race (6)
with clean cloth dampened with MEK (C-309). Apply a
film of the appropriate lubricant to trunnion and inner
race.
CAUTION
INNER RACE IS THERMAL FITTED TO
T R U N N I O N . D O N O T AT T E M P T T O
I N S TA L L I N N E R R A C E W I T H O U T
HEATING. IF INNER RACE IS ALLOWED
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Page 94 Rev. 3 10 JAN 2011
TO COOL BEFORE PRESSING
O P E R AT I O N S A R E C O M P L E T E D ,
DAMAGE TO TRUNNION OR INNER
RACE MAY OCCUR.
c. Heat bearing inner races (6) to a temperature
of 200 to 275°F (93 to 135°C).
CAUTION
PRESSING DIRECTLY AGAINST END OF
TRUNNION WILL DISTORT CENTER OF
TRUNNION. SUPPORT TRUNNION
THROUGH THE CENTER WITH A BRASS
OR ALUMINUM ROD.
d. Position bearing inner race (6), with part
number facing outboard, on trunnion (4) and press
until flush with trunnion spindle. Repeat for opposite
end of trunnion. Allow parts to cool to room
temperature.
e. Clean radius grooves on spindles of trunnion
(4) with clean cloths dampened with MEK (C-309).
Wipe surface dry before MEK evaporates. Apply a
bead of sealant (C-308) to inboard end of bearing
inner races (6) to blend with body of trunnion
(Figure 62-44). Allow sealant to cure at 70 to 80°F (21
to 27°C).
2. Assemble pillow blocks (14, Figure 62-43) as
follows:
a. Clean adjusting screws (18) and threads in
spindles of trunnion (4) with cloths dampened with
MEK (C-309). Thread adjusting screw into trunnion
halfway, using a 1/4 inch hexagon wrench.
b. Apply coating of the appropriate lubricant to
new packings (16), surfaces of thrust washers (17),
and wear discs (23). Install packings on thrust
washers and place thrust washers and wear discs into
ends of trunnion spindles with closed end outboard.
c. Thoroughly clean bearings (7) with
drycleaning solvent (C-304) and dry with filtered,
compressed air. Coat bearings with lubricating oil
(C-013).
d. On grease lubricated hubs, hand pack
bearings (7) with grease (C-001).
ECCN 9E991
 BHT-206L-CR&O-3

DETAIL A

B
B

12

2 3 23
15
GAP B
14
21
GAP A
2
13
1

SECTION B-B
(SHIMMING)

1. Nut 7. Bearing 13. Bushing 19. Grease fitting

2. Steel washer 8. Plug 14. Pillow block 20. Shim
3. Yoke 9. Packing 15. Pillow block pad 21. Washer
4. Trunnion 10. Packing 16. Packing 22. Pillow block pad
5. Seal 11. Sight plug 17. Thrust washer 23. Wear disc
6. Bearing inner race 12. Bolt 18. Adjusting screw

206L_CRO_62_0038

Figure 62-43. Trunnion Assembly

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BHT-206L-CR&O-3

Figure 62-44. Trunnion Requirements

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Page 96 Rev. 3 10 JAN 2011 ECCN 9E991

NOTE
The chamfered outer diameter end of
bearing shall be seated in outboard end of
pillow block.
e. Apply heat lamp to pillow block (14). When
pillow block is heated, press bearing (7), with part
number exposed, into pillow block until seated. Repeat
on opposite pillow block.
f. Clean outer surfaces of new seal (5) and inner
mating surfaces of pillow blocks (14) with clean cloths
dampened with MEK (C-309). Wipe dry with clean
cloth before MEK evaporates.
g. Apply a thin coat of sealant (C-308) to outer
surfaces of seal (5) and to mating surfaces in pillow
block (14).
h. Install seals (5) in pillow blocks.
(1) For grease lubricated hubs, press seal
with lip pointing outboard into pillow block
(Figure 62-43, Detail A). This will allow grease to
purge when lubricating. Apply a coat of grease (C-001)
to seal and trunnion bearing inner race.
(2) For oil lubricated hubs, press seal with lip
pointing inboard into pillow block (Detail A). Apply a
coat of lubricating oil (C-013) to seal and trunnion
bearing inner race.
i. Apply a film of corrosion preventive compound
(C-104) to surfaces of pillow block (14), which will
contact yoke (3), and to shank of bolts (12) and
bushings (13).
3. Assemble trunnion (4) in yoke (3) as follows:
CAUTION
USE CARE TO AVOID DAMAGING SEALS
DURING INSTALLATION ON BEARING
INNER RACES.
a. Position trunnion (4) in yoke (3) and install
pillow blocks (14) on each spindle of trunnion.
b. Install the washers (21) and the bushings (13)
on each pillow block (14).
ECCN 9E991
BHT-206L-CR&O-3
c. Secure each pillow block (14) with the bolts
(12), steel washers (2), and nuts (1). Install the bolt
head on the yoke side.
NOTE
The tare torque on a new nut (1) is
approximately 10 inch-pounds (1.1 Nm).
d. Torque the nuts (1) 84 to 107 inch-pounds (9.5
to 12 Nm) plus tare torque.
e. Determine the required thickness for the shim
(20) at each of the four pillow block attachments. To do
so, use any of the two following procedures:
Method A:
(1) Press the pillow block (14) against the
yoke (3) with firm pressure.
(2) Measure the gap A between the washer
(21) and the bushing (13) at several locations, as
shown in Figure 62-43.
(3) Round down the measured gap to the
nearest multiple of 0.002 inch (0.051 mm) to get the
required thickness for the shim (20). Example:
Measured gap = 0.0095 inch (0.241 mm)
Required thickness = 0.008 inch (0.20 mm)
Method B:
NOTE
The following step allows the pillow blocks
(14) to be forced outboard, similar to the
final installed position.
(1) Torque the trunnion adjusting screws (18)
115 to 130 inch-pounds (13.0 to 14.6 Nm).
(2) Release air pressure from the pillow
blocks (14) through the grease fittings (19).
(3) Measure the gap B between the pillow
block pad (15) and the yoke (3) at several locations, as
shown in Figure 62-43.
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BHT-206L-CR&O-3
(4) Round down the measured gap to the
nearest multiple of 0.002 inch (0.051 mm) to get the
required thickness for the shim (20). Example:
Measured gap = 0.0095 inch (0.241 mm)
Required thickness = 0.008 inch (0.20 mm)
(5) Loosen the adjusting screws (18).
NOTE
The shims (20) are 0.048 inch (1.22 mm)
thick and each lamination is 0.002 inch
(0.051 mm) thick.
f. As required, peel the shims (20) to the
previously determined thicknesses.
g. Remove the nuts (1) and install the shims (20)
between the washers (21) and the bushings (13).
NOTE
The tare torque on a new nut (1) is
approximately 10 inch-pounds (1.1 Nm).
h. Install and torque the nuts (1) 84 to 107
inch-pounds (9.5 to 12 Nm) plus tare torque.
i. Coat all exposed areas of bolts (12), washers
(2 and 21), bushings (13), and nuts (1) with corrosion
preventive compound (C-101).
j. Apply two coats of polyurethane coating
(C-245) to paint 0.12 inch (3.0 mm) wide marks across
the head of bolts (12) to flanges on the yoke (3) and
from the nuts (1) to flange on the pillow blocks (14).
k. On grease lubricated hubs, coat threads of
grease fitting (19) with epoxy polyamide primer
(C-204) and install in grip. Torque 5 to 10 inch-pounds
(0.6 to 1.1 Nm).
l. On oil lubricated hubs, coat new packings (9
and 10) with lubricating oil (C-013) and insert on filler
plug (8) and sight plug (11).
m. Install sight plug (11) in pillow block (14) and
torque 50 inch-pounds (5.65 Nm). Install filler plug
62-00-00
Page 98 Rev. 3 10 JAN 2011
finger tight. Pillow blocks will be serviced after trunnion
centering is completed.
4. Center main rotor trunnion.
a. Fabricate main rotor trunnion centering
workaid (Figure 62-45).
b. Torque adjusting screws, from inside trunnion
bore, 115 to 130 inch-pounds (13.0 to 14.6 Nm) plus
tare torque.
c. Position yoke outboard journals in V blocks
located on a surface plate. Support yoke base with a
miniature jack. The jack will be used to level yoke
(Figure 62-46).
d. Insert trunnion centering workaid in trunnion
splined bore and snugly tighten the knurled nut to
secure the workaid in place.
e. Level yoke using the miniature jack and use a
vernier height gauge to measure. Measure from the
surface plate to the bottom edge of the workaid at
each end.
f. Check trunnion centering.
(1) Measure the distance between yoke
inboard bearing upper edge and the surface plate.
Measure the distance from the upper edge of the
trunnion centering workaid to the surface plate and
subtract this dimension from the first dimension.
Record as dimension A.
(2) Measure the distance from the surface
plate and the lower edge of the workaid. Measure the
distance from the surface plate and the yoke inboard
bearing lower edge. Subtract this dimension from the
other. Record as Dimension B.
(3) Dimension A and Dimension B shall be
equal within 0.003 inch (0.076 mm) (Figure 62-46).
g. Use a 1/4 inch hexagon wrench to reposition
adjusting screws (18, Figure 62-43) to obtain 0.003
inch (0.076 mm) or less difference between Dimension
A and Dimension B. Torque adjusting screws 115 to
130 inch-pounds (13.0 to 14.6 Nm) plus tare torque.
Check trunnion centering again after each adjustment.
ECCN 9E991
 BHT-206L-CR&O-3

