BHT-412-MM-8

CHAPTER 67 — FLIGHT CONTROLS

CONTENTS — MAINTENANCE PROCEDURES

Paragraph Chapter/Section Page

Number Title Number Number

FLIGHT CONTROL SYSTEMS (PRIOR TO S/N 36087)

67-1 Introduction ...................................................................... 67-00-00 11

67-2 Troubleshooting ......................................................... 67-00-00 11

FLIGHT CONTROLS RIGGING

67-3 Flight Control Rigging ....................................................... 67-00-00 13

67-4 Collective Controls ..................................................... 67-00-00 13
67-5 Cyclic Controls ........................................................... 67-00-00 17
67-6 Cyclic Controls (Primary Method) ........................ 67-00-00 17
67-7 Cyclic Controls (Alternate Method) ...................... 67-00-00 33
67-8 Cyclic Position Sensors ....................................... 67-00-00 42
67-9 Anti-Torque Controls .................................................. 67-00-00 47
67-10 Aerodynamically Actuated Elevator ........................... 67-00-00 54

COLLECTIVE FLIGHT CONTROLS

67-11 Collective Controls ........................................................... 67-00-00 61

67-12 Hydraulic Servo Cylinder Boot ................................... 67-00-00 61
67-13 Removal............................................................... 67-00-00 61
67-14 Inspection ............................................................ 67-00-00 61
67-15 Installation............................................................ 67-00-00 61
67-16 Hydraulic Cylinder Extension Tube ............................ 67-00-00 61
67-17 Removal............................................................... 67-00-00 61
67-18 Inspection ............................................................ 67-00-00 61
67-19 Installation............................................................ 67-00-00 65
67-20 Hydraulic Cylinder Extension Universal ..................... 67-00-00 65
67-21 Removal............................................................... 67-00-00 65
67-22 Inspection ............................................................ 67-00-00 65
67-23 Installation............................................................ 67-00-00 65
67-24 Piston Rod Clevis....................................................... 67-00-00 65
67-25 Removal.............................................................. 67-00-00 65
67-26 Inspection ............................................................ 67-00-00 67
67-27 Installation............................................................ 67-00-00 67
67-28 Servo Valve Balance Spring ...................................... 67-00-00 67
67-29 Removal............................................................... 67-00-00 67
67-30 Servo Valve Balance Spring — Inspection .......... 67-00-00 70
67-31 Servo Valve Balance Spring — Installation ......... 67-00-00 70
67-32 Collective Flight Control Cylinder ............................... 67-00-00 70
67-33 Collective Flight Control Cylinder — Removal.... 67-00-00 70
67-34 Collective Flight Control Cylinder — Inspection.. 67-00-00 70
67-35 Collective Flight Control Cylinder — Installation. 67-00-00 70
67-36 Left Cyclic and Collective Boost Support ................... 67-00-00 71
67-37 Left Cyclic and Collective Boost Support
— Removal .......................................................... 67-00-00 71

67-00-00
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CONTENTS — MAINTENANCE PROCEDURES (CONT)

Paragraph Chapter/Section Page

Number Title Number Number

67-38 Left Cyclic and Collective Boost Support

— Inspection........................................................ 67-00-00 71
67-39 Left Cyclic and Collective Boost Support
— Installation ....................................................... 67-00-00 74A
67-40 Adjustable Rod End Tube .......................................... 67-00-00 74A
67-41 Adjustable Rod End Tube — Removal ................ 67-00-00 74A
67-42 Adjustable Rod End Tube — Inspection.............. 67-00-00 74A
67-43 Installation ........................................................... 67-00-00 77
67-44 Pitch Control Bellcrank............................................... 67-00-00 77
67-45 Removal .............................................................. 67-00-00 77
67-46 Inspection ............................................................ 67-00-00 77
67-47 Installation ........................................................... 67-00-00 77
67-48 Collective Force Gradient........................................... 67-00-00 77
67-49 Removal .............................................................. 67-00-00 77
67-50 Inspection ............................................................ 67-00-00 77
67-51 Repair .................................................................. 67-00-00 81
67-52 Installation ........................................................... 67-00-00 81
67-53 Collective Bellcrank.................................................... 67-00-00 82
67-54 Removal .............................................................. 67-00-00 82
67-55 Inspection ............................................................ 67-00-00 82
67-56 Installation ........................................................... 67-00-00 82
67-57 Collective Link ............................................................ 67-00-00 82
67-58 Removal .............................................................. 67-00-00 82
67-59 Inspection ............................................................ 67-00-00 82
67-60 Installation ........................................................... 67-00-00 82
67-61 Collective Rotary Actuator.......................................... 67-00-00 82
67-62 Removal .............................................................. 67-00-00 82
67-63 Inspection ............................................................ 67-00-00 85
67-64 Repair .................................................................. 67-00-00 85
67-65 Installation ........................................................... 67-00-00 85
67-66 Adjustable Collective Control Tube ............................ 67-00-00 85
67-67 Removal .............................................................. 67-00-00 85
67-68 Inspection ............................................................ 67-00-00 85
67-69 Installation ........................................................... 67-00-00 85
67-70 Control Lever and Stop Assembly.............................. 67-00-00 88
67-71 Removal .............................................................. 67-00-00 88
67-72 Inspection ............................................................ 67-00-00 88
67-73 Installation ........................................................... 67-00-00 88
67-74 Pilot Collective Boot ................................................... 67-00-00 88A
67-75 Removal .............................................................. 67-00-00 88A
67-76 Inspection ............................................................ 67-00-00 88A
67-77 Installation ........................................................... 67-00-00 90
67-78 Collective Jackshaft ................................................... 67-00-00 90
67-79 Removal .............................................................. 67-00-00 90
67-80 Inspection ............................................................ 67-00-00 93
67-81 Installation ........................................................... 67-00-00 93
67-82 Collective Transducers............................................... 67-00-00 95
67-83 Removal (Helicopters S/N 33001 through 36086) 67-00-00 95
67-84 Removal (Helicopters S/N 36087 and Subsequent) 67-00-00 95

67-00-00
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CONTENTS — MAINTENANCE PROCEDURES (CONT)

Paragraph Chapter/Section Page

Number Title Number Number

67-85 Inspection ............................................................ 67-00-00 98

67-86 Repair .................................................................. 67-00-00 98
67-87 Installation............................................................ 67-00-00 98
67-88 Installation............................................................ 67-00-00 98
67-88A Adjustment (Helicopters 36037 and Subsequent 67-00-00 98A
67-89 Friction Clamp ............................................................ 67-00-00 99
67-90 Removal............................................................... 67-00-00 99
67-91 Inspection ............................................................ 67-00-00 99
67-92 Repair .................................................................. 67-00-00 99
67-93 Installation............................................................ 67-00-00 99

CYCLIC FLIGHT CONTROLS

67-94 Cyclic Controls.................................................................. 67-00-00 103

67-95 Hydraulic Cylinder Extension Tube ............................ 67-00-00 103
67-96 Removal............................................................... 67-00-00 103
67-97 Inspection ............................................................ 67-00-00 106
67-98 Installation............................................................ 67-00-00 106
67-99 Hydraulic Servo Cylinder Boot ................................... 67-00-00 106
67-100 Removal............................................................... 67-00-00 106
67-101 Inspection ............................................................ 67-00-00 106
67-102 Installation............................................................ 67-00-00 106
67-103 Hydraulic Cylinder Extension Universal ..................... 67-00-00 106
67-104 Removal............................................................... 67-00-00 108
67-105 Inspection ............................................................ 67-00-00 108
67-106 Bearing Replacement .......................................... 67-00-00 108
67-107 Installation............................................................ 67-00-00 108
67-108 Left Cyclic Piston Rod Clevis ..................................... 67-00-00 108
67-109 Removal............................................................... 67-00-00 108
67-110 Inspection ............................................................ 67-00-00 108
67-111 Repair .................................................................. 67-00-00 108
67-112 Installation............................................................ 67-00-00 108
67-113 Right Cyclic Piston Rod Clevis................................... 67-00-00 110
67-114 Removal............................................................... 67-00-00 110
67-115 Inspection ............................................................ 67-00-00 110
67-116 Installation............................................................ 67-00-00 110
67-117 Left Cyclic Flight Control Cylinder .............................. 67-00-00 112
67-118 Left Cyclic Flight Control Cylinder — Removal.... 67-00-00 112
67-119 Left Cyclic Flight Control Cylinder — Inspection.. 67-00-00 112
67-120 Left Cyclic Flight Control Cylinder — Installation. 67-00-00 112
67-121 Right Cyclic Flight Control Cylinder............................ 67-00-00 116A
67-122 Right Cyclic Flight Control Cylinder — Removal . 67-00-00 116A
67-123 Right Cyclic Flight Control Cylinder — Inspection 67-00-00 116B
67-124 Right Cyclic Flight Control Cylinder — Installation 67-00-00 116B
67-125 Right Cyclic Boost Cylinder Support .......................... 67-00-00 120
67-126 Right Cyclic Boost Cylinder Support — Removal 67-00-00 120
67-127 Inspection ............................................................ 67-00-00 121
67-128 Installation............................................................ 67-00-00 121
67-129 Cyclic Control Tubes .................................................. 67-00-00 121

67-00-00
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CONTENTS — MAINTENANCE PROCEDURES (CONT)

Paragraph Chapter/Section Page

Number Title Number Number

67-130 Removal .............................................................. 67-00-00 121

67-131 Inspection ............................................................ 67-00-00 124
67-132 Repair .................................................................. 67-00-00 124
67-133 Installation ........................................................... 67-00-00 124
67-134 Mixing Lever Assembly .............................................. 67-00-00 124
67-135 Removal .............................................................. 67-00-00 124
67-136 Inspection ............................................................ 67-00-00 124
67-137 Repair .................................................................. 67-00-00 124
67-138 Installation ........................................................... 67-00-00 124
67-139 Fore and Aft Proximity Switch .................................... 67-00-00 126
67-140 Removal .............................................................. 67-00-00 126
67-141 Inspection ............................................................ 67-00-00 126
67-142 Repair .................................................................. 67-00-00 126
67-143 Installation ........................................................... 67-00-00 126
67-144 Lateral Proximity Switch............................................. 67-00-00 126
67-145 Removal .............................................................. 67-00-00 126
67-146 Inspection ............................................................ 67-00-00 126
67-147 Repair .................................................................. 67-00-00 126
67-148 Installation ........................................................... 67-00-00 128
67-149 Lateral Series Actuator............................................... 67-00-00 128
67-150 Removal .............................................................. 67-00-00 128
67-151 Inspection ............................................................ 67-00-00 128
67-152 Repair .................................................................. 67-00-00 128
67-153 Installation ........................................................... 67-00-00 128
67-154 Longitudinal Series Actuator ...................................... 67-00-00 128
67-155 Removal .............................................................. 67-00-00 128
67-156 Inspection ............................................................ 67-00-00 128
67-157 Repair .................................................................. 67-00-00 131
67-158 Installation ........................................................... 67-00-00 131
67-159 Rotary Actuator (Lateral Cyclic) ................................. 67-00-00 131
67-160 Removal .............................................................. 67-00-00 131
67-161 Inspection ............................................................ 67-00-00 131
67-162 Installation ........................................................... 67-00-00 131
67-163 Rotary Actuator (Fore and Aft Cyclic) ........................ 67-00-00 131
67-164 Removal .............................................................. 67-00-00 131
67-165 Inspection ............................................................ 67-00-00 134
67-166 Installation ........................................................... 67-00-00 134
67-167 Force Gradient (Fore and Aft Cyclic) ......................... 67-00-00 134
67-168 Removal .............................................................. 67-00-00 134
67-169 Inspection ............................................................ 67-00-00 136
67-170 Repair .................................................................. 67-00-00 136
67-171 Installation ........................................................... 67-00-00 137
67-172 Force Gradient (Lateral Cyclic) .................................. 67-00-00 138
67-173 Force Gradient (Lateral Cyclic) — Removal ........ 67-00-00 138
67-174 Force Gradient (Lateral Cyclic) — Inspection...... 67-00-00 138
67-175 Force Gradient (Lateral Cyclic) — Repair............ 67-00-00 138
67-176 Force Gradient (Lateral Cyclic) — Installation ..... 67-00-00 138
67-177 Transducers (Fore and Aft Cyclic) ............................. 67-00-00 141
67-178 Transducers (Fore and Aft Cyclic) — Removal ... 67-00-00 141

67-00-00
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CONTENTS — MAINTENANCE PROCEDURES (CONT)

Paragraph Chapter/Section Page

Number Title Number Number

67-179 Transducers (Fore and Aft Cyclic) — Inspection . 67-00-00 141

67-180 Transducers (Fore and Aft Cyclic) — Repair....... 67-00-00 141
67-181 Transducers (Fore and Aft Cyclic) — Installation 67-00-00 141
67-182 Jackshaft (Fore and Aft) Tube and Lever
Assembly (Right Side)................................................ 67-00-00 143
67-183 Removal............................................................... 67-00-00 143
67-184 Inspection ............................................................ 67-00-00 143
67-185 Installation............................................................ 67-00-00 143
67-186 Jackshaft (Fore and Aft) Tube and Lever
Assembly (Left Side) .................................................. 67-00-00 146
67-187 Removal............................................................... 67-00-00 146
67-188 Inspection ............................................................ 67-00-00 148
67-189 Installation............................................................ 67-00-00 148
67-190 Jackshaft Housing...................................................... 67-00-00 150
67-191 Removal............................................................... 67-00-00 150
67-192 Inspection ............................................................ 67-00-00 150
67-193 Installation............................................................ 67-00-00 150
67-194 Arm Assembly ............................................................ 67-00-00 150
67-195 Removal............................................................... 67-00-00 150
67-196 Inspection ............................................................ 67-00-00 152
67-197 Installation............................................................ 67-00-00 152
67-198 Lateral Transducers (Cyclic Controls)........................ 67-00-00 155
67-199 Removal............................................................... 67-00-00 155
67-200 Inspection ............................................................ 67-00-00 155
67-201 Repair .................................................................. 67-00-00 155
67-202 Installation............................................................ 67-00-00 155
67-203 Cyclic Stick Boot ........................................................ 67-00-00 155
67-204 Removal............................................................... 67-00-00 155
67-205 Inspection ............................................................ 67-00-00 155
67-206 Installation............................................................ 67-00-00 155
67-207 Pilot Cyclic Control Stick Assembly............................ 67-00-00 155
67-208 Removal............................................................... 67-00-00 155
67-209 Inspection ............................................................ 67-00-00 158
67-210 Installation............................................................ 67-00-00 158

ANTI-TORQUE CONTROLS

67-211 Anti-Torque Controls ........................................................ 67-00-00 161

67-212 Pitch Change Control Bellcrank ................................. 67-00-00 161
67-213 Removal............................................................... 67-00-00 161
67-214 Inspection ............................................................ 67-00-00 161
67-215 Repair .................................................................. 67-00-00 161
67-216 Installation............................................................ 67-00-00 161
67-217 Anti-Torque Control Tube Guides .............................. 67-00-00 161
67-218 Removal............................................................... 67-00-00 161
67-219 Inspection ............................................................ 67-00-00 161
67-220 Installation............................................................ 67-00-00 161
67-221 Flight Control Tubes and Bellcranks .......................... 67-00-00 165
67-222 Removal............................................................... 67-00-00 165

67-00-00
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CONTENTS — MAINTENANCE PROCEDURES (CONT)

Paragraph Chapter/Section Page

Number Title Number Number

67-223 Inspection ............................................................ 67-00-00 165

67-224 Installation ........................................................... 67-00-00 165
67-225 Walking Beam Support Assembly.............................. 67-00-00 165
67-226 Removal .............................................................. 67-00-00 165
67-227 Inspection and Repair.......................................... 67-00-00 165
67-228 Installation ........................................................... 67-00-00 165
67-229 Control Cylinder ........................................................ 67-00-00 165
67-230 Removal .............................................................. 67-00-00 165
67-231 Inspection ............................................................ 67-00-00 166
67-232 Repair .................................................................. 67-00-00 168
67-233 Installation ........................................................... 67-00-00 168
67-234 Series Actuator........................................................... 67-00-00 168
67-235 Removal .............................................................. 67-00-00 168
67-236 Inspection ............................................................ 67-00-00 169
67-237 Installation ........................................................... 67-00-00 169
67-238 Walking Beam and Friction Clamp............................. 67-00-00 172
67-239 Removal .............................................................. 67-00-00 172
67-240 Inspection ............................................................ 67-00-00 172
67-241 Repair .................................................................. 67-00-00 172
67-242 Installation ........................................................... 67-00-00 172
67-243 Magnetic Brake .......................................................... 67-00-00 172
67-244 Removal .............................................................. 67-00-00 174
67-245 Inspection ............................................................ 67-00-00 174
67-246 Repair .................................................................. 67-00-00 174
67-247 Installation ........................................................... 67-00-00 174
67-248 Control Transducer .................................................... 67-00-00 175
67-249 Removal .............................................................. 67-00-00 175
67-250 Inspection ............................................................ 67-00-00 175
67-251 Repair .................................................................. 67-00-00 175
67-252 Installation ........................................................... 67-00-00 175
67-253 Force Gradient ........................................................... 67-00-00 175
67-254 Removal .............................................................. 67-00-00 177
67-255 Inspection ............................................................ 67-00-00 177
67-256 Repair .................................................................. 67-00-00 177
67-257 Force Gradient — Installation .............................. 67-00-00 177
67-258 Pedal Adjuster Assembly ........................................... 67-00-00 178A
67-259 Pedal Adjuster Assembly — Removal ................. 67-00-00 178A
67-260 Pedal Adjuster Assembly — Inspection............... 67-00-00 178A
67-261 Installation ........................................................... 67-00-00 180
67-262 Pedals ........................................................................ 67-00-00 180
67-263 Removal .............................................................. 67-00-00 180
67-264 Inspection ............................................................ 67-00-00 180
67-265 Installation ........................................................... 67-00-00 180

AERODYNAMICALLY ACTUATED ELEVATOR

67-266 Aerodynamically Actuated Elevator .................................. 67-00-00 183

67-267 Description ................................................................. 67-00-00 183
67-268 Removal .............................................................. 67-00-00 183

67-00-00
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CONTENTS — MAINTENANCE PROCEDURES (CONT)

Paragraph Chapter/Section Page

Number Title Number Number

67-269 Inspection ............................................................ 67-00-00 183

67-270 Aerodynamically Actuated Elevator — Repair..... 67-00-00 185
67-271 Aerodynamically Actuated Elevator — Installation 67-00-00 186A
67-272 Elevator Control Tube ................................................ 67-00-00 188
67-273 Removal............................................................... 67-00-00 188
67-274 Inspection ............................................................ 67-00-00 188
67-275 Installation............................................................ 67-00-00 188

FLIGHT CONTROLS — DIGITAL AFCS

67-276 Digital AFCS Flight Controls (SN 36087 and

Subsequent) ..................................................................... 67-00-00 191
67-277 Description ................................................................. 67-00-00 191

FLIGHT CONTROLS RIGGING — S/N 36087 AND SUBSEQUENT

67-278 Flight Controls Rigging (S/N 36087 and Subsequent)...... 67-00-00 193
67-278A Collective Controls (S/N 36087 and Subsequent) ............ 67-00-00 193
67-278B Cyclic Controls (S/N 36087 and Subsequent) .................. 67-00-00 193
67-279 Anti-Torque Controls (SN 36087 and Subsequent) ......... 67-00-00 203