206L_CRO_62_0040

Figure 62-45. Trunnion Centering Workaid

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BHT-206L-CR&O-3

Figure 62-46. Trunnion Centering

62-00-00
Page 100 Rev. 3 10 JAN 2011 ECCN 9E991

h. Level yoke and trunnion again and repeat
step f.
i. When centering is within limits, remove
centering tool and rotate trunnion back and forth about
12 times. Install trunnion, centering workaid, and
check centering again.
NOTE
If trunnion rotational preload exceeds
50 inch-pounds (5.65 Nm), thrust washers
were not lubricated prior to assembly.
j. Check trunnion rotational preload. Attach
spring scale to center of trunnion spline lower end in
line with yoke journals and pull scale vertically. Ignore
initial breakaway force.
k. If more than 50 inch-pounds (5.65 Nm) is
required to rotate trunnion, do the following:
(1) Disassemble trunnion and check for
roughness of surfaces contacting thrust washers and
wear discs.
(2) Check for proper lubrication between
mating surfaces.
(3) Assemble trunnion and check centering
and breakaway force again.
CAUTION
DO NOT MOVE ADJUSTING SCREWS.
l. Secure adjusting screws (18) when trunnion
centering is complete.
(1) Clean heads of adjusting screws (18) and
open threads inside trunnion (4) using cloths
dampened with safety solvent (C-319).
(2) Use a cotton swab to apply a film of
activator for sealant (C-320) to heads of adjusting
screws and threads inside trunnion. Allow 2 to 3
minutes drying time.
ECCN 9E991
BHT-206L-CR&O-3
(3) Apply a small bead of sealant (C-320) to
thread area of adjusting screws and to threads in
trunnion journal. The sealant will be drawn into thread
area by capillary action, sealing screws in place.
Complete sealing of screws is ensured when a purple
ring of sealant remains around screw heads. Allow
sealant to cure at 70 to 80°F (21 to 27°C) for 60 to 90
minutes. Fill cavities for adjusting screws with sealant
(C-308).
5. Assemble yoke (3, Figure 62-47) with
tension-torsion straps (1), wear sleeves (2), strap
fittings (5), strap pins (7), and static stops (10).
a. During hub assembly apply corrosion
preventive compound (C-104) to the following
components and as indicated in Figure 62-41.
(1) Yoke (12, Figure 62-15) surfaces that
contact strap fittings, radius rings, and pillow blocks.
(2) Tension-torsion strap (65) spool bore and
faces.
(3) Strap fitting (15) surfaces that contact
strap pin, radius ring, and strap assembly.
(4) Strap pin (16), radius rings (14), strap
bolts (56), and blade bolt (57) shanks.
(5) Grip (54) surfaces in contact with strap
bolts (56), and nuts (49), blade bolts (57), and
tension-torsion straps (65).
(6) Pitch horn (40) surfaces that contact
pitch horn trunnion (38), grip (54), and attachments.
NOTE
Do not allow corrosion preventive
compound (C-104) to contact inboard
flanged surface of inboard strap fittings in
area to be sealed (Figure 62-51, Detail A).
b. During hub assembly, apply corrosion
preventive compound (C-104) to unprimed outboard
and unprimed inner diameter of spindles of yoke (3,
Figure 62-47).
c. During hub assembly, apply sealant (C-308) to
the following parts as indicated.
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BHT-206L-CR&O-3

SECTION A-A A
(AFTER INSTALLATION)
A

1. Tension-torsion strap 6. Radius ring

2. Wear sleeve 7. Strap pin
2A. Nut 8. Laminated shim
2B. Washer 9. Rubber stop
3. Yoke 10. Static stop
3A. Retainer 11. Bolt
4. Deleted 12. Steel washer
5. Strap fitting

NOTES

1 Apply corrosion preventive compound (C-101) on all faying surfaces.

2 Apply corrosion preventive compound (C-104) to unprimed bores.

3 Deleted.

4 Apply sealant (C-308).

206L_CRO_62_0042

Figure 62-47. Yoke and Strap

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Page 102 Rev. 3 10 JAN 2011 ECCN 9E991

NOTE
Clean surfaces to which sealant is to be
applied with clean cloths dampened with
MEK (C-309). Wipe dry with clean, lint-free
cloths before MEK dries.
(1) Seal strap fitting around yoke inner
diameter to seal yoke. No edge voids allowed
(Figure 62-49, Detail C)
(2) Seal closure (7) to grip (2). No edge
voids allowed.
(3) Seal pitch horn (8, Figure 62-52) to outer
diameter of seal (14) prior to installation.
(4) Seal packing (3, Figure 62-49) to retainer
(4) and to grip (2).
WARNING
INCORRECT INSTALLATION OF STRAP
FITTING WILL MAKE IT VERY DIFFICULT
OR IMPOSSIBLE TO RAISE COLLECTIVE
CONTROL STICK IN THE EVENT OF
HYDRAULIC SYSTEM FAILURE.
6. Install wear sleeve (2, Figure 62-47) on each
spindle of yoke (3) as follows:
a. Fabricate wear sleeve installation workaid
(Figure 62-48).
b. Clean yoke spindles and inner diameter of
wear sleeve with MEK (C-309) and wipe dry.
c. Apply 0.25 inch (6.35 mm) bead of sealant
(C-308) to circumference of yoke spindle fillet radius.
d. Heat wear sleeve (2, Figure 62-47) with a heat
lamp until hot to touch. Using protective glove, position
inner diameter chamfered end of wear sleeve on end
of yoke spindle. Make sure that wear sleeve is
perpendicular to yoke spindle.
e. Support yoke on a press and position wear
sleeve workaid over wear sleeve and yoke spindle.
ECCN 9E991
BHT-206L-CR&O-3
Press wear sleeve onto yoke spindle until sleeve
bottoms out on yoke radius.
f. Clean outer diameter of wear sleeve with
cloths dampened in MEK (C-309). Make sure that all
adhesive is removed from wear sleeve outer diameter.
g. Apply a bead of sealant (C-308) around
inboard end of wear sleeve to flange height. Fair
adhesive to form a fillet radius between inboard end of
wear sleeve and yoke, with no edge voids permitted.
h. Repeat step b through step g on opposite side
of yoke.
i. Insert tension-torsion strap (1) into bore of
yoke (3) extending into center of yoke.
j. Position radius ring (6) on strap fitting (5).
k. Mate strap fitting with tension-torsion strap
and install strap pin (7) into strap fitting and strap.
l. Pull strap outboard in yoke to seat radius ring
in yoke. Rotate strap until flat on strap fitting is parallel
to lower surface of yoke.
m. Place full laminated shim (8) and static stop
(10), into position on yoke (3) by strap fitting (5).
NOTE
Shim stack-up shall be kept in original
alignment and position for reinstallation.
n. Install bolts (11), with steel washers (12) and
torque 175 inch-pounds (19.8 Nm). Measure gap
between cutout in strap fitting and static stop.
o. Remove bolts (11), steel washers (12), static
stop (10), and shims (8). Adjust thickness to provide
0.002 to 0.004 inch (0.05 to 0.10 mm) pinch fit
between static stop and strap fitting.
p. Push tension-torsion strap inboard about
1.0 inch (25 mm) into center of yoke (3).
q. Clean surface of strap fitting (5) inboard of
packing groove and mating surface of yoke bore with
MEK (C-309).
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BHT-206L-CR&O-3

206L_CRO_62_0045

Figure 62-48. Wear Sleeve Installation Workaid

62-00-00
Page 104 Rev. 3 10 JAN 2011 ECCN 9E991
 BHT-206L-CR&O-3

NOTES

1 Apply corrosion preventive compound (C-101) on all external faying surfaces.

2 Apply adhesive sealant (C-308).

3 Apply corrosion preventive compound (C-104) on all internal faying surfaces.

4. Applicable to all hubs.

206L_CRO_62_0044a

Figure 62-49. Grip and Retainer Assembly (Sheet 1 of 2)

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BHT-206L-CR&O-3

206L_CRO_62_0044b

Figure 62-49. Grip and Retainer Assembly (Sheet 2 of 2)

62-00-00
Page 106 Rev. 3 10 JAN 2011 ECCN 9E991

r. Apply a bead of sealant (C-308) to strap fitting
surface inboard of packing groove. Push fitting
outboard to seat in yoke. Make sure there is no void in
yoke.
s. Reinstall rubber stop (9), premeasured
laminated shim (8), static stop (10) with bolts (11) and
steel washers (12). Tighten bolts snug.
NOTE
Centering of static stops (10) and torquing
of bolts (11) will be accomplished after main
rotor hub and blade installation on
helicopter.
t. Repeat step e through step s for opposite side
of yoke.
u. Apply a bead of sealant (C-308) around
exposed inboard flanged end of strap fitting (5) and
mating surface of yoke (3).
CAUTION
SUPPORT YOKE ON WOODEN BLOCKS
DURING ASSEMBLY OF GRIPS.
7. Assemble grips (2, Figure 62-49) as follows:
a. Install buffer pads (1) and closures (7) on grips
(2) as follows:
NOTE
Prior to bonding, apply chemical film
material (C-100) and epoxy polyamide
primer (C-204) to grip tangs, faying with
buffer pads.
(1) Abrade buffer pads (1) and closures (7)
on areas to be bonded with 180 grit abrasive paper
(C-423) and wipe clean with a cloth moistened with
aliphatic naphtha (C-305). Wipe dry with a clean cloth.
Clean mating surfaces on grips (2) with aliphatic
naphtha (C-305) and wipe dry.
NOTE
Protect parts with barrier material (C-427) if
bonding cannot be accomplished
immediately.
ECCN 9E991
BHT-206L-CR&O-3
b. Buffer pads:
(1) Mix adhesive (C-331) per manufacturers
instructions. As soon as adhesive is thoroughly mixed,
apply adhesive to both bonding surfaces extending
approximately 0.0625 inch (1.6 mm) past edge of
buffer pad on grip.
(2) Press parts firmly together, ensuring
buffer pads are aligned with bushings in grip, for blade
bolts (Figure 62-49, Detail A). Remove excess
adhesive with cloths dampened in MEK (C-309). Apply
approximately 10 PSI (69 kPa) bond line pressure
over full bond area throughout 24 hour cure time at 70
to 80°F (21 to 27°C) or for 60 minutes at 180 to 200°F
(82 to 93°C). Fair and smooth squeeze-out around
buffer pads. During cure cycle, check for edge voids
and fill as necessary.
c. Closures:
(1) Apply a thin even coat of sealant (C-308)
to mating surfaces of closure (7) and grips (2). Allow
adhesive to dry to a tacky state (evidenced by
adhering, but not transferring, to a finger when
touched).
(2) Press parts together firmly. Make sure
that closures are firmly seated to grips. Fair adhesive
squeeze-out and cure at 70 to 80°F (21 to 27°C) for
4 hours minimum. No edge voids are permitted.
NOTE
Make sure sealant will not leak into strap
recess.
8. Assemble packings (3 and 6), retainer (4), and
excluder (5).
a. Clean outboard groove in retainer (4) and
mating surface area in bore of grips (2) with a sharp
plastic scraper and clean cloths dampened in MEK
(C-309).
b. Fabricate main rotor hub excluder mandrel
(Figure 62-50).
c. Insert small end of mandrel into inboard side
of retainer (4, Figure 62-49).
d. Lubricate packing (6), excluder (5), and
tapered section of mandrel with grease (C-001).
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BHT-206L-CR&O-3

206L_CRO_62_0074

Figure 62-50. Main Rotor Hub Excluder Mandrel

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Page 108 Rev. 3 10 JAN 2011 ECCN 9E991

NOTE
Heating excluder slightly with heat gun will
facilitate installation. Do not exceed 200°F
(93°C).
e. Position packing (6) on mandrel followed by
excluder (5) with lip pointing toward retainer. Slide
excluder and packing over mandrel into retainer
groove.
9. Install retainer into grip.
a. Apply a coat of sealant (C-308) to outboard
groove of retainer (4) and install new packing (3) in
groove. Apply a coat of sealant (C-308) to packing and
to mating surfaces inside grip (2) (Figure 62-49,
Detail C).
b. lnstall retainer (4) (with packing end first) in
grip (2). Make sure retainer is firmly seated inside grip
bore.
c. Repeat procedure for the remaining grip.
CAUTION
DO NOT HEAT GRIPS ABOVE 200°F
(93°C) DURING SEALANT CURE.
PACKINGS AND EXCLUDER WILL BE
DAMAGED.
d. Cure sealant for 72 hours at 70 to 80°F (21 to
27°C) or for 1 hour at 70 to 80°F (21 to 27°C) plus
2 hours at 175 to 200°F (79 to 93°C).
10. Assemble grip and pitch horn as follows:
CAUTION
D O N O T H E AT G R I P S A B O V E
200°F (93°C) DURING BEARING
INSTALLATION. DAMAGE TO PACKINGS
AND EXCLUDER MAY RESULT.
NOTE
If new roller bearings (9, Figure 62-51) are
being installed, thoroughly clean in
ECCN 9E991
BHT-206L-CR&O-3
drycleaning solvent (C-304) to remove
corrosion preventive compound.
a. Coat outboard bearing (9) and spacer (10)
with lubricating oil (C-013) or grease (C-001), as
applicable. Apply heat lamp to bearing area of grip
(16). Carefully insert bearing into grip (with part
number facing outboard) until fully seated. Position
spacer into grip.
b. Clean outer diameter of new seal (14,
Figure 62-52) and mating surface of pitch horn (8) with
clean cloths dampened with MEK (C-309).
c. Apply a thin film of sealant (C-308) to outer
diameter of seal and mating inner diameter of pitch
horn.
d. For grease lubricated hubs, press seal into
pitch horn with lip of seal outboard. For oil lubricated
hubs, press seal into pitch horn with lip of seal inboard.
Apply a coating of lubricating oil (C-013) or grease
(C-001), as applicable, to lip of seal.
e. Apply a film of corrosion preventive compound
(C-104) to shank of bolts (15), barrel of pitch horn
trunnion (17), and mating surface of pitch horn (8).
Use pitch horn trunnion workaid (Figure 62-21) to
spread pitch horn. lnsert pitch horn trunnion with
clamp slots aligned with bolt holes. Remove pitch horn
trunnion workaid. As an alternate procedure, insert a
phenolic wedge into pitch horn slot to install pitch horn
trunnion.
f. lnstall bolts (15, Figure 62-52), steel washers
(16), and nuts (18) on pitch horn (8). Install one
washer under bolt heads and one washer under nuts.
Torque nuts uniformly to 60 inch-pounds (6.78 Nm).
11. Assemble grip reservoir (5) on oil lubricated hubs.
a. Lubricate new stat-o-seals (4) and new
packings (7, 9, and 11) with lubricating oil (C-013).
b. lnsert packing (9) in groove on sight glass
(10). With packing (11) and countersunk washer (12)
on bolt (13), insert bolt into sight glass. Countersunk
side of washer must be in contact with packing against
sight glass.
c. Insert bolt (13) into center hole on face side of
pitch horn (8).
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BHT-206L-CR&O-3

1. Yoke
2. Laminated shim
3. Rubber stop
4. Static stop
5. Bolt
6. Steel washer
7. Pitch horn
8. Packing
9. Roller bearing
10. Spacer
11. Washer
12. Nut
13. Spring
14. Blade latch
15. Nut
16. Grip
17. Nut
18. Washer
19. Bolt
20. Blade bolt
21. Packing
22. Cap
23. Nut
24. Steel washer
25. Bolt
26. Tension-torsion strap
27. Wear sleeve
28. Plug

NOTE
1 Springs (13) are no longer required
and may be removed.

206L_CRO_62_0046

Figure 62-51. Main Rotor Hub Assembly

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 BHT-206L-CR&O-3

206L_CRO_62_0047

Figure 62-52. Pitch Horn and Reservoir

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ECCN 9E991 10 JAN 2011 Rev. 3 Page 111
BHT-206L-CR&O-3
d. lnsert packing (7) in groove on grip reservoir
(5). Position reservoir over bolt (13) and in contact with
pitch horn (8).
e. lnstall stat-o-seal (4) on bolt next to reservoir.
lnstall thin steel washer (3), lockwasher (2) and nut (1)
on bolt (13). Torque nut until lockwasher is fully
compressed, then back off 1 full turn ±30°.
12. On grease lubricated hubs, coat threads of relief
valve (20) with unreduced epoxy polyamide primer
(C-204). Install relief valve in pitch horn and torque 15
to 20 inch-pounds (1.7 to 2.2 Nm).
13. Lubricate new packing (19) with grease (C-001)
or lubricating oil (C-013), as applicable, and insert in
groove on outboard face of pitch horn (8).
14. Assemble pitch horns and grips to yoke.
a. Support yoke on work surface with a piece of
wood approximately 2 x 4 x 10 inches (50.8 x 101.6 x
254 mm) between static stops.
b. Apply a film of grease (C-001) or lubricating oil
(C-013), as applicable to outer diameter of wear
sleeve (27, Figure 62-51), bearing journals on spindle
of yoke (1), lip of seal in pitch horn (7), and to packing
(8). Also lubricate excluder installed in grip (16).
c. Position pitch horn (7) onto spindle of yoke
(1). Carefully guide seal in pitch horn onto wear sleeve
(27). Make sure packing (8) is still in groove on grip
face of pitch horn.
d. Slide inboard roller bearing (9) onto yoke
spindle with part number facing inboard.
e. Fit grip (16) over spindle of yoke (1) and slide
inboard, carefully rotating back and forth until
engaging tension-torsion strap (26). Continue rotating
and pressing grip onto spindle of yoke until bores for
strap bolt (19) are aligned.
CAUTION
DO NOT ALLOW GRIPS OR YOKE TO
ROTATE ON PITCH CHANGE AXIS. IF
62-00-00
Page 112 Rev. 3 10 JAN 2011
GRIP OR YOKE IS ALLOWED TO
ROTATE ON THE PITCH CHANGE AXIS
BEYOND 90°, REPLACE MAIN ROTOR
GRIP RETENTION STRAPS. USE
T-HANDLE WORKAID OR LOCKWIRE TO
SECURE GRIPS.
f. Insert new or existing strap bolt (19), as
applicable, through grip (16) and tension-torsion strap
from trailing edge side, engaging notch in flange of
strap bolt with pin in grip.
g. Wipe excess corrosion preventive compound
from exposed threads of strap bolt (19) and install
washer (11) and nut (12) on strap bolt. Torque nut after
grip (16) and pitch horn (7) are attached.
h. Press pitch horn (7) and grip (16) together
while ensuring packing (8) is still in groove and holes
for bolts (25) are aligned.
i. Coat shanks of bolts (25) and steel washers
(24) with epoxy polyamide primer (C-204) and install
through pitch horn and grip with bolt heads inboard.
lnstall steel washers (24) and nuts (23). Uniformly
torque nuts to 120 inch-pounds (13.5 Nm) plus tare
torque.
j. Use socket wrench (T101554) to torque nut
(12) 180 foot-pounds (244 Nm).
NOTE
Springs (13) are no longer required and
may be removed.
k. lnstall spring (13), if applicable, blade latch
(14), and nut (15) on each end of strap bolt (19).
Tighten nuts only enough to remove free play from
blade latches. Nuts will be torqued after main rotor
blades are installed.
l. Install the plug (28) on the blade bolt (20) as
follows:
(1) Lightly abrade the faying surfaces of the
plug (28) and the blade bolt (20) with a 180 grit or finer
abrasive paper (C-423).
(2) Clean the parts with MEK (C-309) and
dry.
ECCN 9E991
 BHT-206L-CR&O-3

u. Clean and spray coat entire main rotor hub

NOTE
For the adhesive (C-313), use Metalset-A-4
only.
(3) Bond the plug (28) onto the blade bolt
(20) with adhesive (C-313).
m. Install blade bolt (20) in grip (16) and install
washer (18) and nut (17). Tighten nut finger tight. Nut
will be torqued when main rotor blades are installed.
with preservative oil (C-125).
v. After initial ground run and tracking, service
grips and pillow blocks per the instructions in
Chapter 12 of the applicable Maintenance Manual
(MM) to make sure cavities are completely filled.
Repeat lubrication after first flight.
62-36. MAIN ROTOR HUB — PAINTING

n. Apply a film of grease (C-001) to new packing MATERIALS REQUIRED

(21) and position on cap (22). Firmly press cap into
blade bolt (20). Refer to BHT-ALL-SPM for specifications.

o. On oil lubricated hubs, fill bearing cavities of NUMBER NOMENCLATURE

pillow blocks (14, Figure 62-43) with lubricating oil
C-100 Chemical Film Material
(C-013) through filler plug (8) hole. Work out all air
bubbles and fill until sight plug (11) is half full. Torque
C-108 Cadmium Plating
filler plug 15 inch-pounds (1.70 Nm). Secure filler plug
Solution
to sight plug with lockwire (C-405).
C-204 Epoxy Polyamide
p. On grease lubricated hubs, purge lubricate Primer
pillow blocks through grease fittings (19).
C-245 Polyurethane Coating
q. For grease lubricated hubs, purge lubricate
C-426 Masking Tape
grip through grease fitting (60, Figure 62-15).

r. For oil lubricated hubs, fill grip reservoirs (5,

Figure 62-52) with lubricating oil (C-013) through vent
fitting (6). Work out air bubbles and fill sight glass (10)
half full.
s. If not previously accomplished, install
modification data plate and serial number data plate to
main rotor hub yoke with adhesive (C-331) as follows:
(1) Stamp overhaul information on data plate
prior to bonding to yoke.
(2) Apply firm contact pressure to plates.
Cure for 72 hours at 70 to 90°F (21 to 32°C) (handling
strength is obtained in 24 hours), or for 60 minutes at
175 to 185°F (79 to 85°C).
NOTE
Refer to BHT-ALL-SPM, Chapter 3 and
Chapter 4, for application of chemical film
treatment and application of protective
paint finishes, respectively.
1. Touch up all exposed bare aluminum surfaces
with chemical film material (C-100).
2. Touch up all steel parts that were previously
cadmium plated with cadmium plating solution
(C-108).
3. Mask areas of main rotor hub not requiring paint,
using masking tape (C-426) (Figure 62-42).

NOTE 4. Prime main rotor hub with one coat of epoxy

Delay coating hub with WD-40 until paint polyamide primer (C-204).
has dried.
5. Paint main rotor hub with two spray coats of
t. Paint main rotor hub (paragraph 62-36). polyurethane coating (C-245).