CYCLIC CONTROLS — DIGITAL AFCS

67-280 Cyclic Controls (SN 36087 and Subsequent) ................... 67-00-00 207
67-281 Description........................................................................ 67-00-00 207
67-282 Rotary Actuator (Fore and Aft Cyclic) ........................ 67-00-00 207
67-283 Removal............................................................... 67-00-00 207
67-284 Inspection ............................................................ 67-00-00 210
67-285 Installation............................................................ 67-00-00 210
67-286 Rotary Actuator (Lateral Cyclic) ................................. 67-00-00 210
67-287 Removal............................................................... 67-00-00 210
67-288 Inspection ............................................................ 67-00-00 210
67-289 Installation............................................................ 67-00-00 212
67-290 Force Gradient (Fore and Aft Cyclic) ......................... 67-00-00 212
67-291 Removal............................................................... 67-00-00 212
67-292 Inspection ............................................................ 67-00-00 212
67-293 Repair .................................................................. 67-00-00 212
67-294 Installation............................................................ 67-00-00 212
67-295 Force Gradient (Lateral Cyclic) .................................. 67-00-00 215
67-296 Removal............................................................... 67-00-00 215
67-297 Inspection ............................................................ 67-00-00 217
67-298 Repair .................................................................. 67-00-00 217
67-299 Installation............................................................ 67-00-00 217
67-300 Anti-Torque Controls (SN 36087 and Subsequent) .......... 67-00-00 219
67-301 Description ................................................................. 67-00-00 219
67-302 Anti-Torque Transducers ........................................... 67-00-00 219
67-303 Removal............................................................... 67-00-00 219
67-304 Inspection ............................................................ 67-00-00 219
67-305 Repair .................................................................. 67-00-00 219

67-00-00
ECCN EAR99 29 OCT 2009 Rev. 13 Page 7
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CONTENTS — MAINTENANCE PROCEDURES (CONT)

Paragraph Chapter/Section Page

Number Title Number Number

67-306 Installation ........................................................... 67-00-00 224

67-307 Anti-Torque Force Gradient ....................................... 67-00-00 224
67-308 Removal .............................................................. 67-00-00 224
67-309 Inspection ............................................................ 67-00-00 224
67-310 Repair .................................................................. 67-00-00 224
67-311 Installation ........................................................... 67-00-00 224
67-312 Anti-Torque Rotary Actuator ...................................... 67-00-00 225
67-313 Removal .............................................................. 67-00-00 225
67-314 Inspection ............................................................ 67-00-00 225
67-315 Repair .................................................................. 67-00-00 227
67-316 Installation ........................................................... 67-00-00 227
67-317 Anti-Torque Series Actuators ..................................... 67-00-00 227
67-318 Removal .............................................................. 67-00-00 227
67-319 Inspection ............................................................ 67-00-00 229
67-320 Installation ........................................................... 67-00-00 229

FIGURES

Figure Page
Number Title Number

67-1 Collective Rigging ...................................................................................... 14

67-1A Collective Controls (4-Axis Configuration) ................................................. 16C
67-2 Cyclic Rigging ............................................................................................ 19
67-3 Cyclic Rigging — Hydraulic Cylinders ....................................................... 23
67-4 Cyclic Rigging — Bellcrank Stops ............................................................. 24
67-5 Cyclic Rigging — Swashplate .................................................................... 27
67-6 Cyclic Rigging — Actuators ....................................................................... 29
67-7 Cyclic Rigging — Transducer .................................................................... 30
67-8 Cyclic Friction Adjustment ......................................................................... 33
67-9 Cyclic Rigging (Alternate Method) ............................................................. 36
67-10 Position Verification ................................................................................... 44
67-11 Fore and Aft Cyclic Sensor Adjustment ..................................................... 45
67-12 Lateral Cyclic Sensor Adjustment .............................................................. 48
67-13 Anti-Torque Rigging ................................................................................... 51
67-14 Rigging Tool (T103206) ............................................................................. 53
67-15 Control Motion Transducer Rigging ........................................................... 55
67-16 Elevator Rigging ........................................................................................ 56
67-17 Collective Controls ..................................................................................... 62
67-18 Hydraulic Servo Cylinder Boot ................................................................... 63
67-19 Hydraulic Cylinder Extension Tube ........................................................... 64
67-20 Hydraulic Cylinder Extension Universal ..................................................... 66
67-21 Piston Rod Clevis ...................................................................................... 68
67-22 Servo Valve Balance Spring ...................................................................... 69
67-23 Collective Flight Control Cylinder .............................................................. 72
67-24 Left Cyclic and Collective Boost Support ................................................... 75
67-25 Adjustable Rod End Tube .......................................................................... 76

67-00-00
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FIGURES (CONT)

Figure Page
Number Title Number

67-26 Collective Control Bellcrank ....................................................................... 78

67-27 Collective Force Gradient (Applicable to Helicopters with
4-Axis AFCS/Flight Director Kit Installed) .................................................. 79
67-28 Collective Bellcrank (Applicable to Helicopters with
4-Axis AFCS/Flight Director Kit Installed) .................................................. 83
67-29 Collective Link (Applicable to Helicopters with
4-Axis AFCS/Flight Director Kit Installed) .................................................. 84
67-30 Collective Rotary Actuator (Applicable to Helicopters with
4-Axis AFCS/Flight Director Kit Installed) .................................................. 86
67-31 Adjustable Collective Control Tube ........................................................... 87
67-32 Collective Control Lever and Stop Assembly ............................................. 89
67-33 Pilot Collective Stick Boot .......................................................................... 90
67-34 Collective Jackshaft ................................................................................... 91
67-35 Collective Transducers .............................................................................. 96
67-36 Collective Jackshaft Assembly .................................................................. 97
67-36A Control Motion Transducer Adjustment ...................................................... 98C
67-37 Collective Friction Clamp Assembly .......................................................... 100
67-38 Cyclic Controls ........................................................................................... 104
67-39 Hydraulic Cylinder Extension Tube ............................................................ 105
67-40 Hydraulic Cylinder Extension Universal ..................................................... 107
67-41 Left Cyclic Piston Rod Clevis ..................................................................... 109
67-42 Right Cyclic Piston Rod Clevis .................................................................. 111
67-43 Left Cyclic Flight Control Cylinder .............................................................. 113
67-44 Right Cyclic Flight Control Cylinder ........................................................... 116C
67-45 Right Cyclic Control Boost Cylinder Support ............................................. 122
67-46 Right Cyclic Control Tubes and Bellcranks ................................................ 123
67-47 Mixing Lever ............................................................................................. 125
67-48 Fore and Aft and Lateral Proximity Switches ............................................. 127
67-49 Lateral Series Actuator and Proximity Switch ............................................ 129
67-50 Longitudinal Series Actuator ...................................................................... 130
67-51 Lateral Cyclic Rotary Actuator ................................................................... 132
67-52 Fore and Aft Cyclic Rotary Actuator .......................................................... 133
67-53 Fore and Aft Cyclic Force Gradient ........................................................... 135
67-54 Fore and Aft Cyclic Force Gradient Assembly ........................................... 136
67-55 Lateral Cyclic Force Gradient .................................................................... 139
67-56 Lateral Cyclic Force Gradient Assembly .................................................... 140
67-57 Fore and Aft Cyclic Transducers ............................................................... 142
67-58 Fore and Aft Cyclic Jackshaft Tube and Lever Assembly
(Right Side) ................................................................................................ 144
67-59 Fore and Aft Cyclic Jackshaft Tube and Lever Assembly
(Right Side) Alignment ............................................................................... 145
67-60 Fore and Aft Cyclic Jackshaft Tube and Lever Assembly
(Left Side) .................................................................................................. 147
67-61 Fore and Aft Cyclic Jackshaft Tube and Lever Assembly
(Left Side) Alignment ................................................................................. 149
67-62 Cyclic Jackshaft Housing ........................................................................... 151
67-63 Cyclic Controls Arm ................................................................................... 153
67-64 Cyclic Controls Arm and Washer Positioning ............................................ 154
67-65 Lateral Transducer .................................................................................... 156

67-00-00
ECCN EAR99 29 OCT 2009 Rev. 13 Page 9
BHT-412-MM-8

FIGURES (CONT)

Figure Page
Number Title Number

67-66 Cyclic Stick Boot ........................................................................................ 157

67-67 Pilot Cyclic Stick ........................................................................................ 159
67-68 Anti-Torque Controls ................................................................................. 162
67-69 Pitch Change Control Bellcrank ................................................................. 163
67-70 Control Tube Guides ................................................................................. 164
67-71 Anti-Torque Control Support ...................................................................... 166
67-72 Anti-Torque Hydraulic Cylinder .................................................................. 167
67-73 Anti-Torque Hydraulic Cylinder Bearing Inspection Tool ........................... 169
67-74 Directional Series Actuator ........................................................................ 170
67-75 Directional Series Actuator Assembly ....................................................... 171
67-76 Walking Beam and Friction Clamp Assembly ............................................ 173
67-77 Magnetic Brake .......................................................................................... 174
67-78 Control Transducer and Force Gradient .................................................... 176
67-79 Force Gradient Assembly .......................................................................... 178
67-80 Pedal Adjuster ........................................................................................... 179
67-81 Anti-Torque Pedals .................................................................................... 181
67-82 Aerodynamically Actuated Elevator and Horn ........................................... 184
67-83 Elevator Inspection (Installed) ................................................................... 186
67-84 Elevator Control Tube ................................................................................ 189
67-85 Cyclic Controls Rigging (36087 and Subsequent) ..................................... 194
67-86 Anti-Torque Controls Rigging (36087 and Subsequent) ............................ 199
67-87 Cyclic Controls (36087 and Subsequent) .................................................. 208
67-88 Fore and Aft Cyclic Rotary Actuator Removal/Installation
(36087 and Subsequent) ........................................................................... 209
67-89 Lateral Cyclic Rotary Actuator Removal/Installation
(36087 and Subsequent) ........................................................................... 211
67-90 Fore and Aft Cyclic Force Gradient Removal/Installation
(36087 and Subsequent) ........................................................................... 213
67-91 Fore and Aft Cyclic Force Gradient (36087 and Subsequent) ................... 214
67-92 Lateral Cyclic Force Gradient Removal/Installation
(36087 and Subsequent) ........................................................................... 216
67-93 Lateral Cyclic Force Gradient (36087 and Subsequent) ........................... 218
67-94 Anti-Torque Controls (36087 and Subsequent) ......................................... 220
67-95 Anti-Torque Transducer Removal/Installation
(36087 and Subsequent) ........................................................................... 221
67-96 Anti-Torque Force Gradient (4-Axis Configuration) ................................... 222
67-97 Anti-Torque Rotary Actuator (4-Axis Configuration) ................................... 226
67-98 Anti-Torque Servo Actuator Removal/Installation
(36087 and Subsequent) ........................................................................... 228
67-99 Anti-Torque Series Actuator (36087 and Subsequent) .............................. 230

67-00-00
Page 10 Rev. 13 29 OCT 2009 ECCN EAR99

FLIGHT CONTROL SYSTEMS (PRIOR TO S/N 36087)
67-1. INTRODUCTION
The following paragraphs contains information and
instructions for maintenance of both standard and
automatic flight control systems. Refer to paragraph
67-276 for digital flight control system.
The standard flight control system includes a cyclic
control stick for fore and aft and lateral controls, a
collective pitch control stick for vertical control and
anti-tor que pedals for directional control. An
aerodynamically actuated elevator increases stability
about the longitudinal axis.
Electrically operated force trim systems consisting of
electromechanical rotary actuators and force gradients
(cyclic controls) and magnetic brake and force gradient
(anti-torque controls) are connected in parallel to the
cyclic and anti-torque controls, position the flight
controls in response to a signal from either the pilot or
AFCS system to establish a flight reference point,
provide artificial force feel and stabilization of the cyclic
and anti-torque controls.
The stick centering indicator system consists of two
proximity switches and two cyclic centering (CYC CTR)
caution lights (kit 412-704-115-101). The lights are
located on the pilot and copilot instrument panel.
System circuitry is activated whenever the rotor RPM
warning light is illuminated. During ground operations
below normal operating range, excessive cyclic inputs
will illuminate the CYC CTR caution lights. Properly
positioning cyclic stick will extinguish the lights.
The Automatic Flight Control System (AFCS) consists
of the standard flight control system plus added AFCS
BHT-412-MM-8
components in the cyclic and directional control
systems.
The AFCS cyclic control systems incorporate four
electromechanical series actuators, two connected in
series in the roll system and two connected in series in
the pitch system. Four transducers, two in roll system
and two in pitch system are used to convert mechanical
movement to electrical signals for injection of pilot
control commands to the AFCS.
AFCS anti-torque directional system incorporates a
single electrical servo actuator and a transducer. The
servo actuator is located forward of the directional
hydraulic actuator. The transducer is connected to the
bellcrank aft of the pedals.
Forward servo actuator in each cyclic system and
directional series actuators are controlled by helipilot,
HP-1 system. Aft actuators in each system are
controlled by HP-2 system.
When the optional flight director kit is installed an
additional transducer is added to the collective control
system.
For helicopters S/N 36037 and subsequent, dual
element transducers are installed. The second element
is used when a Flight Data Recorder (FDR) is installed.
Refer to Chapter 98 for AFCS system wiring diagrams.
67-2. TROUBLESHOOTING
Refer to Chapter 29 for flight control hydraulic systems
troubleshooting.
67-00-00
27 FEB 2009 Rev. 12 Page 11/12
 BHT-412-MM-8

FLIGHT CONTROLS RIGGING

67-3. FLIGHT CONTROL RIGGING d. Apply corrosion preventive compound (C-101)

The following paragraphs provide rigging instructions
for the collective, cyclic, anti-torque (tail rotor), and
aerodynamically actuated elevator control systems. For
engine power lever controls (throttle), refer to
Chapter 76.
to threads of all adjustable end bearings and clevises
after adjustment.
e. Torque control jam nuts to 80 to 100
inch-pounds (9.04 to 11.30 Nm) after adjustment unless
other torque is specified.

67-4. COLLECTIVE CONTROLS f. Control tubes must be free to rotate several

degrees about longitudinal axis. Loosen jam nuts,
MATERIALS REQUIRED adjust end fittings, and torque jam nuts, if necessary.
Remove and replace lockwire (C-405) as necessary.
Refer to BHT-ALL-SPM for specifications and source.
2. Disconnect the following controls tubes:
NUMBER NOMENCLATURE
a. Disconnect extension tube (2, Figure 67-1)
C-101 Corrosion Preventive from collective lever (1) by removing cotter pin, nut, four
Compound washers, and bolt.
C-308 Adhesive
b. Disconnect control tube (4) from collective
C-405 Lockwire hydraulic cylinder (3) by removing cotter pin, nut, two
washers, bolt, and clip.

c. Disconnect control tube (7) from lever (8) by

removing cotter pin, nut, two washers, and bolt.
SPECIAL TOOLS REQUIRED
NOTE
NUMBER NOMENCLATURE
The following two substeps are only
DPPH200 Push-Pull Dial Gauge applicable to helicopters with 4-axis AFCS/
(Spring Scale) Flight Director kit installed.

T103287-101 Collective Lever d. Disconnect force gradient (1, Figure 67-1A)

Positioning Tool from control lever (6).

1. Comply with the following general procedures
when rigging collective controls:
a. When a rigging procedure requires a specific
position to accomplish the following steps, manually
hold controls in position or secure controls in position
with pilot friction adjustment.
b. Tolerance for rigging dimensions is ± 0.03 inch
(0.76 mm).
c. All adjustable control tubes shall have a
maximum of 1.0 inch (25.4 mm) of exposed threads
after adjustment. If control tubes have inspection holes,
threads shall be engaged sufficiently to cover holes.
e. Disconnect link (3) from rotary actuator (2).
3. If available, connect hydraulic power cart to
helicopter. Do not apply hydraulic power at this time.
4. Position pilot collective stick (14, Figure 67-1)
against the UP stop, hold in position, and tighten pilot
collective friction adjuster (13).
5. Position top edge of bellcrank (6) 0.52 inch (13.21
mm) above top of support (5), as shown in Detail C.
6. Adjust control tube (7) to lever (8). Tighten jam nut
on control tube clevis. Install control tube on lever using
bolt, two washers, nut, and cotter pin.

67-00-00
27 FEB 2009 Rev. 12 Page 13
BHT-412-MM-8

3 DETAIL A

0.070 IN.
(1.778 mm)

CENTER
LINE
NEUTRAL
VALVE
POSITION 16

DETAIL B

4
15
5
6

8 9 7
DETAIL B
14
13

12 4
SEE 5 0.52 IN.
10 DETAIL F (13.21 mm)
7
6
SEE DETAIL D
DETAIL C

412_MM_67_0021

Figure 67-1. Collective Rigging (Sheet 1 of 3)

67-00-00
Page 14 Rev. 11 30 MAR 2007
 BHT-412-MM-8

17
18

4.67 IN. (118.61 mm)

4.70 IN. (119.38 mm)

2
19
17

1
28

29
27
2

DETAIL A

12
FWD

26

21
11
22
25
20
24
DETAIL D
DETAIL E
VIEW LOOKING INBOARD 23
AT COLLECTIVE JACKSHAFT
AND MINIMUM COLLECTIVE
FRICTION CLAMP

412_MM_67_0006

Figure 67-1. Collective Rigging (Sheet 2 of 3)

67-00-00
30 MAR 2007 Rev. 11 Page 15
BHT-412-MM-8

0.000 TO 0.002 IN. 8 9

(0.000 TO 0.051 mm)

10

DETAIL F
APPLICABLE TO HELICOPTERS 7
S/N 36069 AND SUBSEQUENT

1. Collective lever 16. Actuator valve lever

2. Extension tube 17. Pin
3. Collective hydraulic cylinder 18. Swashplate support
4. Control tube 19. Transmission
5. Support 20. Nut
6. Bellcrank 21. Elbow support
7. Control tube 22. Gear sector
8. Lever 23. Gear sector
9. Stop 24. Shim
10. Control tube 25. Control tube
11. Minimum collective friction clamp 26. Control tube
12. Collective jackshaft 27. Collective lever positioning
13. Pilot collective friction adjuster tool (T103287-101)
14. Pilot collective stick 28. Screw
15. Piston 29. Plate assembly

412_MM_67_0007

Figure 67-1. Collective Rigging (Sheet 3 of 3)

67-00-00
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 BHT-412-MM-8

A
4 B

3
2
9

8 1
7
10
5
6

4
2 2

1. Force gradient
2. Rotary actuator
3. Link
4. Bellcrank A B
5. Control tube
6. Control lever
7. Control tube
8. Collective jackshaft
9. Pilot collective friction adjuster
10. Pilot collective stick
412_MM_67_0026

Figure 67-1A. Collective Controls (4-Axis Configuration)

67-00-00
27 FEB 2009 Rev. 12 Page 16A
BHT-412-MM-8

7. Ensure pilot collective stick (14) is positioned as 203.37 Nm) on extension tube (2), and apply lockwire
described in step 4. (C-405). Apply sealant (C-308) around nut, lockwire,
and threads of clevis.
8. Move actuator valve lever (16) up to bottom
collective hydraulic cylinder (3) in UP position. Set
actuator valve lever 0.070 inch (1.778 mm) above
center line neutral valve position (Detail B) and hold in CAUTION
position.

DO NOT MOVE PILOT COLLECTIVE

9. Adjust control tube (4) to fit actuator valve lever
(16). Shorten rod end bearing three turns. Tighten jam
nut against rod end bearing on control tube. Install
control tube on actuator valve lever.
NOTE
If collective lever positioning tool (27) is
available, skip step 10 and perform step 11.
10. Position collective lever (1) 4.67 to 4.70 inches
(118.62 to 119.38 mm) above base of swashplate
support (18) to center of pin (17) (Detail A).
11. Secure collective lever positioning tool (27) to pin
(17) on collective lever (1) with screw (28), then pull up
on collective lever to seat collective lever positioning
tool base on plate assembly (29).
12. Apply hydraulic power from hydraulic cart to
helicopter.
CAUTION
STICK (14) WITH COLLECTIVE LEVER
POSITIONING TOOL (27) INSTALLED.
15. Install extension tube (2) to collective lever (1)
using bolt, washers, nut, and cotter pin (paragraph
67-19).
a. If applicable, remove collective lever
positioning tool (27).
NOTE
Alternate method of adjusting extension
tube (2) without pressurizing hydraulic
system is outlined in step 16 through
step 20.
16. Position collective lever (1) and pilot collective
stick (14), as outlined in step 13.
17. Exert sufficient downward pressure on collective
hydraulic cylinder (3) to hold actuator valve lever (16)
at top of travel (Detail B).