62-00-00
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BHT-206L-CR&O-3

62-37. MAIN ROTOR HUB — PRESERVATION hardware to prevent movement during handling or
transit. Install 80 units of desiccant and seal container.

MATERIALS REQUIRED 62-38. MAIN ROTOR LOCK

Refer to BHT-ALL-SPM for specifications. 62-39. MAIN ROTOR LOCK — INSPECTION

NUMBER NOMENCLATURE 1. Inspect lock (6, Figure 62-1) for wear and
damage. Maximum depth of scoring allowed is
C-001 Grease
0.005 inch (0.127 mm). Make sure both locking tangs
C-013 Lubricating Oil engage mast nut splines when parts are installed.

C-101 Corrosion Preventive 62-40. MAIN ROTOR LOCK — REPAIR

Compound

C-426 Masking Tape

MATERIALS REQUIRED
C-427 Barrier Material
Refer to BHT-ALL-SPM for specifications.

1. Lubricate main rotor hub by filling reservoirs half NUMBER NOMENCLATURE

full with lubricating oil (C-013) or purging pitch horn
trunnions and grips with grease (C-001). C-100 Chemical Film Material

C-423 Abrasive Paper

2. Apply a coat of corrosion preventive compound
(C-101) to all bare metal, uncoated and unprimed C-464 India Stone
surfaces (blade bolts, bushings, and splines).
1. Polish out acceptable damage with 400 to 600
3. Enclose main rotor hub in barrier material (C-427) grit abrasive paper (C-423), or fine India stone
and seal with masking tape (C-426). (C-464).

4. Securely pack main rotor hub in a metal or 2. Touch up repaired areas with chemical film
wooden shipping container with cushioning and material (C-100).

62-00-00
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 BHT-206L-CR&O-3

FLAP RESTRAINT ASSEMBLY

62-41. FLAP RESTRAINT ASSEMBLY MATERIALS REQUIRED (Cont)

62-42. FLAP RESTRAINT ASSEMBLY — Refer to BHT-ALL-SPM for specifications.

DISASSEMBLY
NUMBER NOMENCLATURE
1. Remove springs (7, Figure 62-53) from eyebolts
C-245 Polyurethane Coating
(6 and 8).
C-304 Drycleaning Solvent
2. Remove nuts (12), thin steel washers (11), bolts
(14), and arm assemblies (4). C-423 Abrasive Paper

C-464 India Stone

3. Remove nuts (1), steel washers (2, 3, and 5) and
eyebolt (6). Tie washers, nuts, and bolt together and
tag for installation in correct position.
CAUTION
4. Remove eyebolts (8) and washers (9) from
support (10).
D O N O T A L L O W S O LV E N T S O R
62-43. FLAP RESTRAINT ASSEMBLY — COMPOUNDS TO MAKE CONTACT WITH
INSPECTION PA R T S M A D E O F E L A S T O M E R I C
MATERIAL OR DAMAGE WILL OCCUR.
1. lnspect arm assemblies (4, Figure 62-53) for
wear and damage. lnspect stop for bond line 1. Polish out acceptable damage with fine India
separation. If separation is evident, replace arm. stone (C-464) or 400 to 600 grit abrasive paper
(C-423). Remove abrasive residue with drycleaning
2. lnspect support (10) for wear and damage. solvent (C-304).

3. lnspect bearings (13) in arm assemblies (4) for

play. Maximum play in bearing is 0.006 inch
(0.152 mm) radial and 0.030 inch (0.762 mm) axial. CAUTION
Replace bearing if play is excessive.

DO NOT ALLOW EPOXY POLYAMIDE

4. Inspect springs (7) for correct rate. Spring should
PRIMER OR POLYURETHANE COATING
extend 1.0 inch (25.4 mm) when a pull of 0.84 pound
TO ENTER BOLT HOLES OR THREADED
(3.74 N), plus or minus 0.08 pound (0.356 N) is
AREAS.
applied. Replace springs that extend beyond these
limits.
2. Apply one coat of epoxy polyamide primer
(C-204) and two coats of polyurethane coating (C-245)
62-44. FLAP RESTRAINT ASSEMBLY — REPAIR
to surfaces within 8 hours after priming.

MATERIALS REQUIRED 62-45. FLAP RESTRAINT ASSEMBLY —

ASSEMBLY
Refer to BHT-ALL-SPM for specifications.
1. lnstall arm assemblies (4, Figure 62-53) on
NUMBER NOMENCLATURE support (10). Upper stop surfaces must be adjacent to
mating eyebolt (8). lnstall bolts (14) from inboard side
C-204 Epoxy Polyamide
of support. Install thin steel washer (11) and nuts (12).
Primer
Torque nuts 30 to 40 inch-pounds (3.39 to 4.52 Nm)

62-00-00
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BHT-206L-CR&O-3

Figure 62-53. Flap Restraint

62-00-00
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 BHT-206L-CR&O-3

2. Place three steel washers (9) on each eyebolt (8) 2. Mask bearing (13, Figure 62-53) with masking
and install on support (10). tape (C-426).

3. Place one steel washer (5) on each eyebolt (6)
and insert in inboard side of arm assembly (4). Install
eight steel washers (3) and nine steel washers (2) on
each eyebolt. lnstall and torque nuts (1) 60 to
85 inch-pounds (6.78 to 9.60 Nm).
4. Apply corrosion protective coating to all exterior
surfaces of flap restraint (paragraph 62-46).
3. Mix one part clear polyurethane coating (C-245)
to 1.5 to 2 parts thinner (C-206) and apply by spray or
brush as follows:
a. Spray — Apply a spray coat from a distance of
6 to 8 inches (152.4 to 203.2 mm) from the surfaces.
After 15 to 30 minutes drying time, apply a second
coat in the same manner.

62-46. FLAP RESTRAINT ASSEMBLY — b. Brush — Apply using a fine hair brush (camel
CORROSION PROTECTION or ox hair, not nylon) and paint brush coating quickly
over the surface overlapping previous strokes, but not
reworking entire coated area. After 30 minutes drying
time, apply a second coat in same manner as the first.
MATERIALS REQUIRED
4. Curing of protective coating may be
Refer to BHT-ALL-SPM for specifications.
accomplished as follows:
NUMBER NOMENCLATURE
a. Air dry — After second coat is applied, full
C-206 Thinner cure can be obtained in approximately 48 hours at 70
to 80°F (21 to 27°C).
C-245 Polyurethane Coating
b. Heat dry — After second coat is applied,
C-305 Aliphatic Naphtha
accelerated curing can be accomplished by air drying
C-309 MEK for 30 minutes, then heat lamp bake at 150°F (66°C)
for 2 hours.
C-423 Abrasive Paper
5. Remove masking tape.
C-426 Masking Tape
6. After curing, coating shall be smooth and uniform
The flap restraint shall receive two coats of the over entire surface with no area of part uncoated.
corrosion protective coating. Anodized aluminum parts Coating shall have a dry film thickness of 0.0012 to
should receive protective coating after reassembly or 0.0020 inch (0.0305 to 0.0508 mm). Areas found to be
installation on the helicopter. Cadmium plated steel uncoated may be spot repaired in accordance with
parts should receive the protective coating prior to step 7.
reassembly.
7. Isolated areas of non-adhesion shall be
1. Thoroughly clean surfaces to receive protective refinished by feathering in uncoated areas with 400 to
coating with a cloth saturated with MEK (C-309). Wipe 600 grit abrasive paper (C-423). Wipe areas with
surfaces dry with a clean cloth before MEK aliphatic naphtha (C-305) and refinish in accordance
evaporates. with step 3.

62-00-00
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ROTATING CONTROLS
62-47. SWASHPLATE AND SUPPORT
62-48. SWASHPLATE AND SUPPORT
DISASSEMBLY
CAUTION
SUPPORT PIVOT SLEEVE TO PREVENT
DAMAGE TO SUPPORT.
NOTE
Prior to disassembly, inspect swashplate
and support assembly for abnormal
damage (paragraph 62-50, step 1).
1. Remove collective lever (29, Figure 62-54) and
link (21).
a. Remove lockwire from screws (26). Remove
screws, washers (25), and pins (27) from collective
lever (29).
b. On assemblies 206-010-450-101/-121 and
-123, remove nut (47), washers (46), and bolts (45).
Remove pins (27) from collective lever.
c. Remove cotter pins (12), nut (11), aluminum
washer (10), and bolt (13).
d. Remove cotter pins (31), nut (30), aluminum
washer (24), and bolt (23). Remove collective lever
(29) and collective lever link (21) from support (8).
2. Lift inner ring (7) and outer ring (42) together with
pivot sleeve (2) from support (8).
3. Disassemble pivot sleeve (2) and inner and outer
rings (7 and 42).
a. Remove lockwire and remove bolts (35) and
countersunk washers (36). Remove outer cap (34)
ECCN 9E991
BHT-206L-CR&O-3
with seal (38) from outer ring (42). Remove and
discard seal.
—
b. Index mark the duplex bearing set (41), inner
cap (40), and pivot sleeve (2) to assure proper
reinstallation.
c. Remove lockwire and remove bolts (33) and
countersunk washers (32), top half of bearing set (4),
laminated shims (39), and inner cap (40) from inner
ring (7). Measure and record shim thickness for
reinstallation.
d. Carefully work outer ring (42) from inner
ring (7).
CAUTION
TA KE PRECA UTIO NS TO PREV ENT
INNER RING AND SLEEVE FROM
FALLING.
e. Place outer ring (42) and inner ring (7) in
press. Support outer ring in press and carefully press
inner ring and pivot sleeve (2) from outer ring.
f. Heat outer ring (42) and invert. Tap on
wooden surface to dislodge duplex bearing (41).
Remove and discard lower seal (38). Remove cotter
pins (15), nuts (16), bushings (17), slider bearing (18),
and bolts (5) from slots in pivot sleeve (2) and inner
ring (7). Discard packing (6).
g. Rotate pivot sleeve 90° and raise out of inner
ring (7).
h. Raise pivot sleeve (2) in inner ring (7) and
remove lower bearing set (4) from inner ring.
i. Remove upper and lower sleeve bearings (1)
from pivot sleeve by inserting a 1/16 to 1/8 inch drive
pin through sealant covered pilot holes in sleeve
adjacent to bearings (Figure 62-55).
62-00-00
10 JAN 2011 Rev. 3 Page 119
BHT-206L-CR&O-3

45
46
47
29 27
DETAIL A
(FOR 206-010-450-101, -121 AND
-123 ASSEMBLIES ONLY)

SEE DETAIL A

206L_CRO_62_0049a

Figure 62-54. Swashplate and Support (Sheet 1 of 2)

62-00-00
Page 120 Rev. 3 10 JAN 2011 ECCN 9E991
 BHT-206L-CR&O-3

1. Sleeve bearing 17. Bushing 33. Bolt

2. Pivot sleeve 18. Slider bearing 34. Outer cap
3. Bushing 19. Spacer 35. Bolt
4. Bearing set 20. Bushing 36. Countersunk washer
5. Bolt 21. Link 37. Grease fitting
6. Packing 22. Spherical bearing 38. Seal
7. Inner ring 23. Bolt 39. Laminated shim
8. Support 24. Aluminum washer 40. Inner cap
9. Bushing 25. Aluminum washer 41. Duplex bearing
10. Aluminum washer 26. Screw 42. Outer ring
11. Nut 27. Pin 43. Spherical bearing
12. Cotter pin 28. Bushing 44. Stud
13. Bolt 29. Collective lever 45. Bolt
14. Spherical bearing 30. Nut 46. Washer
15. Cotter pin 31. Cotter pin 47. Nut
16. Nut 32. Countersunk washer

206L_CRO_62_0049b

Figure 62-54. Swashplate and Support (Sheet 2 of 2)

62-00-00
ECCN 9E991 10 JAN 2011 Rev. 3 Page 121
BHT-206L-CR&O-3

Figure 62-55. Pivot Sleeve Modified with Pilot Holes

62-00-00
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 BHT-206L-CR&O-3

62-49. SWASHPLATE AND SUPPORT — 1. Visually inspect swashplate and support and
CLEANING review accompanying records to determine if
swashplate has been subjected to an accident or
incident outside the realm of normal usage.
MATERIALS REQUIRED
a. If there is evidence of accident or incident
Refer to BHT-ALL-SPM for specifications. damage, accomplish the following.

NUMBER NOMENCLATURE (1) lnspect for mechanical damage to

external surfaces of swashplate and support
C-304 Drycleaning Solvent components.
C-309 MEK
(2) Check for smooth rotation of duplex
C-339 Ethyl Alcohol bearings (41, Figure 62-54) and free vertical
movement of collective lever (29).
C-436 Paint Remover
b. Assemblies or components found to be
defective or worn or damaged beyond limits shall be
1. Clean all swashplate parts with drycleaning
replaced.
solvent (C-304). Clean teflon bearing surfaces with a
cloth dampened with MEK (C-309) or ethyl alcohol
(C-339). c. Assemblies that have attained maximum
service as listed in retirement schedule shall be
replaced. Refer to Chapter 4 of the applicable
Maintenance Manual (MM).
CAUTION
2. lnspect parts dimensionally and replace parts that
do not fall within inspection limits. Tolerances and
DO NOT SPIN BEARINGS WHILE AIR limits set forth in illustrations for damage limits are
DRYING. maximum acceptable. Parts exceeding these limits
shall be scrapped.
2. Dry parts with filtered, compressed air and
lint-free clean cloths.
NOTE

3. Remove paint from metal parts using paint Limits charts are provided to show required
remover (C-436). fit between mating parts. It is not intended
all dimensions listed on limits chart be
checked as a prescribed overhaul
62-50. SWASHPLATE AND SUPPORT — procedure. However, parts exhibiting
INSPECTION evidence of wear or physical damage shall
be checked dimensionally.

MATERIALS REQUIRED a. lnspect pivot sleeve (2), inner ring (7), support
(8), collective lever link (21), collective lever (29), outer
Refer to BHT-ALL-SPM for specifications. cap (34), and outer ring (42) for mechanical and
corrosion damage (Figure 62-57 through
NUMBER NOMENCLATURE Figure 62-63).

C-001 Grease b. lnspect spherical bearings (14 and 43,

Figure 62-54) in inner ring (7), outer ring (42), and
C-407 Abrasive Pad collective lever (29) for axial wear. If wear exceeds
0.010 inch (0.254 mm) radial or axial, replace bearing
C-411 Steel Wool
(BHT-ALL-SPM, Chapter 9).

62-00-00
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BHT-206L-CR&O-3

11
SECTION A-A

NO. DESCRIPTION LOCATION MINIMUM MAXIMUM REMARKS

INCHES (mm) INCHES (mm)
1 Bearing (width of O.D. — — — — If Teflon shows any
Teflon surfaces) damage.
2 Inner cap O.D. — — — — Groove maximum
(206-010-455-001) depth 0.002 inch
(0.050 mm).

2A Inner cap O.D. — — — — Groove maximum

(206-010-455-103) depth 0.005 inch
(0.127 mm).

3 Inner ring O.D. 4.997 (126.93) 5.000 (127.00) Groove maximum

depth 0.002 inch
(0.050 mm).

4 Pivot sleeve sphere O.D. 3.999 (101.58) 4.003 (101.67) Maximum 0.002 inch
Pivot sleeve sphere slots I.D. — — — — (0.050 mm) wear
below adjacent
unworn surface.

5 Swashplate support O.D. 2.558 (64.98) 2.562 (65.07) Maximum 0.002 inch
(0.050 mm) wear
below adjacent
unworn surface.

6 Pin O.D. 0.3710 (9.43)

7 Pivot sleeve Teflon lined I.D. — — — — If Teflon shows any
bearings damage.

8 Collective lever bushings I.D. — — 0.363 (9.22)

O.D. 0.501 (12.73) — —

9 Link bushings I.D. — — — — If Teflon shows any

damage.
10 Spacer O.D. 0.5595 (14.22) —
—
11 Swashplate I.D. — — 0.363 (9.22)
support bushings O.D. 0.501 (12.73) — —
12 Pivot sleeve Teflon I.D. — — — — If Teflon shows any
bearings damage.
206L_CRO_62_0051

Figure 62-56. Swashplate and Support — Wear Limits

62-00-00
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 BHT-206L-CR&O-3

3
206-010-454
PIVOT SLEEVE

DAMAGE LOCATION SYMBOLS

TYPE OF DAMAGE MAXIMUM DAMAGE AND REPAIR DEPTH

MECHANICAL 0.010 inch (0.25 mm) 2 0.020 inch (0.51 mm)

BEFORE AND AFTER REPAIR

CORROSION
BEFORE REPAIR 0.005 inch (0.13 mm) 0.010 inch (0.25 mm)
AFTER REPAIR 0.010 inch (0.25 mm) 4 2 0.020 inch (0.51 mm) 4

MAXIMUM AREA PER 0.10 square inch (65 mm2) 2 Not critical
FULL DEPTH REPAIR

NUMBER OF REPAIR AREAS One per lug 2 Not critical

EDGE CHAMFER 0.040 inch (1.02 mm) 2 0.040 inch (1.02 mm)

BUSHING BORES 0.001 inch (0.03 mm)

for 1/4 circumference

NOTES
1 Minimum radius of repair is 0.35 inch (8.9 mm).

2 Damage must not penetrate the hard anodized surface or the tungsten carbide surface. Damage
not penetrating the anodized surface or the tungsten carbide surface should be lightly polished
with fine crocus cloth (C-500). Any crack in the tungsten carbide surface is cause for replacement.

3 Minimum radius of repair is 0.50 inch (12.7 mm).

4 Corrosion must be removed to two times the depth of the corrosion damage but not to exceed the given limits.
206L_CRO_62_0052_c01

Figure 62-57. Pivot Sleeve — Damage Limits

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BHT-206L-CR&O-3

206L_CRO_62_0053

Figure 62-58. Inner Ring — Damage Limits

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 BHT-206L-CR&O-3

206L_CRO_62_0054

Figure 62-59. Swashplate Support — Damage Limits

62-00-00
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BHT-206L-CR&O-3

1
LINK
206-010-407

DAMAGE LOCATION SYMBOLS

TYPE OF DAMAGE MAXIMUM DAMAGE AND REPAIR DEPTH

MECHANICAL 0.010 inch (0.25 mm) 0.030 inch (0.76 mm)

BEFORE AND AFTER REPAIR

CORROSION
BEFORE REPAIR 0.005 inch (0.13 mm) 2 0.015 inch (0.38 mm) 2
AFTER REPAIR 0.010 inch (0.25 mm) 0.030 inch (0.76 mm)

MAXIMUM AREA PER 0.10 square inch (65 mm2) 0.25 square inch (161 mm2)
FULL DEPTH REPAIR

NUMBER OF REPAIR AREAS One per end Two

EDGE CHAMFER 0.030 inch (0.76 mm) 0.030 inch (0.76 mm)

NOTES
1 Bore damage shall not exceed 0.001 inch (0.025 mm) for 1/4 circumference.

2 Corrosion must be removed to two times the depth of the corrosion damage but not to
exceed the given limits.

206L_CRO_62_0055

Figure 62-60. Collective Lever Link (206-010-407) — Damage Limits

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 BHT-206L-CR&O-3

1
LINK
206-010-446

DAMAGE LOCATION SYMBOLS

TYPE OF DAMAGE MAXIMUM DAMAGE AND REPAIR DEPTH

MECHANICAL 0.005 inch (0.13 mm) 0.010 inch (0.25 mm)

BEFORE AND AFTER REPAIR

CORROSION
BEFORE REPAIR 0.0025 inch (0.063 mm) 2 0.005 inch (0.13 mm) 2
AFTER REPAIR 0.005 inch (0.13 mm) 0.010 inch (0.25 mm)

MAXIMUM AREA PER 0.100 square inch (65 mm2) 0.25 square inch (161 mm2)
FULL DEPTH REPAIR

NUMBER OF REPAIR AREAS One per end Two

EDGE CHAMFER 0.005 inch (0.13 mm) N/A

NOTES
1 Bore damage shall not exceed 0.001 inch (0.025 mm) for 1/4 circumference.

2 Corrosion must be removed to two times the depth of the corrosion damage but not to
exceed the given limits.

206L_CRO_62_0077

Figure 62-60A. Collective Lever Link (206-010-446) — Damage Limits

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BHT-206L-CR&O-3

1
COLLECTIVE LEVER
206-010-467

DAMAGE LOCATION SYMBOLS

TYPE OF DAMAGE MAXIMUM DAMAGE AND REPAIR DEPTH

MECHANICAL 0.010 inch (0.25 mm) 0.030 inch (0.76 mm)

BEFORE AND AFTER REPAIR

CORROSION
BEFORE REPAIR 0.005 inch (0.13 mm) 2 0.015 inch (0.38 mm) 2
AFTER REPAIR 0.010 inch (0.25 mm) 0.030 inch (0.76 mm)

MAXIMUM AREA PER 0.15 square inch (97 mm2) 0.25 square inch (161 mm2)
FULL DEPTH REPAIR

NUMBER OF REPAIR AREAS One per segment Not critical

EDGE CHAMFER 0.030 inch (0.76 mm) 0.050 inch (1.27 mm)

NOTES
1 Bore damage shall not exceed 0.001 inch (0.025 mm) for 1/4 circumference.