WHEN PERFORMING OPERATIONAL

CAUTION
CHECK OF COLLECTIVE CONTROLS
WITH HYDRAULIC POWER APPLIED,
ENSURE CYCLIC STICK IS IN CENTER
DO NOT ALLOW COLLECTIVE
POSITION.
CONTROLS BELOW HYDRAULIC
CYLINDER (3) TO MOVE WHILE
NOTE ACCOMPLISHING THE FOLLOWING
If hydraulic power cart is not available, refer STEP.
to note preceding step 16.
18. Adjust extension tube (2) to fit collective lever (1),
13. With collective lever (1) set as per step 10 or then shorten tube by one complete turn of upper
step 11, position pilot collective stick (14) against clevis.
DOWN stop. Tighten pilot collective friction
adjuster (13). 19. Torque jam nut 1500 to 1800 inch-pounds
(169.47 to 203.37 Nm) on extension tube (2) and
14. Adjust extension tube (2) to fit collective lever (1). secure with lockwire (C-405). Apply sealant (C-308)
Torque jam nut 1500 to 1800 inch-pounds (169.47 to around nut, lockwire, and threads of clevis.

67-00-00
Page 16B Rev. 12 27 FEB 2009

20. Install extension tube (2) to collective lever (1)
using bolt, washers, nut, and cotter pin (paragraph
67-19).
21. Adjust stop (9) as shown in Detail F, applicable to
helicopters 36069 and subsequent. Torque jam nut to
80 to 100 inch-pounds (9.04 to 11.30 Nm) and secure
with lockwire (C-405).
NOTE
The following step is only applicable to
helicopters with 4-axis AFCS/Flight Director
kit installed.
21A.Rig collective trim system as follows:
a. Position pilot collective stick (10,
Figure 67-1A) against its down stop.
b. Connect force gradient (1) to control lever (6).
c. Position output arm of rotary actuator (2) as
shown in Detail A.
d. Position and hold output arm of rotary actuator
(2) against its outboard left-hand stop.
e. Adjust link (3) to fit between the bellcrank (4)
and rotary actuator (2) positioned per step d, then
BHT-412-MM-8
extend the rod end bearing 2 1/2 complete turns and
secure to output arm of the rotary actuator (2).
22. Adjust minimum friction as follows:
NOTE
Step a and step b are applicable to
helicopters without 4-axis AFCS/Flight
Director kit installed when a hydraulic
power cart is not used.
a. Disconnect control tube (10, Figure 67-1) from
collective jackshaft (12) by removing cotter pin, nut,
two washers, and bolt.
b. Attach a spring scale at the center of upper
throttle grip within 0.50 inch (12.7 mm). Correct
measurement is 13 to 14 pounds (35.6 to 48.9 N)
up-collective stick force. Proceed to step d.
NOTE
Measurement in step c requires the use of
a hydraulic power cart.
For helicopters with AFCS/4-axis Flight
Director kit installed, measurement is taken
with collective force trim OFF.
67-00-00
27 FEB 2009 Rev. 12 Page 16C/16D
 BHT-412-MM-8

c. Attach a spring scale at center of upper throttle support is within no less than one tooth of rolling off its
grip within 0.50 inch (12.7 mm). Correct measurement mating pinion.
is 8 to 11 pounds (35.6 to 48.9 N) (helicopters without
4-axis Flight Director kit installed) or 4 to 4.5 pounds 67-5. CYCLIC CONTROLS
(17.8 to 20.0 N) (helicopters with 4-axis AFCS/Flight
Director kit installed) up-collective stick force. Two methods of rigging cyclic controls are provided in
the following paragraphs. The primary method is
d. Tighten or loosen nut (20) to adjust minimum provided in paragraph 67-6 and the alternate method in
collective friction clamp (11), as shown in Detail D, to paragraph 67-7.
obtain correct sliding force.
67-6. Cyclic Controls (Primary Method)
e. After friction is adjusted within limits, connect SPECIAL TOOLS REQUIRED
control tube (10) if disconnected in step a (paragraph
67-81).
NUMBER NOMENCLATURE
23. Move collective controls through full travel and
Commercial Inclinometer
check for binding and/or obstruction of control
movement. T101291-103 Swashplate Rigging
Tool
24. Turn off hydraulic power cart and disconnect from
helicopter.
MATERIALS REQUIRED
25. Ensure all collective control bolts are installed and
cotter pins and lockwire are installed, where applicable.
Refer to BHT-ALL-SPM for specifications and source.

26. Check throttle controls for binding or obstruction NUMBER NOMENCLATURE

as follows:
a. Disconnect left and right adjustable throttle
control tubes (25 and 26) from each bellcrank by
removing nut, two washers, and bolt.
b. Check marked tooth of flex shaft is engaged
with 10th tooth space of mating gear sectors (22 and
23) on both pilot and copilot collective elbow.
c. Roll both throttle grips on pilot (and copilot, if
installed) collective sticks to full INCR position against
stop.
NOTE
If binding or obstruction occurs in copilot
throttle grips when rotated, adjust shims (24)
between airframe structure and elbow
support (21) to minimize lateral deflection of
elbow assembly flex shafts.
d. Adjust control tubes (25 and 26) to fit, torque
jam nuts, and install.
e. Cycle both throttle grips through full travel and
ensure each gear sector on both pilot and copilot elbow
C-101 Corrosion Preventive
Compound
C-308 Adhesive
C-405 Lockwire
NOTE
Rigging procedures contained herein
pertain to helicopters with dual controls
installed in basic control systems.
1. Comply with the following general procedures
when rigging cyclic controls (Figure 67-2).
a. When a rigging procedure requires a specific
position to accomplish the following steps, manually
hold controls in position or secure controls in position
with friction adjustment.
b. Tolerance for rigging dimensions is ±0.03 inch
(0.76 mm).
c. All adjustable control tubes shall have no more
than 1.0 inch (25.40 mm) of exposed threads or less
than 1.5 threads, after adjustment.

67-00-00
27 FEB 2009 Rev. 12 Page 17
BHT-412-MM-8
d. Apply corrosion preventive compound (C-101)
to threads of all adjustable rod bearings and clevises
after adjustment.
e. Torque control jam nuts to 80 to 100
inch-pounds (9.04 to 11.30 Nm) after adjustment unless
other torque is specified.
f. Control tubes must be free to rotate several
degrees about longitudinal axis. Loosen jam nuts,
adjust end fittings, and torque jam nuts, if necessary.
2. Connect hydraulic power cart to helicopter. Do not
apply hydraulic power at this time.
NOTE
During rigging, care must be taken to
prevent helicopter from moving. Keep
helicopter as level as possible.
3. Retract stop bolts as far as possible (Figure 67-3
and Figure 67-4).
4. Disconnect the following control tubes and force
gradients.
a. Disconnect extension tube (2, Figure 67-2)
from swashplate (1) by removing cotter pin, nut,
washers, and bolt.
b. Disconnect extension tube (3) from swashplate
(1) by removing cotter pin, nut, washers, and bolt.
c. Disconnect control tube (8) from bellcrank (7)
by removing two nuts, four washers, and two bolts, and
from valve arm (4) by removing two nuts, four washers,
and two bolts. Remove control tube and tag.
d. Disconnect control tube (9) from bellcrank (10)
by removing two nuts, four washers, and two bolts, and
from valve arm (13) by removing two nuts, four
washers, and two bolts. Remove control tube and tag.
e. Disconnect fore and aft cyclic force gradient
(17) and clevis (20) from jackshaft (16) by removing nut
and washer.
f. Disconnect fore and aft cyclic transducers (34)
from jackshaft (16) by removing nut, lock washer, two
washers, and bolt.
67-00-00
Page 18 Rev. 11 30 MAR 2007
g. Disconnect control tube (22) from jackshaft
(16) by removing nut, three washers, and bolt, and
remove control tube (24) from bellcrank (31) by
removing nut, three washers, and bolt.
h. Disconnect lateral cyclic transducers (29) from
bellcrank (31) by removing nut, two washers, two
spacers, and bolt.
i. Disconnect lateral cyclic force gradient (26)
from bellcrank (31) by removing cotter pin, nut, two
washers, bushing and bolt.
NOTE
Helicopters S/N 33001 through 33061 have
control tube (30) (204-001-016-13) installed.
Helicopters S/N 33062 and subsequent use
control tube (412-001-307-101), which is a
replacement for all serial number
helicopters.
j. Disconnect lateral control tube (30) from pilot
cyclic stick (33) by removing nut, two washers, and bolt.
Remove control tube and tag.
5. Verify length of centered fore and aft cyclic series
actuator (14, Figure 67-2) of 27.505 to 27.555 inches
(698.627 to 699.897 mm).
6. Verify length of centered lateral cyclic series
actuator (35) of 56.295 to 56.345 inches (1429.893 to
1431.163 mm).
7. Level helicopter (Chapter 8).
8. Position pilot cyclic stick (33) with respect to deck
using an inclinometer, bubble protractor, or equivalent
as follows:
a. Place pilot cyclic stick (33) against extreme
forward stop. Measure and record angle of stick relative
to deck.
b. Place pilot cyclic stick (33) against extreme aft
stop. Measure and record angle of stick relative to deck.
c. Place pilot cyclic stick (33) against extreme
right lateral stop. Measure and record angle of stick
relative to deck.
 BHT-412-MM-8

412_MM_67_0009a

Figure 67-2. Cyclic Rigging (Sheet 1 of 3)

67-00-00
ECCN EAR99 29 OCT 2009 Rev. 13 Page 19
BHT-412-MM-8

36

37 44

53
45
3
38 46
3 47
SEE DETAIL D
DETAIL D
DETAIL A

48

49

50
51
2
52

5 DETAIL E

36. Boot
37. Support
38. Support
SEE DETAIL E
39. Bolt
40. Support (ref) 95 TO 110 IN-LBS
43 1 (10.73 TO 12.43 Nm)
41. Cotter pin
42 42. Nut
1 43. Washer 200 TO 250 IN-LBS
44. Support bracket 2 (22.60 TO 28.25 Nm)
41
39 45. Nut
46. Nut 900 TO 1100 IN-LBS
47. Lockwire 3 (101.68 TO 124.28 Nm)
40
48. Lower actuator body
49. Lower piston
50. Locking device
51. Jam nut
DETAIL B 52. Rod end bearing
LEFT CYCLIC FLIGHT 53. Keyed washer
CONTROL CYLINDER

412_MM_67_0009

Figure 67-2. Cyclic Rigging (Sheet 2 of 3)

67-00-00
Page 20 Rev. 11 30 MAR 2007
 BHT-412-MM-8

Figure 67-2. Cyclic Rigging (Sheet 3)

67-00-00
30 SEP 2003 Rev. 7 Page 21
BHT-412-MM-8
d. Place pilot cyclic stick (33) against extreme left
lateral stop. Measure and record angle of stick relative
to deck.
e. Position pilot cyclic stick (33) at mid-position
within 0.5° utilizing one-half total stick deflections as
measured in step a and step b (fore and aft cyclic) and
step c and step d (lateral cyclic). Tighten friction
adjustment knob (32) to maintain this position.
9. Check and adjust (if necessary) control tube (30)
between pilot cyclic stick (33) and bellcrank (31). Verify
dimension A and B between bellcrank and bulkhead
are equal within 0.030 inch (0.762 mm) (Figure 67-2,
Detail C). Torque jam nut and install control tube.
10. Adjust rod end bearing (52, Detail E) on left cyclic
hydraulic cylinder (5) as follows:
a. Remove cotter pin (41), nut (42), washer (43),
and bolt (39) from support (40).
b. Push lower actuator body (48) full up and pull
lower piston (49) full down (Detail E).
c. Remove lockwire and loosen jam nut (51) and
adjust rod end bearing (52) to align bolt holes in rod end
bearing (52) and support (40).
CAUTION
IMPROPER TORQUE TECHNIQUE CAN
DESTROY TAB ON LOCKING DEVICE
(50). ROD END BEARING (52) MUST BE
HELD SECURE TO PREVENT DAMAGING
LOCKING DEVICE.
d. Torque jam nut (51) to 200 to 250 inch-pounds
(22.60 to 28.25 Nm) and secure to locking device (50)
with lockwire (C-405).
e. Inspect locking device (50) to ensure tab is in
groove of rod end bearing (52) and that it was not
damaged when jam nut (51) was tightened. Replace
locking device if tab is twisted or damaged.
NOTE
Alignment procedures are applicable to all
three cylinders.
67-00-00
Page 22 Rev. 12 27 FEB 2009
11. Align left cyclic hydraulic cylinder (5, Figure 67-2)
to support (40) as follows:
a. Ensure extension tube (2) is disconnected from
swashplate (1).
b. Move lower piston rod up and clear of support
(40). Lower piston rod end bearing (52) must be able to
be moved freely down, up, and then down, and bolt (39)
replaced without any pressure, forcing, binding, or
bending of piston rod in fore, aft, left, or right direction.
One person must guide extension tube (2) to prevent
damage when conducting this step.
c. If cylinder meets requirements of step b, it is
considered in alignment. If cylinder is aligned, proceed
to step d. If cylinder is misaligned, accomplish step e
through step m.
d. Install bolt (39), washer (43), nut (42), and
cotter pin (41). Loosely install upper extension tube (2)
to swashplate by installing washer and bolt.
e. Remove lockwire (47) from jam nut (46),
bearing nut (45), and keyed washer (53).
f. Loosen jam nut (46) and bearing nut (45) so
cylinder is loose.
g. Move rod end bearing (52) up approximately
0.5 inch (12.7 mm) above support (40). Rotate lower
end of cylinder in a 3.0 inch (76.2 mm) circle.
h. Position rod end bearing (52) directly over lugs
of support (40) and move piston down and install
bolt (39).
i. Tighten bearing nut (45) by hand
(approximately 70 inch-pounds (7.91 Nm).
j. Remove bolt (39) and move rod end bearing up
and out of support (40) then move down. Rod end
bearing (52) must be free of any side loading. Repeat
step e through step j until free of side loading.
k. Install bolt (39). Torque bearing nut (45) to 200
inch-pounds (22.60 Nm).
l. If cylinder meets requirements of step b, install
washer (43) and nut (42) and torque to 95 to 100
inch-pounds (10.73 to 12.43 Nm). Install cotter pin (41).
Complete installation of upper extension tube (2) by
installing two washers, cotter pin, and the nut.
 BHT-412-MM-8

m. Torque bearing nut (45) to 900 to 1100
inch-pounds. (101.68 to 124.28 Nm). Torque jam nut
(46) to 900 to 1100 inch-pounds (101.68 to 124.28
Nm). Secure nuts (45 and 46) to keyed washer (53)
with lockwire (C-405).
n. Connect control tube (8) to valve arm (4), by
installing bolt, washers, and nut. Leaving tube
disconnected from bellcrank (7).

67-00-00
30 MAR 2007 Rev. 11 Page 22A/22B
 BHT-412-MM-8

Figure 67-3. Cyclic Rigging — Hydraulic Cylinders

67-00-00
30 SEP 2003 Rev. 7 Page 23
BHT-412-MM-8

Figure 67-4. Cyclic Rigging — Bellcrank Stops

67-00-00
Page 24 Rev. 7 30 SEP 2003

NOTE
Repeat step 10 and step 11 on right cyclic
hydraulic cylinder (12). With main rotor pitch
links connected, all cyclic and collective
adjustments or checks shall be
accomplished using a hydraulic boost.
12. Turn on hydraulic power cart and apply hydraulic
power to helicopter.
CAUTION
WHEN PERFORMING OPERATIONAL
CHECK OF CYCLIC CONTROLS WITH
HYDRAULIC SYSTEM PRESSURIZED,
ENSURE COLLECTIVE STICK IS
POSITIONED NEAR MID TRAVEL.
13. Adjust control tubes (2 and 3, Figure 67-3) as
follows:
a. Adjust control tubes (2 and 3) to a length of
20.86 inches (529.84 mm).
b. Torque jam nuts to 80 to 100 inch-pounds (9.04
to 11.30 Nm) on control tubes (2 and 3).
c. Connect each control tube (8 and 9, Figure
67-2) to each bellcrank (7 and 10) temporarily with a
bolt.
14. Make sure that pilot cyclic stick (33) is
perpendicular to deck within 0.5° (as determined in step
8) and is held in this position.
15. Disconnect four pitch link assemblies from pitch
horns (Chapter 62).
16. Set swashplate angle with respect to mast using
swashplate rigging tool (T101291-103) as follows
(Figure 67-5):
a. Ensure helicopter is level (Chapter 8).
b. Position swashplate rigging tool
(T101291-103) on rotating portion of swashplate with
swashplate positioned fore and aft.
BHT-412-MM-8
c. Set swashplate angle with respect to mast
utilizing an inclinometer, or equivalent, located on upper
surface of rigging tool as follows:
(1) Fore and aft: set swashplate 0° 33' to 1.0°
3' down forward.
(2) Lateral: set swashplate 1.0° 0' to 1.0° 30'
down left.
NOTE
Provide a minimum of 1.5 exposed threads
to left extension tube (2, Figure 67-2) upper
clevis. If required at completion of step 18, it
is permissible to equally shorten control
tubes (8 and 9) a maximum of five complete
turns of adjustable rod end bearing.
Shortening control tube assemblies (8 and
9) adjustable rod end bearing 1.5 turns is
equal to approximately one thread of
extension tube (2 and 3) upper clevis.
17. Hold swashplate in position, adjust length of right
hydraulic cylinder extension tube (8, Figure 67-5) to fit
swashplate. Adjust length of left hydraulic cylinder
extension tube to fit swashplate.
18. Torque nuts (9) on both extension tubes (8) to
1500 to 1800 inch-pounds (169.47 to 203.37 Nm) and
secure with lockwire (C-405). Apply adhesive (C-308)
to nut, lockwire, threads of clevis, and both extension
tubes.
19. Connect clevis (10) to swashplate horn (1) by
installing washer (3), bolt (2), washers (4 and 5), nut (6),
and cotter pin (7).
20. Remove swashplate rigging tool (T101291-103)
and inclinometer.
21. Connect four pitch links to pitch horns
(Chapter 62).
22. Set stop bolts on bellcranks (6 and 11, Figure 67-3)
as follows:
a. Position pilot cyclic stick (33, Figure 67-2)
perpendicular to deck within 0.5° and tighten friction
adjustment knob (32).
67-00-00
27 FEB 2009 Rev. 12 Page 25
BHT-412-MM-8

NOTE h. Position pilot cyclic against extreme right

Aluminum strip work aids may be used in
lieu of making marks on hydraulic cylinders
as described in steps b. through d. Fabricate
two strips of aluminum from aluminum
sheet. Scribe index marks on aluminum
strips to correspond to marks described in
steps b. through d. Attach strips to cylinder
(1 and 4, figure 67-3) with tape or rubber
cushion clamps.
b. Make an index mark on each cyclic hydraulic
cylinder and a corresponding mark on any suitable
point on airframe structure with a soft lead pencil as
shown on figure 67-3. Label index mark "N" (neutral,
and record dimensions for each actuator.
c. Measure 1.61 in. (40.89 mm) above index mark
“N” (neutral) on the hydraulic cylinder and mark with
soft lead pencil on cylinder. Label index mark “F”
(forward).
d. Measure 1.61 in. (40.89 mm) below index mark
“N” neutral on the hydraulic cylinder and mark another
mark with soft lead pencil on cylinder. Label index mark
“A” (aft).
lateral stop. Move stick toward aft right corner position
until index mark “A” on left hydraulic cylinder (4, figure
67-3) coincides with recorded dimension for that
actuator. Hold this position and adjust stop bolt (6,
figure 67-4) in stop (10) to make contact with bellcrank
(7).
23. Turn off hydraulic power cart.
24. Adjust copilot control tubes (22 and 24, figure
67-2) as follows:
a. Place pilot cyclic (33) and copilot cyclic (15) in
extreme left position against stops and hold. Adjust
control tube (24) to fit bellcrank (31). Torque jam nut on
clevis on control tube (24). Install control tube (24) on
bellcrank (31) by installing bolt, washer, nut and cotter
pin.
b. Place pilot and copilot cyclics in extreme
forward position against stops and hold. Adjust control
tube (22) to fit jackshaft (16). Torque jam nut on clevis
on control tube (22). Install control tube (22) on
jackshaft (16) by installing bolt, washer, nut and cotter
pin.