2 Corrosion must be removed to two times the depth of the corrosion damage but not to
exceed the given limits.

206L_CRO_62_0056

Figure 62-61. Collective Lever (206-010-467) — Damage Limits

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 BHT-206L-CR&O-3

1
COLLECTIVE LEVER
206-010-447

DAMAGE LOCATION SYMBOLS

TYPE OF DAMAGE MAXIMUM DAMAGE AND REPAIR DEPTH

MECHANICAL 0.005 inch (0.13 mm) 0.010 inch (0.25 mm)

BEFORE AND AFTER REPAIR

CORROSION
BEFORE REPAIR 0.0025 inch (0.063 mm) 2 0.005 inch (0.13 mm) 2
AFTER REPAIR 0.005 inch (0.13 mm) 0.010 inch (0.25 mm)

MAXIMUM AREA PER 0.15 square inch (97 mm2) 0.25 square inch (161 mm2)
FULL DEPTH REPAIR

NUMBER OF REPAIR AREAS One per segment Not critical

EDGE CHAMFER 0.005 inch (0.13 mm) 0.010 inch (0.25 mm)

NOTES
1 Bore damage shall not exceed 0.001 inch (0.025 mm) for 1/4 circumference.

2 Corrosion must be removed to two times the depth of the corrosion damage but not to
exceed the given limits.

206L_CRO_62_0078

Figure 62-61A. Collective Lever (206-010-447) — Damage Limits

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BHT-206L-CR&O-3

Figure 62-62. Outer Cap — Damage Limits

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 BHT-206L-CR&O-3

Figure 62-63. Outer Ring — Damage Limits

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BHT-206L-CR&O-3
c. Inspect duplex bearing (41) as follows:
(1) Make sure the duplex bearing (41) is a
matched serial numbered set. If serial numbers are
different, discard the duplex bearing.
(2) Inspect races and balls of each individual
bearing for mechanical and corrosion damage, and for
pitting, brinelling, spalling, and scoring (Figure 62-64).
CAUTION
MAKE SURE NOT TO REMOVE THE V
MARK WHEN YOU POLISH OUT
CORROSION. THE V MARK CANNOT BE
REAPPLIED IN THE FIELD. IF THE V
MARK IS NOT VISIBLE, THE BEARING IS
UNSERVICEABLE.
(3) Polish out corrosion on the inner and
outer diameters and face sides of the bearing with an
abrasive pad (C-407) or steel wool (C-411).
(4) Clean the applicable bearing(s) after
polishing corrosion (paragraph 62-49).
(5) Hand pack the applicable bearing(s) with
grease (C-001).
d. Inspect flange bushings (9 and 28) for
mechanical and corrosion damage (Figure 62-65).
Replace as required (paragraph 62-52).
e. Inspect threads in inner ring (7, Figure 62-54)
and outer ring (42) for damage. Check stud (44) in
outer ring for damaged threads or looseness.
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(1) Do not chase threads in inner ring (7)
with a tap. These are helicoil inserts. If threads are not
satisfactory, replace helicoil insert (BHT-ALL-SPM).
(2) Do not chase threads in outer ring (42)
with a tap. These are a specially formed thread. If
threads are not satisfactory, replace outer ring.
f. lnspect grease fittings (37) in outer cap (34)
for serviceability.
3. lnspect teflon lined bearings or bushings (1, 3, 4,
18, and 20, Figure 62-54) for fabric looseness or teflon
penetration. If teflon fabric fibers are beginning to
show through or show any damage, replace bearings
or bushings (BHT-ALL-SPM, Chapter 9).
a. lnspect bushing bores in part for damage.
Damage greater than 0.001 inch (0.025 mm) for
1/4 circumference requires part to be replaced
(BHT-ALL-SPM, Chapter 9).
4. During each overhaul, perform Fluorescent
Penetrant Inspection (FPI) of swashplate and support
components (paragraph 62-51).
5. After assembly, inspect swashplate assembly for
proper friction adjustment (paragraph 62-54).
62-51. SWASHPLATE AND SUPPORT —
FLUORESCENT PENETRANT INSPECTION
1. Perform a Fluorescent Penetrant Inspection (FPI)
on the components of the swashplate and support
listed in Table 62-2 (BHT-ALL-SPM, Chapter 6).
ECCN 9E991
 BHT-206L-CR&O-3

FACE SIDE
A
FACE SIDE

A BACK SIDE

BACK SIDE

DUPLEX BEARING
206-010-443
FACE SIDE

SECTION A-A

DAMAGE LOCATION SYMBOLS

TYPE OF DAMAGE MAXIMUM DAMAGE AND REPAIR DEPTH

MECHANICAL No damage No damage No damage No damage

BEFORE AND AFTER REPAIR

CORROSION
BEFORE AND AFTER REPAIR 5.0000 In. 1 6.1240 In. 2 1.2300 In. 3 No damage
(127.000 mm) (155.550 mm) (31.242 mm)
maximum ID minimum OD minimum
distance
between
face sides

NOTES

1 It is acceptable to have 5.0005 inch (127.012 mm) maximum inside diameter (ID) for 25% of the area.

2 It is acceptable to have 6.1235 inch (155.537 mm) minimum outside diameter (OD) for 25% of the area.

3 It is acceptable to have 1.2295 inch (31.230 mm) minimum distance between face sides for 25% of the
face side area.

4. Pitting, spalling, brinelling, or scoring on races and balls is not permitted.

206L_CRO_62_0069

Figure 62-64. Duplex Bearing — Damage Limits

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BHT-206L-CR&O-3

FLANGE BUSHING
(206-010-425-003)

DAMAGE LOCATION SYMBOLS

TYPE OF DAMAGE MAXIMUM DAMAGE AND REPAIR DEPTH

MECHANICAL 0.001 In. (0.025 mm) No damage 0.005 In. (0.13 mm)
BEFORE AND AFTER REPAIR

CORROSION 0.001 In. (0.025 mm) No damage 0.005 In. (0.13 mm)
BEFORE AND AFTER REPAIR

MAXIMUM AREA PER 1/4 circumference N/A 1/4 circumference

FULL DEPTH REPAIR x 1/2 length

NUMBER OF REPAIR AREAS One N/A One

EDGE CHAMFER 0.010 In (0.25 mm) No damage 0.010 In (0.25 mm)

BEFORE AND AFTER REPAIR x 45° x 45°

NUMBER OF EDGE CHAMFER One N/A One

DAMAGE

NOTE
No cracks permitted.

206L_CRO_62_0070

Figure 62-65. Collective Lever/Swashplate Support Bushing — Damage Limits

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Table 62-2. Swashplate Fluorescent Penetrant Overhaul Inspection Requirements

SPECIAL ACCEPTANCE
DESCRIPTION REFERENCE
REQUIREMENTS

Inner Ring 7, Figure 62-54 None

Pin 27, Figure 62-54 None

Outer Cap 34, Figure 62-54 None

Inner Cap 40, Figure 62-54 None

Outer Ring 42, Figure 62-54 None

Stud 1 44, Figure 62-54 None

NOTE:

1 Fluorescent penetrant visible portion of stud (44) installed in outer ring (42). Do not remove stud.

62-52. SWASHPLATE AND SUPPORT — REPAIR a. Line ream new bushings after installation.

Busing Line Ream Requirements

MATERIALS REQUIRED
Collect Lever 0.3750 to 0.3755 inch
Refer to BHT-ALL-SPM for specifications. (9.525 to 9.538 mm)

Collective Lever Not required

NUMBER NOMENCLATURE
Pivot Sleeve Not required
C-100 Chemical Film Material
Support Must pass 0.3754 inch
C-204 Epoxy Polyamide (9.535 mm) gauge pin
Primer

C-246 Epoxy Primer Coating 3. Replace sleeve bearings (1), spherical bearing
set (4), and duplex bearing (41) if found unserviceable.
C-423 Abrasive Paper
4. If pivot sleeve bushing bore exceeds the
C-500 Crocus Cloth maximum inner diameter limits, the bore may be
reamed and an oversize bushing installed.
1. Polish out acceptable damage with 400 to 600
grit abrasive paper (C-423). Acceptable damage on a. Line ream inner diameter bore 0.5725 to
0.5730 inch (14.5415 to 14.5542 mm).
hard anodized (glossy) surface shall be lightly
polished with fine crocus cloth (C-500). Damage
penetrating through hard anodized or tungsten carbide b. Break sharp edges and apply chemical film
finish requires replacement of part. material (C-100) to reworked surfaces
(BHT-ALL-SPM, Chapter 3).

2. Remove and replace unserviceable bushings (3, c. Coat oversize bushing (206-010-421-101)
9, 20, and 28, Figure 62-54) (BHT-ALL-SPM, outer diameter and sleeve bore with epoxy polyamide
Chapter 9). primer (C-204) and press bushing into sleeve bore.

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BHT-206L-CR&O-3

5. Apply chemical film material (C-100) to all
repaired and bare metal surfaces (BHT-ALLSPM,
Chapter 3).
6. Touch up repaired areas with one coat of epoxy
polyamide primer (C-204).
7. Restore primer on inner and outer rings (7 and
42) as shown in Figure 62-66.
c. Use fabricated workaid to press one seal (5)
into outer cap (3) so lip is pointed down. Press second
seal (5) into outer ring (12) with lip pointing down
(Figure 62-67, Detail A and Detail B).
d. Make sure grease fittings (4) are clear of seals
(5) so purging of duplex bearing (11) can be
accomplished after assembly.
NOTE

62-53. SWASHPLATE AND SUPPORT — Make sure duplex bearing is a matched

ASSEMBLY serial numbered set, and the V mark on
outer race is aligned when installed. The
V mark may be pointing in either direction.

MATERIALS REQUIRED 2. lnstall duplex bearing (11) in outer ring (12).

Refer to BHT-ALL-SPM for specifications.

a. Clean duplex bearing (11) thoroughly
NUMBER NOMENCLATURE (paragraph 62-49). Hand pack bearing with grease
(C-001). Apply a film of grease (C-001) to bore of outer
C-001 Grease ring (12).

C-100 Chemical Film Material

C-104 Corrosion Preventive CAUTION

Compound

C-204 Epoxy Polyamide DO NOT HEAT OUTER RING ABOVE

Primer 200°F (93°C). DAMAGE TO SEALS MAY
RESULT.
C-245 Polyurethane Coating
b. Apply heat lamp to outer ring (12) until hot to
C-308 Sealant
the touch.
C-325 Adhesive
c. Stack duplex bearing (11) with etched V on
C-405 Lockwire outer race aligned. Press duplex bearing firmly into
outer ring (12).

NOTE 3. Install two new sleeve bearings (13) into pivot

sleeve (14).
Early style seal is no longer available. A
new seal with improved lip is available.
a. To permit easy removal, allow end of sleeve
bearings to overlap the 1/8 inches (3.05 mm) holes in
1. lnstall new seals (5, Figure 62-67) in outer cap (3)
modified pivot sleeve (14) (Figure 62-55).
and outer ring (12).

b. Fill both 1/8 inches (3.05 mm) holes with

a. Fabricate a workaid 5.87 inches (149.1 mm) in sealant (C-308) to prevent entrance of water and
diameter for pressing seals (5) into position. foreign particles.

b. Apply a thin film of adhesive (C-325) to outer c. lnstall sleeve bearings (13, Figure 62-67) in
diameter of seals (5). grooves inside pivot sleeve (14).

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 BHT-206L-CR&O-3

INNER RING

4.9971 TO 4.9981 IN.

2
(126.927 TO 126.951 mm)
6.1264 TO 6.1274 IN.
(155.611 TO 155.636 mm) 2
1

SECTION A-A SECTION B-B

NOTES
1 Apply one coat of epoxy primer coating (C-246), 0.0002 to 0.0007 inch (0.006 to 0.017 mm) thick.

2 Dimension applies before primer.

3. Apply chemical film material (C-100) to repaired areas.

4. Touchup repaired areas with epoxy polyamide primer (C-204).

206L_CRO_62_0071

Figure 62-66. Inner and Outer Rings — Corrosion Protection

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BHT-206L-CR&O-3

206L_CRO_62_0059a

Figure 62-67. Outer and Inner Ring and Pivot Sleeve (Sheet 1 of 2)

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 BHT-206L-CR&O-3

Figure 62-67. Outer and Inner Ring and Pivot Sleeve (Sheet 2 of 2)

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BHT-206L-CR&O-3

206L_CRO_62_0065a

Figure 62-68. Swashplate Assembly Requirements (Sheet 1 of 2)

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 BHT-206L-CR&O-3

Figure 62-68. Swashplate Assembly Requirements (Sheet 2 of 2)

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BHT-206L-CR&O-3
d. Apply a film of corrosion preventive compound
(C-104) to mating surfaces of outer cap (3), outer ring
(12), and shank of bolts (1). Position outer cap on
outer ring so that grease fitting (4) is opposite stud on
outer ring.
e. lnstall eight bolts (1) and countersunk washers
(2). Make sure countersunk side of washers is next to
bolt heads. Do not torque at this time.
4. Assemble outer ring (12) and pivot sleeve (14) to
inner ring (22).
a. Apply a film of grease (C-001) to shaft of inner
ring (22) where it will mate with duplex bearing (11).
Apply a light coat of corrosion preventive compound
(C-104) to shank of bolts (20).
b. Support inner ring (22) on wooden blocks to
allow pivot sleeve (14) to hang free when installed.
Position two lower halves of bearing set (8) around
lower portion of spherical feature of pivot sleeve, then
insert into inner ring. Make sure bearing split lines are
oriented 90° from inner ring slots.
CAUTION
SU PP LY A DDITIONA L PA DDING AS
REQUIRED TO PREVENT DAMAGE TO
COMPONENTS DURING APPLICATION
OF TORQUE.
c. Align slots in pivot sleeve (14) with bolt holes
in shaft of inner ring (22). Insert a new packing (21) on
bolts (20) and install through inner ring and pivot
sleeve. From inside of pivot sleeve, position slider
bearings (16) and bushings (17) into slots of pivot
sleeve and onto bolts. Install nuts (18) and torque 60
to 85 inch-pounds (6.8 to 9.6 Nm).
d. Install cotter pins (19) into nuts (18) and bolts
(20). Bend and trim cotter pin tangs so ends will not
contact pivot sleeve (14), slider bearings (16), or
support when installed.
CAUTION
MAKE SURE LIP OF SEAL DOES NOT
ROLL UNDER DURING INSTALLATION.
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e. Carefully position outer ring (12) and duplex
bearing (11) over inner ring (22). Press inner race of
duplex bearing onto inner ring until bearing is firmly
seated on shoulder of inner ring. Use care not to
damage lip of seal (5) in outer ring (Figure 62-67,
Detail A and Detail B).
f. Install inner cap (10), laminated shims (9), and
top half of bearing set (8).
(1) Apply a small bead of adhesive (C-325)
to mating surfaces of inner cap (10) and inner ring
(22).
(2) Install inner cap (10) to top of inner ring
(22) and align bolt holes. Align index marks if
applicable.
(3) Install full laminated shims (9) to inner
cap (10), or use same amount of shims as removed
during disassembly. Shims may be changed during
friction adjustment (paragraph 62-54).
(4) Install top half of bearing set (8) to
laminated shims (9), inner cap (10), and inner ring
(22). Align index marks if applicable.
(5) Carefully start eight bolts (6) with
countersunk washers (7) into threaded holes of inner
ring (22). Make sure countersunk side of washer is
next to bolt heads. Tighten bolts evenly to a torque of
50 to 70 inch-pounds (5.65 to 7.91 Nm).
NOTE
Initial torque should be 50 inch-pounds
(5.65 Nm), which will permit minor
adjustment later.
(6) Tighten eight bolts (1) in outer cap (3)
evenly until reaching a torque of 50 to 70 inch-pounds
(5.65 to 7.91 Nm). Bolts (1 and 6) will be lockwired
after friction adjustment (paragraph 62-54).
g. Verify outer ring (12) will rotate on inner ring
(22) through 360° of rotation in both directions with
moderate friction and no rough spots.
ECCN 9E991
 BHT-206L-CR&O-3

b. Check and adjust swashplate friction

(paragraph 62-54).
CAUTION
c. Purge lubricate swashplate and support
PROTECT SUPPORT FROM DAMAGE assembly at grease fitting with grease (C-001).
BY SLEEVE. Remove excess grease.

5. Carefully position outer ring (1, Figure 62-69),
inner ring (2), and pivot sleeve (3) onto support (16).
lnstall collective lever (7).
a. Make sure serviceable bushings (8, 14, and
17) are installed in collective lever (7), collective lever
link (15), and support (16).
b. Apply a film of corrosion preventive compound
(C-104) to shank of bolts (12 and 21)
7. Refinish swashplate and support assembly as
follows:
a. Mask all bearings, bushings, and all hard
anodized or tungsten carbide surfaces with masking
tape to prevent contact with paint.
b. Treat all bare aluminum surfaces with
chemical film material (C-100) (BHT-ALLSPM,
Chapter 3).

c. Apply one spray coat of epoxy polyamide

c. Insert spacers (13) into collective lever link primer (C-204) and two spray coats of polyurethane
(15) and position between center bushings in coating (C-245) to swashplate and support assembly.
collective lever (7). Install bolt (12), aluminum washers
(6), and nut (5) through lever and link. Torque nut 95 to
62-54. SWASHPLATE AND SUPPORT —
110 inch-pounds (10.74 to 12.42 Nm) and secure with
FRICTION ADJUSTMENT
cotter pin (4).

d. Position collective lever (7) and collective

MATERIALS REQUIRED
lever link (15) to support (16). Flat side of lever must
be up. lnstall bolt (21), aluminum washer (18), and nut
Refer to BHT-ALL-SPM for specifications.
(19) through support and link. Torque nut 95 to
110 inch-pounds. (10.74 to 12.42 Nm) and secure with NUMBER NOMENCLATURE
cotter pin (20).
C-405 Lockwire
e. Position collective lever (7) to pivot sleeve (3)
and install pins (9), screws (10), and aluminum
1. Check swashplate friction as follows:
washers (11). Torque screws 20 to 25 inch-pounds
(2.3 to 2.8 Nm) and secure to lever with lockwire
(C-405). a. Bolt support assembly (9, Figure 62-71) to
workbench using swashplate and support mounting
workaid.
f. For assemblies 206-010-450-101/-121 and
-123, position collective lever (7) to pivot sleeve (3)
and install pins (9), bolts (22), washers (23), and nuts b. Place swashplate inner ring (2) horns to
(24). Torque nuts 20 to 30 inch-pounds (2.26 to 3.38 installed position (both full forward). Push one horn full
Nm) down.

c. Attach a spring scale to inner ring horn

6. Fasten swashplate and support assembly to
bearing. Pull spring scale vertical to horn with steady
swashplate and support mounting workaid
load to cause ring to tilt on spherical surface.
(Figure 62-70) with bolts and nuts.
Disregard initial breakaway value and record minimum
and maximum scale readings during rotation. Repeat
a. Check collective lever (7) for smooth vertical operation several times to ensure accurate readings.
movement without binding or hard spots. Repeat procedure for other inner ring horn.

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BHT-206L-CR&O-3

SEE DETAIL A

9
10

11

22 7
23
24
9
DETAIL A
(FOR 206-010-450-101, -121 AND
-123 ASSEMBLIES ONLY)

206L_CRO_62_0061

Figure 62-69. Collect Lever and Support

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 BHT-206L-CR&O-3

Figure 62-70. Swashplate Support Mounting Workaid

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BHT-206L-CR&O-3

4
SWASHPLATE 5
FRICTION SHOULD BE
15 TO 32 LBS 6
1. Collective lever (66.8 TO 142.3 N)
2. Inner ring 7
3. Outer ring
SPRING SCALE
4. Bearing set
3
5. Bolt
6. Countersunk washer 10
7. Laminated shim
8. Inner cap 8
9. Support assembly
10. Pivot sleeve
2

1 9

206L_CRO_62_0063

Figure 62-71. Swashplate Friction Adjustment

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 BHT-206L-CR&O-3

d. Swashplate friction shall be 15 to 32 pounds

(66.73 to 142.34 N). High and low friction readings at
either location shall be within 4 pounds (17.8 N). For LAMINATIONS
TOTAL
example, if minimum is 25 pounds (111.2 N), SHIM
THICKNESS
maximum reading shall not exceed 29 pounds 45° CUT 90° CUT
(128.9 N), regardless of location.
180° 0.041 inch 0.003 inch 0.002 inch
2. If friction readings vary more than 4 pounds (1.04 mm) (0.08 mm) (0.05 mm)
(17.79 N) at either location, bearing set may require
cleaning or replacement, or uniball may be worn or e. Install required laminated shims (7) and
damaged. reinstall bearing set (4). Align index marks and install
eight bolts (5) and countersunk washers (6). Make
3. Repeat friction checks three or more times for sure countersunk side of washers is toward bolt head.
each inner ring horn to make sure accurate values are
obtained. If the forward, aft, and lateral friction values
vary appreciably, it may be suspected bearing
assemblies are dragging and overhaul of swashplate CAUTION
and support assembly will be required.