25. Turn on hydraulic power cart and apply hydraulic

e. Loosen friction adjustment knob (32, figure power to helicopter.
67-2) on pilot cyclic (33) and position stick against
extreme left lateral stop, then move stick toward
forward left corner position until index mark “F” on left
hydraulic cylinder (4, figure 67-3) coincides with
recorded dimensions for that actuator. Hold this
position and adjust stop bolt (7) in bellcrank (6) to make
WHEN PERFORMING OPERATIONAL
contact with actuator support (8).
CHECK OF CYCLIC CONTROLS WITH
HYDRAULIC SYSTEM PRESSURIZED,
f. Position pilot cyclic against extreme left lateral ENSURE COLLECTIVE STICK IS
stop, then move stick toward aft left corner position until POSITIONED NEAR MID TRAVEL.
index mark “A” on right hydraulic cylinder (1) coincides
with recorded dimension for that actuator. Hold this 26. Move cyclic controls through full travel and check
position and adjust stop bolt (10) in stop (14) to make for binding and/or obstruction of control movement.
contact with bellcrank (11).
27. Turn off hydraulic power cart.
g. Position pilot cyclic against extreme right
lateral stop then move stick toward forward right corner
28. Perform fore and aft cyclic stick centering (figure
position until index mark “F” on right hydraulic cylinder
67-6, detail A), as follows:
(1) coincides with recorded dimensions for that
actuator. Hold this position and adjust stop bolt (3,
figure 67-4) in bellcrank (2) to make contact with a. Position output arm on fore and aft cyclic rotary
actuator support (4). actuator (18, figure 67-2).

67-00-00
Page 26 Rev. 7 30 SEP 2003
 BHT-412-MM-8

POSITION OF T101291-103
RIGGING TOOL
FOR LATERAL CYCLIC

FWD
SWASHPLATE SETTING
POSITION
SWASHPLATE
FORE AND AFT

SEE DETAIL A

PITCH
LINK

POSITION OF T101291-103
RIGGING TOOL
FOR FORE AND AFT CYCLIC
SWASHPLATE SETTING

1 2
SWASHPLATE
(VIEW LOOKING DOWN)
3
10
1. Swashplate horn
4
2. Bolt
3. Washer (AN960C516) 5
4. Washer (AN960C516) 9
5. Washer (AN960C516L)
6. Nut 6
1
7. Cotter pin
8. Hydraulic cylinder extension tube 7
9. Nut
10. Clevis 8

DETAIL A
LOCKWIRE (MS20994C32) TYPICAL

1500 TO 1800 IN-LBS

(169.48 TO 203.37 Nm)

NOTE
1 Apply adhesive (C-308) on nut, lockwire, and threads on clevis.

412_MM_67_0010

Figure 67-5. Cyclic Rigging — Swashplate

67-00-00
30 MAR 2007 Rev. 11 Page 27
BHT-412-MM-8
b. Place pilot cyclic (33) against extreme forward
stop.
c. Place output arm of the fore and aft rotary
actuator (18) against aft stop.
29. Adjust clevis (20) attached to force gradient (17) in
fore and aft cyclic control system to fit jackshaft (16).
Extend clevis 3.5 to 4.0 turns and torque jam nut. Install
fore and aft cyclic force gradient onto fore and aft cyclic
rotary actuator (18) with nut and washer. To install
clevis (20) to jackshaft (16), use bolt, washer, and
lockwire (C-405).
NOTE
Check for approximately 0.9 inch (22.86
mm) cushion at stick grip when against
forward cyclic stick stop.
30. Perform lateral cyclic stick centering (Figure 67-6,
Detail B) as follows:
a. Position output arm on lateral cyclic rotary
actuator (Figure 67-7).
b. Check clearance between lateral cyclic force
gradient (26, Figure 67-2) and structure at extreme
positions of lateral cyclic rotary actuator (25) arm. If
required, re-index arm relative to shaft by one serration
for clearance.
c. Place pilot cyclic against right lateral stop.
d. Place output arm of lateral cyclic rotary
actuator (25) to extreme left position against stop.
e. If necessary to extend clevis (28) to adjust
clevis on lateral cyclic force gradient (26), remove
control tube (24) from bellcrank (31) by removing cotter
pin, nut, three washers, and bolt.
f. Adjust clevis (28) attached to lateral cyclic
force gradient (26) to fit bellcrank (31) and temporarily
install.
g. Place one end of a 6 inch (15.24 cm) (or similar
measuring tool) scale against end cap of lateral cyclic
force gradient (26) and measure to approximate center
67-00-00
Page 28 Rev. 11 30 MAR 2007
of clevis (28). Mark center with soft pencil and record
dimension.
h. Place and hold pilot cyclic against left lateral
stop. Measure and record total travel distance of clevis
(28). Extend clevis one half recorded distance. Torque
jam nut and install on bellcrank (31) with nut, three
washers, bolt, and cotter pin.
i. Install control tube (24) to bellcrank (31) with
nut, three washers (one under bolt head and two under
nut), bolt, and cotter pin.
31. Perform fore and aft cyclic transducer (34)
adjustment as follows:
NOTE
The following procedure applies to
helicopters S/N 33001 through 33213 and S/
N 36001 through 36086 with transducer P/N
412-074-101-101 installed. For helicopters
S/N 36037 through 36086 with
transducer P/N 412-074-101-103 installed,
refer to paragraph 67-278B.
a. With fore and aft cyclic transducer attached to
structure, position pilot cyclic against extreme forward
stop, then against extreme aft stop. Check if
transducers would bottom out if connected to jackshaft
(Figure 67-7).
b. If bottoming occurs, loosen jam nut, adjust rod
end bearings on transducer until bottoming is
eliminated, torque jam nut, then connect transducers to
jackshaft. Overtravel of transducers should be
approximately equal.
32. Perform lateral cyclic transducer (29, Figure 67-2)
adjustment as follows:
NOTE
The following procedure applies to
helicopters S/N 33001 through 33213 and S/
N 36001 through 36086 with transducer P/N
412-074-101-101 installed. For helicopters
S/N 36037 through 36086 with
transducer P/N 412-074-101-103 installed,
refer to paragraph 67-278B.
 BHT-412-MM-8

Figure 67-6. Cyclic Rigging — Actuators

67-00-00
30 SEP 2003 Rev. 7 Page 29
BHT-412-MM-8

Figure 67-7. Cyclic Rigging — Transducer (Sheet 1 of 2)

67-00-00
Page 30 Rev. 7 30 SEP 2003
 BHT-412-MM-8

Figure 67-7. Cyclic Rigging — Transducer (Sheet 2)

67-00-00
30 SEP 2003 Rev. 7 Page 31
BHT-412-MM-8
a. With transducer attached to structure (Figure
67-7), position pilot cyclic against extreme right lateral
stop, then against extreme left lateral stop. Check if
transducers bottom out if connected to bellcrank
(Figure 67-7).
b. If bottoming occurs, loosen jam nut, adjust rod
end bearings on transducers until bottoming is
eliminated, torque jam nut, then connect to bellcrank.
Overtravel of transducers should be approximately
equal.
33. Turn on hydraulic power cart and apply hydraulic
power to helicopter.
CAUTION
WHEN PERFORMING OPERATIONAL
CHECK OF CYCLIC CONTROLS WITH
HYDRAULIC SYSTEM PRESSURIZED,
ENSURE COLLECTIVE STICK IS
POSITIONED NEAR MID TRAVEL.
34. Perform cyclic minimum friction adjustment
(Figure 67-8):
NOTE
Initial adjustment and check of fore and aft
and lateral cyclic force shall be
accomplished by utilizing a hydraulic power
cart connected to helicopter using step a
through step g. Final check and adjustment
shall be accomplished during ground run of
helicopter using step b through step g.
a. Reduce cyclic friction to zero by loosening
clamp. Rotate nut counterclockwise.
b. With force trim OFF, slowly increase stick
friction while simultaneously pulling on cyclic stick with
spring scale attached at midpoint of pilot cyclic grip until
a fore and aft cyclic breakout force of 0.50 to 1.0 pound
(2.22 to 4.44 N) is obtained.
67-00-00
Page 32 Rev. 11 30 MAR 2007
c. Forces to be measured perpendicular to axis of
cyclic stick with stick near center.
d. Check lateral cyclic breakout force of 0.50 to
1.00 pound (2.22 to 4.44 N).
e. If lateral cyclic stick force exceeds above
requirement, adjust fore and aft cyclic friction breakout
within above limits and recheck lateral cyclic breakout
force (step b through step d).
f. Tighten clamp around sleeve with clamp
resting on top surface of nut (Figure 67-8). Tighten
screws to obtain equal gap between clamp halves.
NOTE
Step g through step i are not applicable to
helicopters S/N 36087 and subsequent.
g. With force trim ON, check breakout force of
fore and aft cyclic of 2.25 to 2.75 pounds (10.01 to
12.23 N) and lateral force of 0.50 to 2.00 pounds (2.22
to 8.90 N).
h. If fore and aft or lateral breakout forces exceed
above requirements, repeat step a through step f.
i. If fore and aft or lateral breakout forces still
exceed above requirements, readjust either fore and aft
cyclic force gradient or lateral cyclic force gradient
spring preloads within respective limits to obtain
required breakout force. Repeat step a through step g
with hydraulic power applied.
NOTE
For cyclic force gradient spring preload
adjustments and cyclic control stick mass
balance adjustment, refer to paragraph
67-166 and paragraph 67-171.
35. Remove hydraulic power.
36. Accomplish rigging of cyclic controls; position
sensors in (paragraph 67-8).
 BHT-412-MM-8

67-7. Cyclic Controls (Alternate Method) MATERIALS REQUIRED

SPECIAL TOOLS REQUIRED

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

NUMBER NOMENCLATURE NUMBER NOMENCLATURE

T103281-101/-102 Cyclic Corner Stop C-101 Corrosion Preventive

Rigging Tool Compound

T103286-101 Cyclic Mixing Bellcrank C-308 Adhesive

Rigging Tool
C-405 Lockwire
T103287-111 Collective Lever
Rigging Tool
NOTE
T103288-101 Swashplate Rigging
Tool The procedures contained herein describe
the alternate method of rigging cyclic control
T103347-101 Cyclic Stick Rigging system using special rigging tools listed
Tool above.

Figure 67-8. Cyclic Friction Adjustment

67-00-00
30 SEP 2003 Rev. 7 Page 33
BHT-412-MM-8
1. Comply with the following general procedures
when rigging cyclic controls (Figure 67-2).
a. When a rigging procedure requires a specified
position to accomplish the following steps, manually
hold controls in position or secure controls in position
with pilot friction adjustment.
b. Tolerance for rigging dimensions is ± 0.03 inch
(0.76 mm).
c. All adjustable control tubes shall have no more
than 1.0 inch (25.4 mm) of exposed threads, or less
than 1.5 threads, after adjustment.
d. Apply corrosion preventive compound (C-101)
to threads of all adjustable rod bearings and clevises
after adjustment.
e. Torque control jam nuts 80 to 100 inch-pounds
(9.04 to 11.30 Nm) after adjustment unless other torque
is specified.
f. Control tubes must be free to rotate several
degrees about longitudinal axis. Loosen jam nuts,
adjust end fittings, and torque jam nuts, if necessary.
2. Connect hydraulic power cart to helicopter. Do not
apply hydraulic power at this time.
NOTE
During rigging of cyclic controls, take care to
keep helicopter as level as possible.
3. Retract stop bolts as far as possible (Figure 67-3
and Figure 67-4).
4. Disconnect the following control tubes and force
gradients.
a. Disconnect extension tube (2, Figure 67-2)
from swashplate (1) by removing cotter pin, nut,
washers, and bolt.
b. Disconnect extension tube (3) from swashplate
(1) by removing cotter pin, nut, washers, and bolt.
c. Disconnect control tube (8) from bellcrank (7)
by removing nut, two washers, and bolt, and from valve
arm (4) remove nut, two washers, and bolt. Tag control
tube and valve arm.
67-00-00
Page 34 Rev. 11 30 MAR 2007
d. Disconnect control tube (9) from bellcrank (10)
by removing nuts, two washers, and bolts, and from
valve arm (13) by removing nuts, two washers, and
bolts. Remove control tube and tag.
e. Disconnect fore and aft cyclic transducers (34)
from jackshaft (16).
f. Disconnect control tube (22) from jackshaft
(16) and control tube (24) from bellcrank (31).
g. Disconnect lateral cyclic transducers (29) from
bellcrank (31).
NOTE
Helicopters S/N 33001 through 33061 have
control tube (30) (204-001-016-13) installed.
Helicopters S/N 33062 and subsequent use
control tube (412-001-307-101), which are
provided as spares replacement for all serial
number helicopters.
h. Disconnect control tube (30) from pilot cyclic
stick (33).
5. Verify length of centered fore and aft cyclic series
actuator (14) of 27.505 to 27.555 inches (698.627 to
699.897 mm).
6. Verify length of centered lateral cyclic series
actuator (35) of 56.295 to 56.345 inches (1429.893 to
1431.163 mm).
7. Level helicopter (Chapter 8).
8. Install cyclic stick rigging tool (T103347-101) (2,
Figure 67-9). Align tool with bolt (3) at station 38.65.
9. Place pilot cyclic stick (1) in rigging tool (2), as
shown in Figure 67-9. Position clamp (4) around pilot
cyclic stick (1) and secure with bolt (6) and wing nut (5).
10. Install cyclic mixing bellcrank rigging tool base
(T103286-101) (15) with bolts (8).
11. Tighten screw (17) in slide (16) until slight friction
is felt between slide and rigging tool base
(T103286-101) (15).

12. Position bushing (10) in support (12) over
outboard bolt heads (11) of bellcrank (9).
13. Secure support (12) to slide (16) with screw (13)
and wing nut (14).
14. With support (12) positioned per step 12., move
slide (16) aft to align bellcrank (9) and tighten screw
(17) to secure slide (16).
15. Check and adjust (if necessary) control tube (30,
figure 67-2) located between pilots cyclic stick (33) and
bellcrank (31). Torque jam nut 80 to 100 in.-lbs. (9.04 to
11.30 N-m) and install control tube (30).
16. Remove cyclic mixing bellcrank rigging tool
(T103286-101).
17. Turn on hydraulic power cart and apply hydraulic
power to helicopter.
WHEN PERFORMING OPERATIONAL
CHECK OF CYCLIC CONTROLS WITH
HYDRAULIC SYSTEM PRESSURIZED,
ENSURE COLLECTIVE STICK IS
POSITIONED NEAR MID TRAVEL.
18. Adjust control tubes (8 and 9, figure 67-2) in
accordance with figure 67-3 as follows:
a. Connect control tubes (2 and 3) to valve arms
with bolts, washers, nuts, and cotter pins, leaving tubes
disconnected from bellcranks.
b. Adjust control tubes (2 and 3) to length of 20.86
in. (529.84 mm).
c. Torque jam nuts 80 to 100 in.-lbs. (9.04 to 11.30
N-m) on control tube.
d. Connect each control tube (8 and 9) to each
bellcrank (7 and 10) with bolts, washers, nuts, and
cotter pins.
19. Disconnect four pitch link assemblies from pitch
horns. (Chapter 62)
BHT-412-MM-8
20. Adjust copilot control tubes (22 and 24, figure
67-2) as follows:
a. Remove cyclic stick rigging tool
(T103347-101).
b. Place pilot cyclic (33) and copilot cyclic (15) in
extreme left position against stops and hold. Adjust
control tube (24) to fit bellcrank (31). Torque jam nut on
clevis (27) on control tube (24). Install control tube (24)
on bellcrank (31).
c. Place pilot and copilot cyclics in extreme
forward position against stops and hold. Adjust control
tube (22) to fit jackshaft (16). Torque jam nut on clevis
(21) on control tube (22). Install control tube (22) on
jackshaft (16).
21. Disconnect hydraulic cylinder extension tube (25,
figure 67-9) from collective lever (24).
22. Reconnect cyclic stick rigging tool (T103347-101)
and s ec ur e c ol lec ti ve l ev er r i ggi ng too l ( 27)
(T103287-111) to pin (23) on collective lever (24) with
screw (28), then pull up on lever to seat tool base on
plate assembly (26).
23. Install swashplate rigging tool halves (21 and 22)
(T103288-101) around collective sleeve with index pin
(19) engaged in swashplate outer ring. Secure tool
halves (21 and 22) with screws (18).
24. Lightly tighten screw (20) in aft tool half (21) to seat
sleeve in forward rigging tool half (22), then rotate tool
assembly clockwise to bottom index pin (19) in cutout
of swashplate outer ring.
25. With swashplate rigging tool (T103288-101)
positioned per step 24, push tool assembly down until
all three swashplate positioning lugs are in contact with
outer swashplate bearing retainer. Hold tool and
swashplate in this position and secure with screw (20).
NOTE
If necessary, rotate swashplate outer ring
until bearing retainer ring fasteners clear tool
swashplate positioning lugs.
67-00-00
30 SEP 2003 Rev. 7 Page 35
BHT-412-MM-8

Figure 67-9. Cyclic Rigging (Alternate Method) (Sheet 1 of 4)

67-00-00
Page 36 Rev. 7 30 SEP 2003
 BHT-412-MM-8

Figure 67-9. Cyclic Rigging (Alternate Method) (Sheet 2)

67-00-00
30 SEP 2003 Rev. 7 Page 37
BHT-412-MM-8

19

21
20

18 18

22

F
W
D

VIEW LOOKING DOWN

23

18. Screw
19. Index pin
20. Screw 24
21. Rigging tool half (T103288-101) 28
22. Rigging tool half (T103288-101)
23. Pin
24. Collective lever
25. Extension tube
26. Plate assembly
26
27. Rigging tool (T103287-111)
28. Screw
27

25

412_MM_67_0011

Figure 67-9. Cyclic Rigging (Alternate Method) (Sheet 3 of 4)

67-00-00
Page 38 Rev. 11 30 MAR 2007
 BHT-412-MM-8

Figure 67-9. Cyclic Rigging (Alternate Method) (Sheet 4)

67-00-00
30 SEP 2003 Rev. 7 Page 39
BHT-412-MM-8
26. Ensure collective lever rigging tool (T103287-111)
is positioned per step 22, and swashplate rigging tool
(T103288-101) is positioned per step 23 through step
25 before proceeding.
27. Adjust length of extension tubes (2 and 3, Figure
67-2) to fit swashplate.
NOTE
Provide a minimum of 1.5 exposed threads
to extension tubes (2 and 3) upper clevis. If
required at completion of step 27, it is
permissible to shorten control tubes (8 and
9) equally a maximum of five complete turns
of adjustable rod end bearing. Ensure
extension tubes (2 and 3) are disconnected
from swashplate before adjusting control
tubes (8 and 9). Shortening tube assemblies
(8 and 9) adjustable rod end bearing 1.5
turns is equal to approximately one thread of
extension tube (2 and 3) upper clevis.
28. Torque nuts on both extension tubes 1500 to 1800
inch-pounds (169.47 to 203.37 Nm) and secure with
lockwire (C-405). Apply adhesive (C-308) on nut,
lockwire, threads of clevis, and both extension tubes.
28A.Connect extension tubes (2 and 3) to swashplate
(1) by installing bolts, washers, nut, and cotter pins.
29. Remove swashplate rigging tool (T103288-101).
30. Remove collective lever rigging tool
(T103287-111) and reconnect hydraulic cylinder
extension tube (25, Figure 67-9) to collective lever (24).
31. Install cyclic corner stop rigging tool base
(T103281-101) (34) on left series actuator and secure
in place with screw (30). Attach rod clamp (31) to left
series actuator support and secure with screw (35).
Align slide (33) index mark “N” with pointer on rigging
tool base (34) and secure with screw (32).
32. Install cyclic corner stop rigging tool base
(T103281-102) (34) on right series actuator and secure
in place with screw (30). Attach rod clamp (31) to right
series actuator support and secure with screw (35).
67-00-00
Page 40 Rev. 12 27 FEB 2009
Align slide (33) index mark “N” with pointer on rigging
tool base (34) and secure in position with screw (32).
33. Remove cyclic stick rigging tool (T103347-101).
34. Place pilot cyclic against extreme left lateral stop.
Move stick forward toward forward left corner position
until pointer on left hand rigging tool base (34) aligns
with slide (33) index mark “F” (Figure 67-9).
35. Adjust corner stop bolt (7, Figure 67-3) in bellcrank
(6) to make contact with actuator support (8).
36. Move cyclic stick from forward left corner position
aft toward aft left corner position until pointer on right
rigging tool base (34, Figure 67-9) aligns with slide (33)
index mark “A”.
37. Adjust corner stop bolt (5, Figure 67-3) to make
contact with bellcrank (6).
38. Place pilot cyclic against extreme right lateral stop.
Move stick forward toward forward right corner position
until pointer on right rigging tool base (34, Figure 67-9)
aligns with slide (33) index mark “F”.
39. Adjust corner stop bolt (12, Figure 67-3) in
bellc rank (11) to mak e contac t with actuator
support (13).
40. Move cyclic from forward right corner position aft
towards aft right corner position until pointer on left
rigging tool base (34, Figure 67-9) aligns with slide (33)
index mark “A”.
41. Adjust corner stop bolt (10, Figure 67-3) to make
contact with bellcrank (11).
42. Turn hydraulic power cart off and disconnect from
helicopter.
43. Remove cyclic corner stop rigging tools
(T103281-101 and -102).
44. Connect four pitch links to pitch horns
(Chapter 62).