4. Adjust swashplate and support assembly friction. DO NOT EXCEED 70 INCH-POUNDS

(7.91 NM) TORQUE ON BOLTS.

CAUTION
BEARING SET CAN BE INSTALLED IN
EIGHT DIFFERENT POSITIONS.
BEARING SHALL BE INDEX MARKED
BEFORE REMOVAL AND REINSTALLED
IN THE EXACT SAME POSITION FROM
WHICH REMOVED TO ENSURE
S MO O T H NE S S O F O P E R AT IO N O F
CYCLIC FLIGHT CONTROLS.
NOTE
If bolts (5) are torqued to the minimum
value of 50 inch-pounds (5.65 Nm) to
obtain the initial 15 to 32 pounds (66.73 to
142.34 N) friction, it will permit
readjustment by simply retorquing bolts to
maintain friction.
f. Tighten bolts (5) evenly until a final torque of
50 inch-pounds (5.65 Nm) is attained.

a. Use felt tipped pen to index mark position of
top bearing set (4) and inner cap (8), to outer ring (3)
and pivot sleeve (10).
b. Cut and remove lockwire from the eight
bolts (5) securing bearing set (4). Remove bolts and
countersunk washers (6).
g. Check friction again with a spring scale
(step 1). If required, repeat adjustment of laminated
shim (7) thickness until required swashplate friction is
achieved.
h. Secure heads of bolts (5) together with
lockwire (C-405).

c. Remove bearing set (4) and laminated shim

(7). 62-55. SWASHPLATE COLLAR SET

62-56. SWASHPLATE COLLAR SET —

NOTE
INSPECTION
Two shims (180° each) of equal thickness
are used to adjust swashplate friction. 1. Inspect collar set for damage (Figure 62-72).
d. To increase friction, remove laminations from
laminated shim (7). To reduce friction, add lamination 2. Inspect two steel bushings for looseness and
or use thicker laminated shim. damage.

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BHT-206L-CR&O-3

Figure 62-72. Collar Set — Damage Limits

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 BHT-206L-CR&O-3

62-57. SWASHPLATE COLLAR SET — REPAIR 62-60. SWASHPLATE IDLER LEVER — REPAIR

MATERIALS REQUIRED MATERIALS REQUIRED

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

NUMBER NOMENCLATURE NUMBER NOMENCLATURE

C-204 Epoxy Polyamide C-305 Aliphatic Naphtha

Primer
C-309 MEK
C-305 Aliphatic Naphtha
C-313 Adhesive
C-309 MEK
C-407 Abrasive Pad
C-423 Abrasive Paper
C-423 Abrasive Paper

1. Polish out acceptable damage with 400 grit C-516 Clean Cloth
abrasive paper (C-423).
1. Polish out acceptable damage with 400 grit
2. Replace loose or damaged bushings. abrasive paper (C-423).

a. Press out bushings. Clean collar set bores
with cloth dampened with MEK (C-309) or aliphatic
naphtha (C-305).
b. Apply epoxy polyamide primer (C-204) to
bushings and collar set mating surfaces.
c. Press bushings into bores while primer is still
wet. Remove squeezed out primer.
3. Refinish collar set (paragraph 62-64).
62-58. SWASHPLATE IDLER LEVER
62-59. SWASHPLATE IDLER LEVER
INSPECTION
1. lnspect idler lever for damage (Figure 62-73).
2. lnspect four teflon bushings for looseness or
teflon penetration. If fabric fibers are beginning to
show or fabric is damaged, replace bushings.
2. For model 206L, 206L1, and 206L3 helicopters
Pre TB 206L-99-199 and model 206L4 helicopters S/N
52001 and 52226 Pre TB 206L-99-199, replace loose
or unserviceable bushings (15, Figure 62-74) as
follows:
a. Press out and discard bushings (15).
b. Remove remaining adhesive with an abrasive
pad (C-407).
c. Clean the bushing bores of the idler lever (14)
with a clean cloth (C-516) moistened with aliphatic
naphtha (C-305).
— d. Apply adhesive (C-313) to the outer diameter
of the bushings (15) and to the bushing bores of the
idler lever (14).
e. Install the bushings (15) on the idler lever (14)
and keep a 2.625 inches (66.68 mm) minimum
distance between opposite flanges, as shown in
Figure 62-74, until the adhesive has cured.

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BHT-206L-CR&O-3

Figure 62-73. Idler Lever — Damage Limits

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 BHT-206L-CR&O-3

9 A
8 10 A 13
11

7 11 12 A

A 2
3
3

A 4
1
A 5

6 8
7
9

GAP GAP

1 13

5
VIEW
LOOKING DOWN

(FOR 206L, 206L1, AND 206L3 HELICOPTERS POST TB 206L-99-199,

206L4 HELICOPTERS S/N 52001 AND 52226 POST TB 206L-99-199,
AND 206L4 HELICOPTERS S/N 52227 AND SUBSEQUENT)

206L_CRO_62_0072a

Figure 62-74. Idler Lever Bushings — Replacement (Sheet 1 of 2)

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BHT-206L-CR&O-3

14

2.625 IN. (66.68 mm)

MINIMUM DISTANCE
(2 PLACES)
A
15
TYPICAL
4 PLACES VIEW
LOOKING DOWN

(FOR 206L, 206L1, AND 206L3 HELICOPTERS PRE TB 206L-99-199

AND 206L4 HELICOPTERS S/N 52001 AND 52226 PRE TB 206L-99-199)

1. Collar set
2. Bushing
3. Bushing
4. Bushing
5. Shim
6. Bolt
7. Idler lever
8. Bolt
9. Shim
10. Bushing
11. Bushing
12. Bushing
13. Idler link
14. Idler link
15. Bushing

A ADHESIVE (C-313)

206L_CRO_62_0072b

Figure 62-74. Idler Lever Bushings — Replacement (Sheet 2 of 2)

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3. For model 206L, 206L1, and 206L3 helicopters
Post TB 206L-99-199, model 206L4 helicopters S/N
52001 and 52226 Post TB 206L-99-199, and model
206L4 helicopters S/N 52227 and subsequent, replace
loose or unserviceable bushings (2, 4, 10, and 12) as
follows:
a. Press out and discard bushings (2, 4, 10,
and 12).
b. Remove remaining adhesive with an abrasive
pad (C-407).
c. Clean the bushing bores of the idler lever (7)
with a clean cloth (C-516) moistened with aliphatic
naphtha (C-305).
d. Temporarily install two new bushings (2 and 4)
on the lugs on one side of the idler lever (7).
e. Install the bushing (3) or spacer, as applicable,
in each of the new bushings (2 and 4).
f. Install the collar set (1) between the lugs of
the idler lever (7) and install the bolt (6).
g. Measure and record the gap between a
flanged bushings in the collar set (1) and the mating
bushing (2 or 4) in the idler lever (7), as shown in
Figure 62-74.
h. Calculate and record the required thickness
for a new shim (5) as follows:
Thickness (inch) = Gap - 0.004
NOTE
Each lamination of the shim (5) is
0.002 inch (0.05 mm) thick.
i. Peel the new laminated shim (5) to the
previously calculated thickness.
j. Disassemble the idler lever (7).
k. Apply adhesive (C-313) on both sides of the
shim (5).
ECCN 9E991
BHT-206L-CR&O-3
l. Install the shim (5) under the flange of the
bushing (4).
m. Apply adhesive (C-313) to the outer diameter
of the bushing (4).
n. Install the assembly of the bushing (4) and
shim (5) on the lug of the idler lever (7) that will be
adjacent to the threads of the bolt (6), as shown in
Figure 62-74.
o. Apply adhesive (C-313) to the outer diameter
of the opposite bushing (2).
p. Install the opposite bushing (2) on the idler
lever (7).
q. Identify the collar set side of the idler lever (7)
with a non-permanent marker.
r. Do step d through step j on the opposite lugs
of the idler lever (7) and use the idler link (13) as an
alternative to the collar set (1).
s. Apply adhesive (C-313) on both sides of the
new laminated shim (9).
t. Install the shim (9) under the flange of the
bushing (10).
u. Apply adhesive (C-313) to the outer diameter
of the bushing (10).
v. Install the assembly of the bushing (10) and
shim (9) on the lug of the idler lever (7) that will be
adjacent to the head of the bolt (8), as shown in
Figure 62-74
w. Apply adhesive (C-313) to the outer diameter
of the opposite bushing (12).
x. Install the opposite bushing (12) on the idler
lever (7).
y. Assemble the swashplate drive assembly
before the adhesive cures per the instructions in
Chapter 62 of the applicable Maintenance Manual
(MM). Make sure to install the idler lever (7) with the
marking on the collar set side.
4. Refinish idler lever (paragraph 62-64).
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62-61. SWASHPLATE IDLER LINK b. Clean idler link bores with MEK (C-309) or
aliphatic naphtha (C-305). Make sure all adhesive is
62-62. SWASHPLATE IDLER LINK — removed.
INSPECTION
c. Apply epoxy polyamide primer (C-204) to
bushing and idler link mating surfaces.
1. Inspect idler link for damage (Figure 62-75).
d. Press bushings into bores while primer is still
2. Inspect spherical bearing for axial or radial wear. wet. Remove squeezed out primer.
If wear exceeds 0.010 inch (0.254 mm), replace
bearing (BHT-ALL-SPM, Chapter 9). 3. Refinish idler link (paragraph 62-64).

3. Inspect two steel bushings for looseness and 62-64. SWASHPLATE COLLAR, IDLER LEVER,
damage. AND IDLER LINK — REFINISH

62-63. SWASHPLATE IDLER LINK — REPAIR MATERIALS REQUIRED

Refer to BHT-ALL-SPM for specifications.

MATERIALS REQUIRED
NUMBER NOMENCLATURE
Refer to BHT-ALL-SPM for specifications.
C-100 Chemical Film Material
NUMBER NOMENCLATURE
C-204 Epoxy Polyamide
C-204 Epoxy Polyamide Primer
Primer
C-245 Polyurethane Coating
C-305 Aliphatic Naphtha
C-426 Masking Tape
C-309 MEK
1. Mask bearing and bushings with masking tape
C-423 Abrasive Paper (C-426).

1. Polish out acceptable damage with 400 grit 2. Apply chemical film material (C-100) to bare
abrasive paper (C-423). surfaces (BHT-ALL-SPM, Chapter 3).

3. Apply one spray coat of epoxy polyamide primer

2. Replace loose or unserviceable bushings.
(C-204) and two spray coats of light gull gray
polyurethane coating (C-245) (BHT-ALL-SPM,
a. Press out bushings. Chapter 4).

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Figure 62-75. Idler Link — Damage Limits

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