45. Perform fore and aft cyclic transducer (34, figure
67-2) adjustments as follows:
NOTE
Following procedure applies to helicopters
S/N 33001 through 33213 and S/N 36001
t hr o u gh 3 60 8 6 w i t h t r a n s d u c e r P / N
412-074-101-101 installed. For helicopters
S/N 36037 through 36086 with transducer P/
N 412-074-101-103 installed refer to
paragraph 67-278.
a. Attach fore and aft cyclic transducers to
structure (figure 67-7).
b. Position pilot cyclic against extreme forward
stop, then against extreme aft stop. Check if
transducers would bottom out if connected to jackshaft.
c. If bottoming occurs, adjust rod end bearings on
transducers until bottoming is eliminated and connect
transducers to jackshaft. Overtravel to transducers
should be approximately equal.
46. Perform lateral cyclic transducer (29, figure 67-2)
adjustment as follows:
NOTE
Following procedure applies to helicopters
S/N 33001 through 33213 and S/N 36001
t hr o u gh 3 60 8 6 w i t h t r a n s d u c e r P / N
412-074-101-101 installed. For helicopters
S/N 36037 through 36086 with transducer P/
N 412-074-101-103 installed refer to
paragraph 67-278.
a. Attach lateral cyclic transducer to structure
(figure 67-7).
b. Position pilot cyclic against extreme right
lateral stop, then against extreme left lateral stop.
Check if transducers would bottom out if connected to
bellcrank.
c. If bottoming occurs, adjust rod end bearings on
transducers until bottoming is eliminated and connect
transducers to bellcrank. Overtravel of transducers
should be approximately equal.
BHT-412-MM-8
47. Turn on hydraulic power cart and apply hydraulic
power to helicopter.
WHEN PERFORMING OPERATIONAL
CHECK OF CYCLIC CONTROLS WITH
HYDRAULIC SYSTEM PRESSURIZED,
ENSURE COLLECTIVE STICK IS
POSITIONED NEAR MID TRAVEL.
48. Perform cyclic minimum friction adjustment as
follows:
NOTE
Initial adjustment and check of fore and aft
and lateral cyclic stick force shall be
accomplished by utilizing a hydraulic power
cart connected to helicopter using steps a.
through g. Final check and adjustment shall
be accomplished during ground run of
helicopter using steps b. through g.
a. Reduce cyclic stick friction to zero by loosening
clamp (figure 67-8). Rotate nut counterclockwise.
b. With force trim OFF, slowly increase stick
friction while simultaneously pulling on cyclic stick with
spring scale attached at midpoint of grip until a fore and
aft cyclic breakout force of 0.5 to 1.0 lbs. (2.224 to 4.448
N) is obtained.
c. Forces to be measured perpendicular to axis of
stick with stick near center.
d. Check lateral cyclic breakout force of 0.5 to 1.0
lbs. (2.224 to 4.448 N).
e. If lateral stick force exceeds above
requirement, readjust fore and aft friction breakout
within above limits and recheck lateral breakout force.
f. Tighten clamp around sleeve with clamp
resting on top surface of nut (figure 67-8). Tighten
screws to obtain equal gap between clamp halves.
67-00-00
30 SEP 2003 Rev. 7 Page 41
BHT-412-MM-8

NOTE MATERIALS REQUIRED

Steps g., h., and i. are not applicable to SN
36087 and subsequent. Refer to BHT-ALL-SPM for specifications and source.

g. With force trim ON, check breakout force of NUMBER NOMENCLATURE

fore and aft cyclic stick force of 2.25 to 2.75 pounds
(10.01 to 12.23 N) and lateral stick force of 1.5 to 2.0 C-405 Lockwire
pounds (6.67 to 8.90 N).
1. Verify cyclic rigging (paragraph 67-5 or 67-6) prior
h. If fore and aft or lateral breakout forces exceed to adjustment of cyclic controls position sensor and
above requirements, repeat steps a. through f. above. fore-and-aft cyclic sensor.

i. If fore and aft or lateral breakout forces still

2. Prepare helicopter for rigging as follows:
exceed above requirements, readjust either fore and aft
force gradient or lateral force gradient spring preloads
within their respective limits to obtain required breakout a. Place jacks under helicopter as in jacking
force. Repeat steps a. through g. above with hydraulic procedure (Chapter 7) and raise jacks just high enough
power applied. to prevent helicopter from shifting when maintenance
personnel are working around swashplate and controls.
NOTE
For cyclic force gradient spring preload b. Verify both actuator assemblies, longitudinal
adjustments and cyclic control stick mass and lateral, are centered when electrical power is
balance adjustment, refer to paragraph applied to helicopter. Centering measurement will be
67-166 and 67-171. taken from the center of bolt hole on the clevis on one
end, to the center of rod end bearing on the other end
49. Remove hydraulic power. of the actuator. Centered length of the longitudinal
series actuator (14, Figure 67-2) is 27.505 to 27.555
inches (698.627 to 699.897 mm).
50. Accomplish rigging of cyclic controls position
sensors (paragraph 67-8).
c. Set swashplate to a level position as follows:
67-8. Cyclic Position Sensors
(1) Apply hydraulic power to helicopter.
SPECIAL TOOLS REQUIRED
(2) Position swashplate rigging tool (2, Figure
NUMBER NOMENCLATURE 67-10) on outer cap portion of swashplate (1).

— Inclinometer (3) Position swashplate perpendicular with

respect to mast by moving cyclic stick as required.
T101291-103 Swashplate Rigging Tool
T103356-101 Position Sensor Rigging (4) Place an inclinometer
Tool (propeller-protractor) on upper surface of rigging tool
(2).

(5) Move cyclic stick slightly to obtain desired

attitude of:

(a) Fore and aft cyclic – position

swashplate to 0° ±15'.

(b) Lateral cyclic – position swashplate

to 0° ±15'.

67-00-00
Page 42 Rev. 12 27 FEB 2009

3. Apply cyclic stick friction to hold position
established in preceding step (2.c.5).
4. Rig fore and aft cyclic sensor (figure 67-11) as
follows:
a. Position clamp assembly (13) on idler (5) to
3.05 in. (77.47 mm) dimension as shown. Secure clamp
assembly to idler with yoke (12). Adjust screws (1) to
obtain equal gap between both sides of clamp
assembly and yoke. Secure screw with lockwire
(C-405) (21).
b. Position and hold tool (18) (F/A slot) on sensor
target index attached to the clamp assembly (13).
c. Position switch (15) attached to sensor plate
(10) in opposite slot of tool to align switch with target
(14). Secure sensor plate (10) to support assembly (9)
with screw (8).
d. With tool (18) still positioned per step b.,
position and hold switch (15) against tool to set air gap
0.064 to 0.065 in. (1.625 to 1.651 mm). Secure switch
(15) to sensor plate (10). (See figure 67-12 for
installation).
NOTE
Idler (5) may be disconnected and rotated
180 ° (around vertical axis) on support
assembly (6) to facilitate adjustment of
switch (15).
e. Use tool (18) to recheck switch (15) alignment
and air gap. Readjust as required. Secure retaining
nuts with lockwire (C-405) (21) on either side of sensor
plate (10). Remove tool (18).
5. Rig lateral sensor (figure 67-12) as follows:
a. Position and hold tool (8) on target (9) attached
to arm assembly (6) and bellcrank (7).
b. Position switch (5) attached to sensor plate (3)
in opposite slot of tool to align switch (5) with target (9).
Secure plate (3) to support assembly (1) using screws
(2 and 4).
BHT-412-MM-8
c. With tool (8) still positioned per steps a. and b.,
position and hold switch (5) against tool to set gap
0.078 to 0.080 in. (1.981 to 2.032 mm). Secure switch
(5) to plate (3) using retaining nuts (10 and 11).
NOTE
Support assembly (1) may be adjusted to
facilitate adjustment of sensor.
d. Use tool (8) to recheck switch alignment and air
gap. Adjust as required. Secure retaining nut used to
adjust switch (5) with lockwire (C-405). Remove tool (8)
and remove swashplate rigging tool (2, figure 67-10).
6. Electrical function and sensor rigging checkout.
a. Remove electrical power and remove 8Z1P3
(center connector) from RPM limit warning detector.
(RPM detector is located on shelf in nose compartment
(Chapter 96).
b. Install a jumper wire between pin F and pin G
of 8Z1P3 connector.
c. Apply electrical power and Batt bus 1 and 2 on,
and with hydraulic pressure applied, move pilot cyclic
laterally both directions. Note CYC CTR caution lights
illuminate after stick moves approximately 10% either
side of center.
d. Repeat step 6.c. for fore and aft cyclic.
e. From a centered position, move pilot cyclic
forward until caution light comes on. Hold stick in this
position and check for longitudinal swashplate angle of
1° to 1° 30' down forward with respect to mast.
f. Repeat step 6.e. for aft stick movement.
g. From a centered position, move pilot cyclic to
left until caution light comes on. Hold stick in this
position and check for lateral swashplate angle of 0° 30'
to 1° down left with respect to mast.
h. Repeat step 6.g. for right stick movement.
i. If swashplate angle does not fall within above
limits, rerig as required.
67-00-00
30 SEP 2003 Rev. 7 Page 43
BHT-412-MM-8

Figure 67-10. Position Verification

67-00-00
Page 44 Rev. 7 30 SEP 2003
 BHT-412-MM-8

Figure 67-11. Fore and Aft Cyclic Sensor Adjustment (Sheet 1 of 2)

67-00-00
30 SEP 2003 Rev. 7 Page 45
BHT-412-MM-8

Figure 67-11. Fore and Aft Cyclic Sensor Adjustment (Sheet 2)

67-00-00
Page 46 Rev. 7 30 SEP 2003
 BHT-412-MM-8

j. Remove jumper and connect 8Z1P3 to the e. Torque control jam nuts 80 to 100 inch-pounds
RPM limit warning detector. (9.04 to 11.30 Nm) after adjustment unless other torque
is specified.
67-9. ANTI-TORQUE CONTROLS
f. Control tubes must be free to rotate several
degrees about longitudinal axis. Loosen jam nuts,
SPECIAL TOOLS REQUIRED
adjust end fittings, and torque jam nuts if necessary.

NUMBER NOMENCLATURE 2. Disconnect the following control tubes and force

— Spring Scale (Range to
Measure 5 to 6 Pounds
(22.2 to 26.7 N)
T103206-101 Tail Rotor Rigging Tool
gradient.
a. Disconnect anti-torque force gradient (14,
Figure 67-13) and transducer (20) from pilots pedal
adjuster (21).

MATERIALS REQUIRED b. Disconnect control tube (16) from pilots pedal

adjuster (17).

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

NUMBER NOMENCLATURE
C-104 Corrosion Preventive
Compound
NOTE
Rigging procedures contained herein
pertain to helicopters with dual controls
installed in basic controls systems.
1. Comply with the following general procedures
when rigging anti-torque controls:
a. When a rigging procedure requires a specific
position to accomplish following steps, manually hold
controls in position or secure controls in position with
pilot friction adjustment.
b. Tolerance for rigging dimensions is ±0.03 inch
(0.76 mm).
c. All adjustable control tubes must have a
maximum of 1.0 inch (2.54 mm) of exposed threads
after adjustment. If control tubes have inspection holes,
threads shall be engaged sufficiently to cover holes.
d. Apply corrosion preventive compound (C-104)
to threads of all adjustable rod bearings and clevises
after adjustment.
c. Disconnect control tube (7) from bellcrank (8).
d. Disconnect link (4) from lever (3).
3. Retract two stop bolts on bellcrank (10) as far as
possible.
4. Verify length of centered series actuator (11),
62.865 to 62.915 inches (1596.771 to 1598.041 mm).
5. Push both pilot and copilot left directional pedals
against extreme forward stops. Adjust control tube (16)
to fit, torque jam nut and install.
6. Check two pitch links (2) for 6.180 ± 0.010 inches
(156.972 ±0.254 mm) between bolt hole centers
(Chapter 65).
7. Remove bolt (2, Figure 67-14) retaining pitch link
to crosshead (1).
8. Install tail rotor rigging tool (3) (T103206-101) to
crosshead and against trunnion (5). Retain with bolt (2).
9. Push inboard on crosshead (1) to cause tool to
make firm contact with trunnion (5).
10. Adjust link (4, Figure 67-13) to obtain 0.58 inch
(14.73 mm) clearance with bellcrank (6) (Detail A).
Torque jam nut on link (4), and install link (4) on
bellcrank (6) and lever (3).

67-00-00
27 FEB 2009 Rev. 12 Page 47
BHT-412-MM-8

Figure 67-12. Lateral Cyclic Sensor Adjustment (Sheet 1 of 2)

67-00-00
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 BHT-412-MM-8

Figure 67-12. Lateral Cyclic Sensor Adjustment (Sheet 2)

67-00-00
30 SEP 2003 Rev. 7 Page 49
BHT-412-MM-8
NOTE
If hydraulic power cart is not available, omit
steps 11 through 13. and proceed to note
preceding step 14. If hydraulic power is
available, accomplish steps 11 through 13.
and omit steps 14 through 17.
11. Connect hydraulic cart to helicopter.
12. Apply hydraulic power from hydraulic cart to
helicopter.
13. Position pilot left anti-torque pedal forward against
stop and retain in position. Adjust tube (7) to fit bellcrank
(8). Torque jam nut on tube (7). Install tube (7) on
bellcrank (8).
NOTE
Alternate method of rigging anti-torque
controls without pressurizing the hydraulic
system: If hydraulic power cart is not
available, adjust tube (7) as outlined in steps
14 through 17.
14. Hold pilot left pedal forward against stop.
15. Push down and hold anti-torque hydraulic cylinder
(9) piston rod to bottom anti-torque hydraulic cylinder.
16. Position bellcrank (6) as shown in Detail A and
hold.
17. Adjust tube assembly (7) to fit bellcrank (8), then
shorten by one half turn of clevis on tube (7). Torque
jam nut on clevis on tube (8). Install tube (7) on
bellcrank (8).
18. Remove rigging tool (3, Figure 67-14)
(T103206-101) and install pitch link (6) to crosshead (1)
19. Position pilot left pedal forward against stop.
Adjust forward stop bolt in bellcrank (10, Figure 67-13,
Detail D) 0.005 to 0.015 inch (0.127 to 0.381 mm).
20. Position pilot right pedal forward against stop.
Adjust aft stop bolt in bellcrank arm (10) 0.005 to 0.015
inch (0.127 to 0.381 mm).
67-00-00
Page 50 Rev. 12 27 FEB 2009
21. Turn off hydraulic power and disconnect cart from
helicopter.
22. Rig anti-torque controls force gradient (14) and
magnetic brake (15) as follows:
a. Ensure anti-torque magnetic brake arm (26) is
on anti-torque magnetic brake (15) with index mark D
aligned (Detail C).
b. Place pilot pedals in neutral position and hold.
c. Position arm (26) on anti-torque magnetic
brake (15) at center of travel.
d. Adjust anti-torque force gradient (14) to fit pilot
pedal adjuster (21). Torque jam nut on anti-torque force
gradient clevis.
e. Install anti-torque force gradient (14) on pilot
pedal adjuster (21).
f. Move pilot pedals through full travel and check
clearance between anti-torque force gradient (14) and
structure. If there is interference, correct as described
in step g. below.
g. Remove arm (26) from anti-torque magnetic
brake (15). Move one serration and reinstall. Repeat
clearance check described in step f.
23. Perform directional control motion transducer
adjustment as follows:
NOTE
Following procedure applies to helicopters
S/N 33001 through 33213 and S/N 36001
through 36036. For helicopters S/N 36037
and subsequent refer to paragraph 67-279.
a. Attach transducer (3, Figure 67-15) in
directional control system to support only (4).
b. Place pilot pedal against one stop, then other
stop. Check if transducer (3) bottoms out in either
retracted or extended position if connected to bellcrank
(1).
 BHT-412-MM-8

412_MM_67_0022a

Figure 67-13. Anti-Torque Rigging (Sheet 1 of 2)

67-00-00
27 FEB 2009 Rev. 12 Page 51
BHT-412-MM-8

Figure 67-13. Anti-Torque Rigging (Sheet 2)

67-00-00
Page 52 Rev. 7 30 SEP 2003
 BHT-412-MM-8

2
1 3 4

1. Crosshead
2. Bolt
3. Tail rotor rigging tool (T103206-101)
4. Tail rotor
5. Tail rotor hub trunnion
6. Pitch link

412_MM_67_0023

Figure 67-14. Rigging Tool (T103206-101)

67-00-00
27 FEB 2009 Rev. 12 Page 53
BHT-412-MM-8

c. If bottoming occurs, adjust rod end bearing (2) MATERIALS REQUIRED

on transducer (3) until bottoming is eliminated. Connect
transducer to bellcrank (1). Overtravel of transducer Refer to BHT-ALL-SPM for specifications and source.
should be approximately equal.
NUMBER NOMENCLATURE
24. Adjust anti-torque minimum friction as follows:
C-101 Corrosion Preventive
Compound
a. Attach spring scale to one pilot pedal.
C-405 Lockwire

b. With boost on, measure force required to move NOTE

pedal through neutral position.
c. If required, adjust screw (25, Figure 67-13) on
clamp (24) to obtain friction of 4.5 ± 0.25 pounds (20.16
±1.112 N).
25. Move anti-torque controls through full travel and
check for binding and/or obstruction of control
movement.
Rigging may be accomplished with
helicopter leveled or not leveled. Caution
must be taken not to move helicopter
regardless of leveling.
1. Remove tailboom panel below elevators (2 and 4,
Figure 67-16) to gain access to control tube (5).
2. Remove lockwire from clevis jam nut (10) locking
washer (9). Loosen clevis jam nut.

26. Ensure all control bolts are installed and cotter 3. Remove forward clevis (7) from tube support (6)
pins and lockwire installed where applicable. (paragraph 67-268).

4. Install rigging tool (14) on shaft (15) as follows:

67-10. AERODYNAMICALLY ACTUATED
ELEVATOR
a. Separate rigging tool (14) into two halves by
removing two tool screws (11) and tool washers (12).
SPECIAL TOOLS REQUIRED
b. Position two halves of rigging tool (14) on shaft
(15) with shouldered ends against end cap (13). Secure
NUMBER NOMENCLATURE
halves together with two tool screws (11) and tool
Commercial Feeler Gauge or 0.050 washers (12).
inch (12.7 mm)
(or Equivalent) Shim

TB107 *Clinometer or,

Commercial *Inclinometer

Commercial Shot Bags

(or Equivalent) 20 to 30
Pounds (9.1 to 13.6 Kg)

GS18217 *Propeller Protractor

T103296-101 Rigging Tool

NOTE:

Tools listed above coded with asterisk (*) are

referred to as “protractor” in the following text.

67-00-00
Page 54 Rev. 11 30 MAR 2007
 BHT-412-MM-8

Figure 67-15. Control Motion Transducer Rigging

67-00-00
30 SEP 2003 Rev. 7 Page 55
BHT-412-MM-8

412_MM_67_0008
Figure 67-16. Elevator Rigging (Sheet 1 of 2)

67-00-00
Page 56 Rev. 11 30 MAR 2007
 BHT-412-MM-8

Figure 67-16. Elevator Rigging (Sheet 2 of 2)

67-00-00
30 MAR 2007 Rev. 11 Page 57
BHT-412-MM-8
5. Hold shaft (15) at wrenching flat. Tighten clevis
jam nut (10) against rigging tool (14) until shaft is
extended to maximum length (control tube (5) internal
stop is bottomed).
6. Determine correct elevator nose down position for
rigging as follows:
CAUTION
MAKE SURE THAT INSTRUMENT USED
TO MEASURE DECK ANGLE, WHEN
MOVED FROM LEFT SEAT RAIL TO LEFT
E L E VAT O R , I S P L A C E D I N S A M E
FORE-AND-AFT DIRECTION AS WHEN
DECK ANGLE WAS MEASURED.
a. Position protractor (3) fore and aft on copilot
seat outboard seat rail.
NOTE
Removal of copilot seat is not required.
b. Read and record protractor (3) indication. This
reading indicates helicopter nose up or down position.
c. Add/subtract above indication to/from 6° 4'
(6.067°) and 6° 15' (6.25°). The result is the correct
elevator nose down position for rigging.
Example 1: Step b indicates that helicopter is in a
level position.
6 °04’(6.067 °) + 0 °0’(0.0 °) = 6 °04’(6.067 °)
6 °15’(6.25 °) + 0 °0’(0.0 °) = 6 °15’(6.25 °)
Therefore, correct elevator nose down position
is 6 °04’ (6.067 °) to 6 °15’ (6.25 °) for rigging.
Example 2: Step b indicates that helicopter is in a
1 °50’(1.833 °) nose up position.
6 °04’(6.067 °) – 1 °50’(1.833 °) = 4 °14’(4.234 °)
6 °15’(6.25 °) – 1 °50’(1.833 °) = 4 °25’(4.417 °)
Therefore, correct elevator nose down position
is 4 °14’ (4.234 °) to 4 °25’ (4.417 °) for rigging.
67-00-00
Page 58 Rev. 11 30 MAR 2007
Example 3: Step b indicates that helicopter is in a
1 °50’ (1.833 °) nose down position.
6 °04’(6.067 °) + 1 °50’(1.833 °) = 7 °54’(7.9 °)
6 °15’(6.25 °) + 1 °50’(1.833 °) = 8 °05’(8.083 °)
Therefore, correct elevator nose down position
is 7 °54’ (7.9 °) to 8 °05’ (8.083 °) for rigging.
7. Position left elevator (4) in correct nose down
position, as determined in step 6b as follows:
CAUTION
PROTRACTOR (3) SHALL BE
POSITIONED ON LEFT ELEVATOR (4) AS
SHOWN IN FIGURE 67-16 TO OBTAIN
CORRECT RIGGING.
a. Position protractor (3) on left elevator (4).
b. Position shot bags (1) near leading edge of
right elevator (2) to temporarily hold left elevator (4) in
correct nose down position.
NOTE
If correct position cannot be obtained,
remove lockwire, loosen and adjust aft stop
bolt (17), then reinstall lockwire.
c. Adjust forward and aft stop bolts (17 and 18) to
firmly hold left elevator (4) in correct nose down
position.
d. Verify protractor (3) is in correct position and
left elevator (4) is in correct nose down position.
8. Adjust length of control tube (5) to align mounting
holes of forward clevis (7) and tube support (6) as
follows:
a. Hold shaft (15) at wrenching flat. Rotate
forward clevis (7) until clevis reaches tube support (6).
b. Using shaft (15) wrenching flat, rotate shaft and
forward clevis (7) until mounting holes in forward clevis
and tube support (6) are aligned.

9. Install forward clevis (7) on tube support (6)
(paragraph 67-71).
10. Inspect for minimum thread engagement of shaft
(15) into forward clevis (7) using inspection hole in
forward clevis.
11. Verify protractor (3) is in correct position and left
elevator (4) is in correct nose down position (step 7).
12. Adjust aft stop bolt (17) as follows:
a. Loosen aft stop bolt (17).
b. Position 0.050 inch (1.270 mm) feeler gauge or
shim stock on aft surface of elevator horn (8) in line with
aft stop bolt (17).
c. Tighten aft stop bolt (17) until it contacts feeler
gauge or shim stock.
d. Secure aft stop bolt (17) with aft jam nut (16).
Secure jam nut to stop support with lockwire (C-405).
13. Verify protractor (3) is in correct position and left
elevator (4) is in correct nose down position (step 7).
14. Remove rigging tool (14) as follows:
a. Hold shaft (15) at wrenching flat. Loosen clevis
jam nut (10).
b. Separate rigging tool (14) into two halves by
removing two tool screws (11) and tool washers (12).
BHT-412-MM-8
15. Align keyway in shaft (15) with nearest keyway in
forward clevis (7) by rotating shaft no more than 45°.
Use wrenching flat to rotate shaft.
16. Position locking washer (9) tab in forward clevis (7)
keyway. Tighten clevis jam nut (10) against locking
washer. Secure clevis jam nut to locking washer with
lockwire (C-405).
17. Adjust forward stop bolt (18) as follows:
a. Cut and remove lockwire (C-405) and loosen
forward stop bolt (18).
b. Position a 0.050 inch (1.270 mm) feeler gauge
or shim stock on forward surface of elevator horn (8) in
line with forward stop bolt (18).
c. Tighten forward stop bolt (18) until it contacts
feeler gauge or shim stock.
d. Secure forward stop bolt (18) with forward jam
nut (19). Secure forward jam nut (19) to stop support
with lockwire (C-405).
18. Remove shot bags (1) and protractor (3).
19. Apply corrosion preventive compound (C-101) to
threads of shaft (15) and forward clevis (7).
20. Install tailboom panel below right and left elevators
(2 and 4).
67-00-00
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COLLECTIVE FLIGHT CONTROLS
67-11. COLLECTIVE CONTROLS
Collective controls (figure 67-17) consists of linkage
components from pilot collective stick (13) up to, but not
including, collective lever (1).
NOTE
Automatic flight control system (AFCS) is
functional in collective control system only
when a Flight Director Kit is installed in
helicopter.
Cylinder (5) reduces effort required for control and
reduces feedback forces from main rotor.
Actuation of collective stick (13) causes hydraulic
power assisted collective pitch change of main rotor
blades.
67-12. HYDRAULIC SERVO CYLINDER BOOT
67-13. Removal
1. Open forward pylon fairing (Chapter 52).
2. Open aft pylon access doors (Chapter 52).
3. Remove cotter pin (10, figure 67-18), nut (11),
washers (8, 9, 14 and 16) and bolt (7).
4. Remove nut (2), thin aluminum washers (3 and 5)
and screw (6) and clamp (4).
5. Loosen hydraulic servo cylinder boot (1) from
retaining groove in support bracket at mount bearing
(12) and remove boot.
67-14. Inspection
Inspect hydraulic servo cylinder boot (1) for tears and
deterioration.
67-15. Installation
1. Slide hydraulic servo cylinder boot (1, figure
67-18) over hydraulic cylinder extension tube (13).
Secure bottom of boot (1) into lip in mount bearing (12).
BHT-412-MM-8
2. Position top of boot (1, detail B) on hydraulic
cylinder extension tube (13) 18.45 in. (468.63 mm)
down from centerline of bolt hole in clevis at top of tube
(13).
3. Install clamp (4), screw (6), thin aluminum
washers (3 and 5) and nut (2).
4. Position tube (13) onto collective lever (15) and
install bolt (7), washers (8, 9, 14, and 16), nut (11) and
cotter pin (10).
5. Move collective controls through full travel and
check for binding and/or obstruction of control
movement.
6. Verify collective control rigging is within limits
(paragraph 67-4).
7. Stow hold-open brace assembly and close aft
pylon access door(s).
8. Install forward pylon fairing (Chapter 52).
67-16. HYDRAULIC CYLINDER EXTENSION TUBE
67-17. Removal
1. Open forward pylon fairing (Chapter 52).
2. Open aft pylon access door(s) (Chapter 52).
3. Remove screw (13, figure 67-19) and loosen
clamp (11). Slide hydraulic servo cylinder boot (14) up
to expose hydraulic cylinder extension universal (17).
4. Remove cotter pin (20), nut (19), washers (16 and
18) and bolt (15).
5. Remove cotter pin (7), nut (8), washers (3, 5, 4 and
6) and bolt (2). Remove hydraulic cylinder extension
tube (21) from helicopter.
67-18. Inspection
Inspect tube (21, figure 67-19) for serviceability in
accordance with BHT-412-CR&O.
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BHT-412-MM-8

Figure 67-17. Collective Controls

67-00-00
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 BHT-412-MM-8

Figure 67-18. Hydraulic Servo Cylinder Boot

67-00-00
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BHT-412-MM-8

Figure 67-19. Hydraulic Cylinder Extension Tube

67-00-00
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67-19. Installation
1. Place hydraulic cylinder extension tube (21, figure
67-19) into position on collective lever (1) and install
bolt (2), washer (6), washers (4, 5 and 3) as required,
nut (8), and cotter pin (7).
2. Place tube (21) onto hydraulic cylinder extension
universal (17) and install bolt (15), washer (16), washer
(18), nut (19), and cotter pin (20).
3. Position hydraulic servo cylinder boot (1, figure
67-18) on hydraulic cylinder extension tube (13) to
obtain dimension shown. Install clamp (11, figure
67-19) with screw (13), washer (12), washer (10), and
nut (9).
4. Move collective controls through full travel and
check for interference and binding. Verify hydraulic
servo cylinder boot (14) is correctly positioned and
does not bind when controls are moved through full
travel.
5. Verify collective rigging is within limits, (paragraph
67-4).
6. Close aft pylon access door(s) (Chapter 52).
7. Close forward pylon fairing (Chapter 52).
67-20. HYDRAULIC CYLINDER EXTENSION
UNIVERSAL
67-21. Removal
1. Open forward pylon fairing (Chapter 52).
2. Open aft pylon fairing access door(s) (Chapter
52).
3. Remove screw (4, figure 67-20). Loosen bottom of
hydraulic servo cylinder boot (5) from retaining groove
in support bracket (21). Slide hydraulic servo cylinder
boot upward to expose hydraulic cylinder extension
universal (8).
4. Remove cotter pin (15), nut (14), washers (10 and
13) and bolt (9). Remove hydraulic cylinder extension
universal (8) from piston rod clevis (11) and upper
piston (12).
BHT-412-MM-8
5. Remove cotter pin (18), nut (17), washers (16 and
6) bolt (7) and hydraulic cylinder extension universal
(8).
67-22. Inspection
1. Inspect hydraulic cylinder extension universal (8,
figure 67-20) for mechanical and corrosion damage
(BHT-412-CR&O).
2. Inspect bearings for secure installation in hydraulic
cylinder extension universal and for wear. Replace as
required (BHT-ALL-SPM).
67-23. Installation
1. Place hydraulic cylinder extension universal (8,
figure 67-20) in position in piston rod clevis (11) and
install bolt (9), washer (10), washer (13), nut (14), and
cotter pin (15).
2. Place clevis on end of hydraulic cylinder extension
tube (1) on universal (8) and install bolt (7), washer (6),
washer (16), nut (17), and cotter pin (18).
3. Slide hydraulic servo cylinder boot (5) down and
secure lower end into retaining groove at support
bracket (21).
4. Position top of hydraulic servo cylinder boot (1,
figure 67-18) 18.45 in. (468.63 mm) on hydraulic
cylinder extension tube (13) down from centerline of
bolt hole in clevis at top of tube (13).
5. Secure boot with clamp (2, figure 67-20), screw
(4), washer (3), washer (19), and nut (20).
6. Close aft pylon fairing access door(s) (Chapter
52).
7. Close forward pylon fairing (Chapter 52).
67-24. PISTON ROD CLEVIS
67-25. Removal
1. Open forward pylon fairing (Chapter 52).
2. Open aft pylon fairing access door(s) (Chapter
52).
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BHT-412-MM-8

Figure 67-20. Hydraulic Cylinder Extension Universal

67-00-00
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3. Remove nut (17, figure 67-21), washers (1 and 16)
and screw (2) loosen clamp (3) and slide boot (4) up to
expose piston rod (10) and hydraulic cylinder extension
tube (15).
4. Remove cotter pin (13), nut (12), washers (11 and
6) and bolt (5).
5. Remove lockwire, loosen nut (8) and remove
piston rod clevis (7).
6. Remove nut (8) and lock (9) from piston rod clevis
(7).
67-26. Inspection
1. Inspect piston rod clevis (7, figure 67-21) for nicks,
scratches, and damaged threads.
2. Inspect piston rod clevis (7) for elongated bolt
holes.
67-27. Installation
MATERIALS REQUIRED
Refer to BHT-ALL-SPM for specifications and source.
NUMBER NOMENCLATURE
C-101 Corrosion Preventive
Compound
C-308 Adhesive
C-405 Lockwire
1. Coat threads of piston rod clevis (7, figure 67-21)
with corrosion preventive compound (C-101). Place
lock (9) into nut (8, detail C). Install nut (8) and lock (9)
on clevis (7) with hole in lock (9) up as illustrated.
2. Thread clevis (7) into piston rod (10) and adjust to
obtain 1.90 in. (48.26 mm) from centerline of bolt hole
to top of piston rod (detail B).
3. Torque nut (8) 660 to 780 in.-lbs. (74.57 to 88.13
N-m). Secure with lockwire (C-405).
4. Cover nut (8), lock (9), lockwire and threads on
clevis (7) with adhesive (C-308).
BHT-412-MM-8
AVOID GETTING SEALANT ON PISTON
ROD SURFACE OR SCRAPER AND ROD
SEAL DAMAGE MAY OCCUR.
5. Place hydraulic cylinder extension universal (14)
into clevis (7) and install bolt (5), washer (6), washer
(11), nut (12), and cotter pin (13).
6. Slide hydraulic servo cylinder boot down over
universal and position top of boot 18.45 in. (468.63 mm)
from centerline of bolt hole in top of hydraulic cylinder
extension tube (13, figure 67-18, detail B). Secure
clamp (3, figure 67-21) with screw (2), thin aluminum
washer (1), washer (16), and nut (17).
7. Move collective controls through full travel and
check for interference and binding.
8. Verify collective and/or cyclic control rigging is
within limits (paragraphs 67-4 through 67-8).
9. Close aft pylon fairing access door(s) (Chapter
52).
10. Close forward pylon fairing (Chapter 52).
67-28. SERVO VALVE BALANCE SPRING
The servo valve balance spring is mounted on
collective flight control cylinder to apply an upward
force to control lever.
67-29. Removal
NOTE
Gain access to collective hydraulic flight
control cylinder (1, figure 67-22) through
large access in bottom of helicopter
(Chapter 52).
1. Disconnect top of spring (4) from spring clip (2).
2. Disconnect bottom of spring (4) from spring clip
(3). Remove spring.
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BHT-412-MM-8

Figure 67-21. Piston Rod Clevis

67-00-00
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 BHT-412-MM-8

4
3
SEE
DETAIL A

DETAIL A

1. Collective hydraulic flight control cylinder

2. Spring clip
3. Spring clip
4. Spring

412_MM_67_0012

Figure 67-22. Servo Valve Balance Spring

67-00-00
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BHT-412-MM-8

67-30. Servo Valve and Balance Spring — 9. Carefully remove collective flight control cylinder
Inspection (6) and tube (16).

1. Inspect spring (4, Figure 67-22) for deformation

10. Reposition boot (24) to allow removal of cotter pin
and loss of tension. Free length should be
(23), nut (22), washers (19 and 21), and bolt (18) (Detail
approximately 3.5 inches (88.9 mm).
B). Retain bolt (18), universal (17), and tube (16).

2. Use a spring scale to verify a force of 42.4 pounds

(188.6 N) will stretch spring (4) 1.0 in. (25.4 mm). 11. Loosen jam nut (70) and remove clevis (68) from
upper piston (20).
67-31. Servo Valve and Balance Spring —
Installation 67-34. Collective Flight Control Cylinder —
Inspection
1. Connect bottom of spring (4, Figure 67-22) to
spring clip (3). 1. Inspect collective flight control cylinder (6, Figure
67-23) for damage and signs of leakage.
2. Connect top of spring (4) to spring clip (2).
2. Inspect exposed portion of pistons for wear and
67-32. COLLECTIVE FLIGHT CONTROL corrosion.
CYLINDER
3. Inspect bearings for looseness (BHT-ALL-SPM).
67-33. Collective Flight Control Cylinder —
Removal
67-35. Collective Flight Control Cylinder —
1. Remove access panel on forward side of pylon Installation
support inside cabin (Chapter 52).
MATERIALS REQUIRED
2. Remove aft pylon fairing assembly (Chapter 52).
Refer to BHT-ALL-SPM for specifications and source.
3. Refer to Chapter 29 before performing
maintenance on hydraulic systems. NUMBER NOMENCLATURE

C-002 Hydraulic Fluid

4. Disconnect hoses (38, 46, 52, and 57, Figure
67-23, Detail D). Remove bolts (30 and 37) and elbows C-104 Corrosion Preventive
(32 and 35). Cap or plug open ports to prevent Compound
contamination.
C-127 Corrosion Preventive
Compound
5. Disconnect spring (56) from spring clip (54).
Remove cotter pin (43), nut (42), washers (40 and 41), C-308 Sealant
and bolt (55), and disconnect tube (53). Retain bolt
(55), spring clip (54), and spring (56). C-405 Lockwire

6. Remove cotter pin (51), nut (50), aluminum
washers (49), and bolt (47).
7. Remove nuts (25 and 29) and aluminum washers
(26 and 28) (Detail C).
8. Remove cotter pin (15), nut (14), washers
(10,11,12, and 13), and bolt (9) (Detail A).
1. Cut and remove lockwire and loosen nut (65 and
66, Figure 67-23) so support bracket (27) may be
rotated easily (Detail F).
2. Install clevis (68) with jam nut (70) and lock (69) in
upper piston (21) to dimension of 1.90 inches
(48.26 mm) between end of upper piston (20) and
center of holes in clevis (68).

67-00-00
Page 70 Rev. 13 29 OCT 2009 ECCN EAR99

3. Torque jam nut (70) 660 to 780 inch-pounds
(67.79 to 88.12 Nm) and secure with lockwire (C-405).
Cover jam nut, lock (69), and threads of clevis (68)
with sealant (C-308) (Detail G).
4. Place universal (17), attached to tube (16), into
clevis (68) on upper piston (20) and install bolt (18),
washers (19 and 21), nut (22), and cotter pin (23)
(Detail B).
5. Raise bottom of boot (24) to expose universal
(17) and clevises. Brush corrosion preventive
compound (C-104) on universal and clevises as
required. Brush corrosion preventive compound
(C-104) on mount bearing and in housing cavity.
Position lower end of boot in groove of support
bracket (27).
6. Guide collective flight control cylinder (6) carefully
into helicopter. Place support bracket (27) over studs
in support (5) (Detail C). Install aluminum washers (26)
and torque nuts (25) 75 to 95 inch-pounds (10.73 to
12.43 Nm). Install aluminum washer (28) and torque
nut (29) 120 to 160 inch-pounds (13.6 to 18.1 Nm).
7. Pull lower piston (61) full down and push actuator
(60) full up (Detail E). If hole in rod end bearing (64)
does not align with hole in support (48), adjust rod end
bearing.
CAUTION
IMPROPER TORQUE TECHNIQUE CAN
DESTROY TAB ON LOCKING DEVICE
(62). ROD END BEARING (64) MUST BE
HELD SECURE TO PREVENT
DAMAGING LOCKING DEVICE.
8. Remove lockwire and loosen nut (63), and turn
rod end bearing (64) to align with bolt hole.
9. Torque nut (63) to 200 to 250 inch-pounds (22.60
to 28.25 Nm) and secure to locking device (62) with
lockwire (C-405).
ECCN EAR99
BHT-412-MM-8
10. Inspect locking device (62) to ensure tab is in
groove of rod end bearing (64) and that it was not
damaged when nut (63) was tightened. Replace
locking device if tab is twisted or damaged.
11. Align collective flight control cylinder (6) into
support (48) as follows:
a. Move lower piston rod up and clear of support
(48). Lower piston rod must be able to be moved freely
down, up, and then down, and bolt (47) replaced
without any pressure, forcing, binding, or bending of
piston rod in fore, aft, left, or right direction. One
person must guide extension tube (16) to prevent
damage when conducting this step and subsequent
steps.
b. If cylinder meets requirements of step a, it is
considered in alignment. If cylinder is aligned,
accomplish step h through step j. If cylinder is
misaligned, accomplish step c through step j.
c. Loosen nut (65) and bearing nut (66) so
cylinder is loose.
d. Move rod end bearing (64) up approximately
0.5 inch (12.7 mm) above support (48). Rotate lower
end of cylinder in a 3.0 inch (76.2 mm) circle.
e. Position rod end bearing (64) directly over
lugs of support (48) and move piston down and
temporarily install bolt (47).
f. Tighten bearing nut (66) by hand
(approximately 70 inch-pounds (7.91 Nm)).
g. Remove bolt (47) and move rod end bearing
(64) up and out of support (48), then move down. Rod
end bearing must be free of any side loading. Repeat
step c through step g until free of side loading.
h. Install bolt (47). Torque bearing nut (66) to 200
inch-pounds (22.60 Nm).
67-00-00
29 OCT 2009 Rev. 13 Page 70A/70B

i. If cylinder still meets requirements of step a,
install washer (49) and nut (50) and torque 95 to 100
inch-pounds (10.73 to 12.43 Nm). Install cotter pin (51).
j. Torque bearing nut (66) 900 to 1100
inch-pounds (101.69 to 124.28 Nm). Torque jam nut
(65) 900 to 1100 inch-pounds (101.69 to 124.28 Nm).
Secure nuts (65 and 66) to keyed washer (67) with
lockwire (C-405).
NOTE
If cylinder (6) still cannot be installed without
preload, it is permissible to add one
AN960C416L washer (maximum) on two aft
studs of support (5) between support
bracket (27) and support (5). Or, it is
permissible to add one AN960C416L
washer (maximum) and one AN960C516L
washer (maximum) on each of two forward
studs between support bracket (27) and
support (5).
Use washers (12 and 13) as required to
obtain proper engagement of cotter pin (15)
and nut (14).
12. Position extension tube (16) on collective lever (4).
Install bolt (9), washer (10, 11, 12, and 13), and nut (14).
Install cotter pin (15) (Detail A).
13. After installation and torquing of cylinder assembly
and before installing boot (24) fill mount bearing
housing cavity as required with corrosion preventive
compound (C-104) or corrosion preventive compound
(C-127). Secure boot (24) over universal (17) and
mount bearing housing as shown in Figure 67-18.
14. Secure tube (53, Figure 67-23) to lever (39) with
bolt (55), spring clip (54), washers (40 and 41), nut (42),
and cotter pin (43). Connect spring (56) to spring clip
(54) (Detail D).
15. Lubricate new packings (31, 33, 34, and 36) with
hydraulic fluid (C-002). Install packings (31, 33, 34 and
36), elbows (32 and 35), and bolts (30 and 37).
16. Lubricate new packings (44 and 59) with hydraulic
fluid (C-002). Install packings (44 and 59) and bypass
check valves (45 and 58) if removed. Connect hoses
(38, 46, 52, and 57). Observing hydraulic systems No.
1 and No. 2 labels.
ECCN EAR99
BHT-412-MM-8
17. Bleed hydraulic system (Chapter 29).
18. Energize hydraulic system and operate collective
actuator through ten complete cycles. Visually inspect
system for leaks.
19. Verify collective rigging is within limits (paragraph
67-4).
20. Install pylon access panel removed (Chapter 52).
21. Install aft pylon fairing assembly (Chapter 52).
67-36. LEFT CYCLIC AND COLLECTIVE BOOST
SUPPORT
67-37. Left Cyclic and Collective Boost Support —
Removal
1. Remove transmission from helicopter (Chapter
63).
2. Remove collective hydraulic flight control cylinder
(1, Figure 67-24) (paragraph 67-33).
3. Remove left cyclic hydraulic flight control cylinder
(17) (paragraph 67-118).
4. Remove four nuts (11), one wiring bracket (18),
four washers (19), four washers (10), four bolts (20).
Remove peel shims (9).
5. Remove two nuts (5), two washers (3), two
washers (4), and two bolts (2) releasing cyclic and
collective boost support (7) from aft pylon support (6).
6. Remove two nuts (12), two washers (13), two
washers (14), and two bolts (16) releasing cyclic and
collective boost support (7) from fwd pylon support (15).
Remove cyclic and collective boost support (7).
67-38. Left Cyclic and Collective Boost Support —
Inspection
1. Inspect support (7, Figure 67-24)
(BHT-412-CR&O).
2. Inspect bushings for secure installation in support.
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BHT-412-MM-8

Figure 67-23. Collective Flight Control Cylinder (Sheet 1 of 3)

67-00-00
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 BHT-412-MM-8

17. Universal
9 18. Bolt
4 10 19. Washer (AN960C516)
20. Upper piston
11 21. Washer (AN960C516) 24
22. Nut
12
23. Cotter pin 16
13 24. Boot 17
SEE DETAIL G
14
68 18
15 21
23 22
16
19

20

1.90 IN.
DETAIL A (48.26 mm) DETAIL B

9. Bolt 30
10. Washer (AN960C516) 31
32 30. Bolt
11. Washer (AN960C516) 33 31. Preformed packing
12. Washer (AN960C516) 32. Elbow
13. Washer (AN960C516L) 33. Preformed packing
14. Nut 59 34. Preformed packing
15. Cotter pin 34 35. Elbow
16. Extension tube 58 35
56 36 36. Preformed packing
55 37. Bolt
37
38. Hose
39. Lever
57 40. Washer
41. Washer
54 38 42. Nut
39 43. Cotter pin
44. Preformed packing
53 45. Bypass check valve
40 46. Hose
3 41 47. Bolt
24 42 43
29 48. Support
25 52 49. Aluminum washer
28 1 44
50. Nut
26 51. Cotter pin
47 45 52. Hose
27
53. Tube
5 46 54. Spring clip
48
55. Bolt
56. Spring
SEE DETAIL F
57. Hose
DETAIL C 49 58. Bypass check valve
DETAIL D 59. Preformed packing
25. Nut 50 51
2
26. Aluminum washer
27. Support bracket
75 TO 95 IN-LBS 95 TO 110 IN-LBS 120 TO 160 IN-LBS
28. Aluminum washer
1 (8.47 TO 10.73 Nm) T2 (10.73 TO 12.43 Nm) T3 (13.6 TO 18.1 Nm)
29. Nut
412_MM_67_0013_c01

Figure 67-23. Collective Flight Control Cylinder (Sheet 2 of 3)

67-00-00
ECCN EAR99 29 OCT 2009 Rev. 13 Page 73
BHT-412-MM-8

60

27
62 67
61
66
63 5 65
3 5
64

DETAIL E DETAIL F

68

69
1 S

70 0.12 TO 0.15 IN.

4
(3.0 TO 3.8 mm)

20

SEALANT SHALL NOT EXTEND

BEYOND THIS POINT

DETAIL G

60. Actuator
61. Lower piston S SEALANT (C-308)
62. Locking device
63. Nut 200 TO 250 IN-LBS
64. Rod end bearing 3 (22.60 TO 28.25 Nm)
65. Nut
66. Bearing nut 660 TO 780 IN-LBS
67. Keyed washer 4 (74.57 TO 88.13 Nm)
68. Clevis
69. Lock 900 TO 1100 IN-LBS
70. Jam nut 5 (101.69 TO 124.28 Nm)

NOTE
1 Apply sealant (C-308) around jam nut (70), lock (69), and exposed threads of clevis (68).

412_MM_67_0014_c01

Figure 67-23. Collective Flight Control Cylinder (Sheet 3 of 3)

67-00-00
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 BHT-412-MM-8

67-39. Left Cyclic and Collective Boost Support 7. Install transmission (Chapter 63).
— Installation
67-40. ADJUSTABLE ROD END TUBE
1. Place cyclic and collective boost support (7,
Figure 67-24) into position in helicopter. 67-41. Adjustable Rod End Tube — Removal

2. Install bolts (2), aluminum washers (3), aluminum
washers (4), and nuts (5).
3. Install bolts (16), aluminum washers (14),
aluminum washers (13), and nuts (12).
4. Measure gap between cyclic and collective boost
support (7) and lift beam (8). Peel shims (9) to obtain a
maximum gap of 0.004 inch (0.101 mm). Install bolts
(20), wiring bracket (18), aluminum washers (19),
aluminum washers (10), and nuts (11).
5. Install left cyclic hydraulic flight control cylinder
(17) (paragraph 67-120).
6. Install collective hydraulic flight control cylinder
(1) (paragraph 67-35).
1. Remove adjustable rod end tube (11,
Figure 67-25) from collective pitch control bellcrank (9)
by removing cotter pin (6), nut (7), aluminum washer
(8), and bolt (10).
2. Disconnect spring (15) from spring clip (13).
Remove cotter pin (4), nut (3), steel washers (2 and 1),
and bolt (14), and disconnect adjustable rod end tube
(11). Retain bolt (14), spring clip (13), and spring (15).
67-42. Adjustable Rod End Tube — Inspection
1. Inspect adjustable rod end tube (11,
Figure 67-25) (BHT-412-CR&O).
2. Inspect rod end bearings in adjustable rod end
tube (11) for secure installation and wear
(BHT-ALL-SPM).

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 BHT-412-MM-8

Figure 67-24. Left Cyclic and Collective Boost Support

67-00-00
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BHT-412-MM-8

Figure 67-25. Adjustable Rod End Tube

67-00-00
Page 76 Rev. 7 30 SEP 2003

67-43. Installation
1. Place spring clip (13, figure 67-25) and adjustable
rod end tube (11) into position on lever (12) and secure
with bolt (14), washer (1 and 2), nut (3), and cotter pin
(4).
2. Place adjustable rod end tube (11) into position in
bellcrank (9) and secure with bolt (10), washer (8), nut
(7), and cotter pin (6).
NOTE
Exposed thread at upper rod end bearing
shall not exceed 1.0 in. (25.4 mm).
3. Move collective controls through full travel and
check for binding and/or obstruction of control
movement.
4. Verify collective control rigging within limits
(paragraph 67-4).
67-44. PITCH CONTROL BELLCRANK
67-45. Removal
NOTE
Access to bellcrank is provided through
large access in bottom of helicopter.
1. Remove adjustable rod end tube (7, figure 67-26)
from collective pitch control bellcrank (14) by removing
cotter pin (9), nut (11), aluminum washer (8) and bolt
(6).
2. Remove droop compensator control tube (10) and
adjustable control tube (19) from bellcrank (14) by
removing cotter pin (17), nut (16), aluminum washers
(18 and 20) and bolt (21).
3. Remove bellcrank (14) from support (5) by
removing cotter pin (2), nut (3), aluminum washers (4
and 13) and bolt (12). Remove bellcrank (14) and
washers (22 and 15).
67-46. Inspection
Inspect bellcrank (14, figure 67-26) for mechanical and
corrosion damage (BHT-412-CR&O).
BHT-412-MM-8
67-47. Installation
1. Place bellcrank (14, figure 67-26) in position in
support (5). Use washer (15 and 22) to a maximum of
four to obtain proper fit of bellcrank (14) in support (5).
Install bolt (12), washer (13 and 4), nut (3) and cotter
pin (2).
2. Place tube (19) and tube (10) into bellcrank (14).
Install bolt (21), washers (20 and 18), nut (16), and
cotter pin (17).
3. Place tube (7) into bellcrank (14). Install bolt (6),
washer (8), nut (11), and cotter pin (9).
4. Move pilot collective stick (1) through full travel
and check for binding and/or obstruction of control
movement.
5. Verify collective rigging within limits (paragraph
67-4).
67-48. COLLECTIVE FORCE GRADIENT
NOTE
Applicable to helicopters with 4-axis Flight
Director kit installed.
67-49. Removal
1. Remove access panel from cabin floor forward of
pylon.
2. Disconnect electrical connector (1, figure 67-27).
3. Remove force gradient (8) from collective
bellcrank (4) by removing cotter pin (7), nut (6),
washers (5 and 3), and bolt (2).
4. Remove force gradient (8) from control lever (12)
by removing cotter pin (10), nut (9), washers (11 and
14), and bolt (13).
67-50. Inspection
1. Inspect force gradient (8, figure 67-27) for
corrosion and mechanical damage
(BHT-412-CR&O-1). Superficial mechanical damage is
acceptable without repair. Mechanical damage in
excess of superficial and/or corrosion damage is not
acceptable.
67-00-00
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BHT-412-MM-8

Figure 67-26. Collective Control Bellcrank

67-00-00
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 BHT-412-MM-8

SEE DETAIL A

4
1
5

13 6

14
8
7
1. Electrical connector
9 2. Bolt
3. Aluminum washer
4. Collective bellcrank
11 10
5. Aluminum washer
6. Nut
7. Cotter pin
8. Force gradient
9. Cotter pin
DETAIL A 10. Nut
12
11. Washer
12. Control lever
13. Bolt
14. Washer

412_MM_67_0027a

Figure 67-27. Collective Force Gradient (Applicable to Helicopters with

4-Axis AFCS/Flight Director Kit Installed) (Sheet 1 of 2)

67-00-00
27 FEB 2009 Rev. 12 Page 79
BHT-412-MM-8

Figure 67-27. Collective Force Gradient (Applicable to Helicopters with

4-Axis AFCS/Flight Director Kit Installed) (Sheet 2)

67-00-00
Page 80 Rev. 12 27 FEB 2009

2. Inspect bearing for secure installation in housing
and for wear (BHT-ALL-SPM).
67-51. Repair
1. Repair of force gradient (8) consists of
replacement of unserviceable components and
adjustment of spring preload in accordance with
paragraph 67-52, step 1.
67-52. Installation
MATERIALS REQUIRED
Refer to BHT-ALL-SPM for specifications and source.
NUMBER NOMENCLATURE
C-405 Lockwire
CAUTION
ENSURE THAT FORCE GRADIENT
L E N G TH I S A D J U S TE D P R I O R T O
INSTALLATION ON ROTARY ACTUATOR.
NOTE
The collective force gradient (8, Figure
67-27) is similar in appearance to the force
gradients (8) used in the cyclic controls but
has a different part number. Ensure that
correct part number force gradient (8) is
installed for the collective controls system.
1. If not previously accomplished, adjust spring
preload on force gradient (8) to 40 to 41 pounds (177.9
to 182.4 N) as follows:
a. Loosen jam nut (23) and remove clevis (15)
from shaft (22).
b. Cut nylon braids (33) holding switch and cable
assembly (30) to force gradient (8).
c. Remove nut (28), washer (27), screw (26),
packing (29), and ball (25) from cap (24), and switch
and cable assembly (30).
BHT-412-MM-8
d. Cut lockwire and loosen jam nut (31), remove
cap (24) from cylinder (17).
e. Remove spring assembly (32) from
cylinder (17).
f. Loosen jam nut (21) while holding shaft (22) at
wrench flat. Adjust spring preload to 40 to 41 pounds
(177.9 to 182.4 N) by turning spacer (20), (using
wrench flat) clockwise against spring assembly (32).
Tighten jam nut (21) against spacer (20).
g. Position spring assembly (32) in cylinder (17)
and install cap (24) until all end play is eliminated.
Torque jam nut (31) to 100 pounds (11.298 Nm) and
lockwire (C-405) to prevent turning in either direction.
After assembly verify spring preload of 40 to 41 pounds
(177.9 to 182.4 N).
h. Install ball (25), packing (29), and switch and
cable assembly (30) on cap (24).
i. Install screws (26), washers (27), nuts (28) in
cap (24) and switch and cable assembly (30). Do not
tighten screws at this time.
j. Install clevis (15) on shaft (22). Adjust length of
force gradient (8) as shown in Figure 67-27, sheet 2.
Tighten jam nut (23) to clevis (15).
k. Push and hold switch and cable assembly (30),
and ball (25) against cap (24). Hold this position to
initially adjust switch and cable assembly (30).
l. Adjust switch to actuate within ±0.050 inch
(1.27 mm) linear shaft travel of spring assembly (32)
and secure screws (26).
m. Install nylon braid (33), holding switch, and
cable assembly (30) to force gradient (8).
2. Place force gradient (8) into position on bellcrank
(3). Install bolt (2), steel washers (3 and 5), nut (6), and
cotter pin (7).
3. Place force gradient (8) into position on control
lever (12). Install bolt (13), steel washers (14 and 11),
nut (10), and cotter pin (9).
4. Connect electrical connector (1).
5. Install access panel in cabin floor forward of pylon.
67-00-00
27 FEB 2009 Rev. 12 Page 81
BHT-412-MM-8
67-53. COLLECTIVE BELLCRANK
NOTE
Applicable to helicopters with 4-axis AFCS/
Flight Director kit installed.
67-54. Removal
1. Remove access panel from cabin floor forward of
pylon.
2. Remove collective link (3, Figure 67-28) from
collective bellcrank (15) by removing cotter pin (17), nut
(18), washers (2 and 19), and bolt (1).
3. Remove force gradient (16) from bellcrank (15) by
removing cotter pin (12), nuts (13), washers (11 and
14), and bolt (10).
4. Remove bellcrank (15) from support (4) by
removing cotter pin (9), nut (8), washers (6 and 7), and
bolt (5).
67-55. Inspection
1. Inspect bellcrank (15, Figure 67-28) for
mechanical and corrosion damage in accordance with
BHT-412-CR&O-1 manual.
2. Inspect bearings in bellcrank (15) for secure
installation in bellcrank and for wear (BHT-ALL-SPM).
67-56. Installation
1. Place bellcrank (15, Figure 67-28) into position on
support (4). Install bolt (5), aluminum washers (6 and
7), nut (8), and cotter pin (9).
2. Position force gradient (16) on bellcrank (15) and
install bolt (10), aluminum washers (11 and 14), nut
(13), and cotter pin (12).
3. Position collective link (3) on bellcrank (15) and
install bolt (1), steel washers (2 and 19), nut (18), and
cotter pin (17).
4. Install access panel in cabin floor forward of pylon.
67-00-00
Page 82 Rev. 12 27 FEB 2009
67-57. COLLECTIVE LINK
NOTE
Applicable to helicopters S/N 36069 through
subsequent.
67-58. Removal
1. Remove access panel from cabin floor forward of
pylon.
2. Remove collective link (2, Figure 67-29) from
collective bellcrank (7) by removing cotter pin (8), nut
(9), washers (10 and 11), and bolt (1).
3. Remove collective link (2) from rotary actuator arm
stud (3) by removing cotter pin (4), nut (5), and washer
(6).
67-59. Inspection
1. Inspect link (2, Figure 67-29) for mechanical and
corrosion damage in accordance with
BHT-412-CR&O-1 manual.
2. Inspect bearing in link (2) for security and for wear
(BHT-ALL-SPM).
67-60. Installation
1. Place link (2, Figure 67-29) into position on
bellcrank (7). Install bolt (1), steel washers (10 and 11),
nut (9), and cotter pin (8).
2. Position link (2) on rotary actuator arm stud (3).
Install steel washer (6), nut (5), and cotter pin (4).
3. Install access panel in cabin floor forward of pylon.
67-61. COLLECTIVE ROTARY ACTUATOR
NOTE
Applicable to helicopters with 4-axis AFCS/
Flight Director kit installed.
67-62. Removal
1. Remove access panel from cabin floor forward of
pylon.
 BHT-412-MM-8

Figure 67-28. Collective Bellcrank (Applicable to Helicopters with

4-Axis AFCS/Flight Director Kit Installed)

67-00-00
27 FEB 2009 Rev. 12 Page 83
BHT-412-MM-8

Figure 67-29. Collective Link (Applicable to Helicopters with

4-Axis AFCS/Flight Director Kit Installed)

67-00-00
Page 84 Rev. 12 27 FEB 2009

2. Disconnect electrical connector (6, figure 67-30)
from rotary actuator (7).
3. Remove collective link (10) from rotary actuator
arm stud (4) by removing cotter pin (1), nut (2), and
steel washer (3).
4. Remove rotary actuator (7) from structure (5) by
removing bolts (9) and washers (8).
67-63. Inspection
1. Inspect rotary actuator (7, figure 67-30) for
mec hani cal a nd cor r osi on dama ge and wear
(BHT-ALL-SPM).
2. Inspect rotary actuator arm stud (4) for damaged
threads. No damage that can be detected visually is
acceptable.
3. Inspect electrical receptacle for bent pins and
damaged threads. Superficial damage is acceptable
without repair.
67-64. Repair
Refer to vendor manual for rotary actuator repair
instructions.
67-65. Installation
1. Place rotary actuator (7, figure 67-30) into position
on structure (5). Install four aluminum washers (8), and
four bolts (9).
2. Position link (10) on rotary actuator arm stud (4)
and install steel washer (3), nut (2), and cotter pin (1).
3. Connect electrical connector (6) to rotary actuator
(7).
4. Install access panel in cabin floor forward of pylon.
67-66. ADJUSTABLE COLLECTIVE CONTROL
TUBE
NOTE
Control lever (17, figure 67-31) is applicable
to helicopters S/N 36087 and subsequent.
BHT-412-MM-8
67-67. Removal
1. Remove access panel in aft cabin floor just
forward of pylon (Chapter 52).
2. Remove adjustable collective control tube (6) from
control lever (17 or 18) by removing cotter pin (14), nut
(15), washers (16 and 3) and bolt (2).
3. Remove adjustable collective control tube (6) and
control tube, droop compensator (10) from bellcrank (9)
by removing cotter pin (12), nut (13), washers (11 and
8) and bolt (7).
4. Loosen clamp (4) and slide forward off of boot (5).
5. Slide adjustable collective control tube (6) forward
o u t o f h e l i c o p t e r. P l a c e c o n t r o l t u b e , d r o o p
compensator (10) on airframe structure.
67-68. Inspection
1. Inspect adjustable collective control tube (6, figure
67-31) (BHT-412-CR&O).
2. Inspect rod end bearing for secure installation in
tube and for wear (BHT-ALL-SPM).
67-69. Installation
1. Slide adjustable collective control tube (6, figure
67-31), with rod end bearing aft, into boot (5).
2. Position adjustable collective control tube (6) on
control lever (17 or 18). Install bolt (2), washer (3),
washer (16), nut (15) and cotter pin (14).
3. Position adjustable collective control tube (6) and
control tube, droop compensator (10) on bellcrank (9).
Install bolt (7), washer (8), washer (11), nut (13) and
cotter pin (12).
4. Position forward end of boot (5) on tube (6) 7.9 in.
(200.7 mm) forward of bulkhead with collective control
stick (1) full down and tighten clamp (4).
5. Move pilot collective stick (1) through full travel
and check for interference and binding.
6. Verify collective rigging within limits (paragraph
67-4).
67-00-00
30 SEP 2003 Rev. 7 Page 85
BHT-412-MM-8

Figure 67-30. Collective Rotary Actuator (Applicable to Helicopters with

4-Axis AFCS/Flight Director Kit Installed)

67-00-00
Page 86 Rev. 12 27 FEB 2009
 BHT-412-MM-8

Figure 67-31. Adjustable Collective Control Tube

67-00-00
30 SEP 2003 Rev. 7 Page 87
BHT-412-MM-8
7. Install access panel in the aft cabin floor just
forward of pylon (Chapter 52).
67-70. CONTROL LEVER AND STOP ASSEMBLY
NOTE
Collective stop assembly (19, Figure 67-32)
is applicable to helicopters S/N 36069 and
subsequent. Control lever (11) is applicable
to helicopters S/N 36087 and subsequent.
67-71. Removal
1. Remove access panel from cabin floor forward of
pylon (Chapter 52).
2. Remove flight control tube (1, Figure 67-32) from
control lever (11 or 12) by removing cotter pin (5), nut
(4), washer (3) and bolt (2).
3. Remove adjustable collective control tube (10)
from control lever (11 or 12) by removing cotter pin (9),
nut (8), washer (7) and bolt (6).
NOTE
The following step is only applicable to
helicopters with 4-axis AFCS/Flight Director
kit installed.
3A. Remove cotter pin (10, Figure 67-27), nut (9),
washers (11 and 14), and bolt (13).
4. Remove cotter pin (16, Figure 67-32), nut (15),
washers (14), and bolt (13). Remove control lever (11
or 12).
5. Loosen nut (18) and remove bolt (17) from stop
assembly (19). Remove nut (18) from bolt (17).
6. Remove screws (20) and washers (21) from stop
assembly (19).
7. Remove bolt (22), washer (23), and shim (24).
Remove stop assembly (19).
67-72. Inspection
1. Inspect control lever (11 or 12, Figure 67-32) for
mechanical and corrosion damage (BHT-412-CR&O).
67-00-00
Page 88 Rev. 12 27 FEB 2009
2. Inspect bearings in control lever (11 or 12) for
secure installation in lever and for wear
(BHT-ALL-SPM).
3. Inspect stop assembly (19) and its attaching
hardware for wear, damage, or corrosion.
67-73. Installation
1. Install stop assembly (19, Figure 67-32) and attach
with shim (24), washers (23), and bolt (22).
2. Install washers (21) and screw (20) in the top of the
stop assembly (19).
3. Place nut (18) onto bolt (17) and install in the stop
assembly (19).
4. Adjust stop assembly (19) to the proper limits
(paragraph 67-4).
5. Place control lever (11 or 12) into position in
structure with long end down. Install bolt (13), washers
(14), nut (15), and cotter pin (16).
6. Position adjustable collective control tube (10) and
control lever (11 or 12) and install bolt (6), washers (7),
nut (8), and cotter pin (9).
7. Position flight control tube (1) on control lever (11
or 12) and install bolt (2), washers (3), nut (4) and cotter
pin (5).
NOTE
The following step is only applicable to
helicopters with 4-axis AFCS/Flight Director
kit installed.
8. Position collective force gradient (8, Figure 67-27)
on control lever (12) and install bolt (13), washers (14
and 11), nut (9), and cotter pin (10).
9. Move collective controls through full travel and
check for binding and/or obstructon of controls.
10. Verify collective rigging is within limits (paragraph
67-4).
11. Install access panel in cabin floor forward of pylon
(Chapter 52).
 BHT-412-MM-8

67-74. PILOT COLLECTIVE BOOT 2. Remove screws (2).

The pilot collective stick boot (1, Figure 67-33) is 3. Remove pilot collective stick boot (1).
mounted around base of pilot collective stick to
prevent foreign objects and dirt from fouling controls. 67-76. Inspection
The boot is made of synthetic fabric with a metal base
to secure boot to floor. Snaps provide a tight fit to stick. 1. Inspect pilot collective stick boot (1, Figure 67-33)
A similar boot is installed on copilot stick. for tears and deterioration.
67-75. Removal

1. Unsnap buttons (4, Figure 67-33).

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 BHT-412-MM-8

Figure 67-32. Collective Control Lever and Stop Assembly

67-00-00
30 SEP 2003 Rev. 7 Page 89
BHT-412-MM-8

Figure 67-33. Pilot Collective Stick Boot

2. Inspect for defective buttons (4). 2. Remove access panels from cabin floor under aft
end of pedestal, from under left crew seat, and from
67-77. Installation cabin floor on left side of left crew seat (Chapter 52).

1. Slide pilot collective stick boot (1, figure 67-33)

over pilot collective stick (3). 3. Remove access panel from lower left side of
helicopter just below aft corner of left crew door
(Chapter 52).
2. Install screws (2) to secure boot (1) to floor.

3. Fasten buttons (4). 4. Disconnect collective stick electrical connector.

67-78. COLLECTIVE JACKSHAFT
The collective jackshaft (figure 67-34) installation
consists of the jackshafts, pilot collective stick, throttle
interconnect tubes, bellcranks, and supports. A
downlock is mounted on floor below stick. An elbow and
support are provided to allow a copilot collective stick
to be installed.
5. Remove tube (52, figure 67-34) from stick
assembly (1) by removing cotter pin (9), nut (8),
washers (7) and bolt (6).
6. Remove bolts (18), tapered bushings (17 and 12),
washers (11) and nuts (10). Index bushings for
installation in original location.

67-79. Removal
7. Remove nuts (14 and 19) and washers (13 and 20)
1. Remove pilot collective stick boot (paragraph screws (2 and 5) from stick assembly (1) and remove
67-75). nut (16) and washers (3 and 15) and bolt (4).

67-00-00
Page 90 Rev. 7 30 SEP 2003
 BHT-412-MM-8

Figure 67-34. Collective Jackshaft (Sheet 1 of 2)

67-00-00
30 MAR 2007 Rev. 11 Page 91
BHT-412-MM-8

Figure 67-34. Collective Jackshaft (Sheet 2)

67-00-00
Page 92 Rev. 7 30 SEP 2003
 BHT-412-MM-8

NOTE 67-80. Inspection

Ensure bearing in support (21) is not 1. Inspect stick assembly (1, Figure 67-34) as
damaged in following step. follows:

8. Tap stick assembly (1) with soft mallet to slide stick

out of tube assembly. Remove stick assembly.
9. Remove cotter pin (34), nut (33), washers (30 and
32) and bolt (29). Disengage flight control tube (31).
10. Remove bolts (23), tapered bushings (24 and 26),
washers (27), and nuts (28). Index bushings for
installation in original location.
a. Inspect stick assembly for mechanical and
corrosion damage. Superficial mechanical and
corrosion damage is acceptable if polished out and
repaired area refinished to original condition.
b. Inspect wiring for secure installation and
damaged insulation.
c. Inspect switches for secure installation.

11. Slide tube (25) to the right to disengage tube from d. Inspect throttle controls for smooth operation.
lever (22). Remove tube. If necessary, adjust throttle control gears (paragraph
67-4).

12. Disengage lever (22) and remove. 2. Inspect support (21) as follows:

13. Remove tubes (52) by removing cotter pin (56), a. Inspect support for mechanical and corrosion
nut (57), washers (58 and 60), and bolts (61). damage (BHT-412-CR&O).

14. Remove tube (50) from bellcrank (51) by removing b. Inspect bearing for security and wear
nut (49), washers (48 and 40), and bolt (41). (BHT-ALL-SPM).

15. Remove tubes (59) by removing cotter pin (53), 3. Inspect tubes (25, 52, 59, and 71) for mechanical
nut (54), washers (55 and 62), and bolts (63). and corrosion damage (BHT-412-CR&O).

4. Inspect elbow and support (64) as follows:

16. Remove tube (47) from bellcrank (44) by removing
nut (46), washers (45 and 42), and bolt (43).
a. Inspect elbow and support for mechanical and
corrosion damage (BHT-412-CR&O).
17. Remove cotter pin (76), nut (77), washer (75), and
bolt (78) from tube (59).
b. Inspect power control bellcranks in base of
elbow and support (64) for freedom of movement.
18. Remove bolts (67), tapered bushings (68 and 72),
washers (73), and nuts (74). Index bushings for c. Inspect bearings for security and wear
installation in original location. (BHT-ALL-SPM).

19. Remove nut (70), washers (66 and 69), and bolts 67-81. Installation
(65).
MATERIALS REQUIRED
20. Disengage elbow and support (64) from tube (71)
and remove from helicopter. Refer to BHT-ALL-SPM for specifications and source.

21. Remove tubes (71). NUMBER NOMENCLATURE

C-204 Primer
22. Remove nuts (35), washers (36 and 38), and bolts
(37). Remove support (21). C-430 Tape

67-00-00
27 FEB 2009 Rev. 12 Page 93
BHT-412-MM-8
SPECIAL TOOLS REQUIRED
NUMBER NOMENCLATURE
T27872-2 Reamer
NOTE
If stick (1, Figure 67-34), tube (25), lever
(22), tube (71), or elbow (64) is being
replaced, the new component must be
drilled and reamed to pick up holes existing
in original components. If holes have been
drilled and reamed, proceed to step 8.
1. Assemble jackshaft to dimensions and angles
shown on Figure 67-36. Clamp jackshaft assembly in a
suitable holding fixture.
2. Center punch and drill new holes using an F drill
(0.257 inch). If existing holes are not visible, use a
number 20 drill (0.161 inch) initially to permit hole to be
centered with existing holes.
3. Insert reamer (T27872-2) into hole so pilot projects
through part being reamed. Ream one side for
installation of tapered bushings so bushing will extend
0.007 to 0.060 inch (0.178 to 1.524 mm) (View A-A).
4. Insert reamer (T27872-2) into opposite hole. Insert
a tapered bushing into reamed hole to act as a pilot for
reamer. Ream to depth for installation of tapered
bushings as described in step 3.
5. Repeat step 2 through step 4 for all remaining
holes.
6. Remove jackshaft assembly from holding fixture
and disassemble. Remove all burrs and metal particles.
7. Apply primer (C-204) to all bare metal areas.
8. Apply tape (C-430) between faying surfaces and
place support (21, Figure 67-34) into position in
helicopter and install bolts (37), washers (38), washers
(36), and nuts (35).
9. Place tube (71), lever (22), and tube (25), into
position in helicopter and fit together.
10. Place tubes (52 and 59) into helicopter.
67-00-00
Page 94 Rev. 12 27 FEB 2009
NOTE
Adjust shim to minimize lateral deflection of
shafts during installation.
11. Apply tape (C-430) between faying surfaces of
structure and shims (79), then place elbow and support
assembly (64) in helicopter. Engage tube (71) on elbow
and support assembly. Install bolts (65), washer (66
and 69), and nuts (70). Ensure a 212-001-168-1 shim
(79) is installed between structure and elbow and
support assembly (64).
12. Apply tape (C-430) between faying surfaces of
structure and stick assembly (1), then place stick
assembly in helicopter. Engage tube (25) onto stick
assembly (1). Install screw (2), washer (20), nut (19),
screw (5), washer (13), nut (14), bolts (4), washers (3),
washers (15), and nuts (16).
13. Align holes in tube (71) with holes in elbow and
support (64). Install bolts (67), bushings (68), bushings
(72), washers (73), and nuts (74). Torque nuts 50 to 70
inch-pounds (5.65 to 7.91 Nm).
14. Align holes in tubes (71 and 25) with holes in lever
(22) and support (21) and install bolts (23), bushing (24
and 26), washers (27), and nuts (28). Torque nuts 50 to
inch-pounds (5.65 to 7.91 Nm).
15. Align holes in tube (25) with holes in stick
assembly (1) and install bolts (18), bushings (17),
bushings (12), washers (11), and nuts (10). Torque nuts
inch-pounds (5.65 to 7.91 Nm).
NOTE
After torquing, the washer, nut and washer,
bolt head must clear the surface of the
jackshaft tube within the 0.007 to 0.060 inch
(0.178 to 1.525 mm) limits shown in, Figure
67-36, View AA.
16. Place tubes (52, Figure 67-34) into position and
install bolts (6), washers (7), nuts (8), and cotter pins
(9).
17. Place tubes (59) into position and install bolts (78),
washers (75), nuts (77), and cotter pins (76). Secure
inboard end of tubes (59), with bolts (63), washers (62),
washer (55), nuts (54), and cotter pin (53).

18. Secure tubes (52) to tubes (59) with bolts (61),
washers (60), washers (58), nuts (57), and cotter
pins (56).
19. Place tube (47) into bellcrank (44). Install bolt (43),
washer (42), washer (45) and nut (46).
20. Place tube (50) into bellcrank (51). Install bolt (41),
washer (40), washer (48), and nut (49).
21. Place tube (31) on lever (22). Install bolt (29),
washer (30), washer (32), nut (33), and cotter pin (34).
22. Connect electrical wires from stick assembly (1).
23. Rig collective flight controls (paragraph 67-4).
24. Rig power controls (throttle) (Chapter 76).
25. Install pilot collective stick boot (paragraph 67-77).
26. Install the following access panels (Chapter 52):
a. Cabin floor aft of pedestal.
b. Cabin floor under left crew seat.
c. Cabin floor left side of left crew seat.
67-82. COLLECTIVE TRANSDUCERS
67-83. Removal (Helicopters S/N 33001 through
36086)
NOTE
Helicopters S/N 33001 through 36036 use a
single control motion transducer (2, Figure
67-35) (412-074-101-101). The transducer
(2) has one element and is installed with the
Flight Director Kit (412-706-111-103).
Helicopters S/N 36037 through 36086 use
one control motion transducer (3)
(412-074-101-103). The transducer (3) has
two elements and is installed as part of the
basic ship. Transducer’s element one is
BHT-412-MM-8
used by Flight Director Kit
(412-706-111-107), if installed. Transducer’s
element two is used by Flight Data Recorder
(FDR), if installed.
1. Remove access panel from cabin floor forward of
pylon.
2. Disconnect electrical connector (1).
3. Detach control motion transducer (2 or 3) from the
support (4) by removing cotter pin (8), nut (7), washers
(6), and bolt (5).
4. Detach the transducer’s rod end (10) from bracket
(11) by removing cotter pin (16), nut (15), spacer (14),
washers (13), and bolt (12). Remove transducer (2 or
3).
67-84. Removal (Helico pters S/N 36087 and
Subsequent)
NOTE
Helicopters S/N 36087 and subsequent use
two control motion transducers (18, Figure
67-35) (412-074-101-103). Each transducer
(18) has two elements. One element on
each transducer (18) is used as an input to
autopilot and the second element of one
transducer (18) is used for Flight Data
Recorder Kit (FDR), if installed.
1. Remove access panel from cabin floor forward of
pylon.
2. Disconnect electrical connectors (17).
3. Detach transducers (18) from support (19) by
removing cotter pin (24), nut (23), spacers (21 and 22),
and bolt (20).
4. Detach transducer’s rod ends (26) from bracket
(27) by removing cotter pin (33), nut (32), washers (31),
spacers ( 29 and 30), and bolt (28). Remov e
transducer (18).
67-00-00
27 FEB 2009 Rev. 12 Page 95
BHT-412-MM-8

1. Connector
2. Control motion transducer
3. Control motion transducer
4. Support
5. Bolt
6. Washer
7. Nut
8. Cotter pin
9. Jam nut
10. Rod end
11. Bracket
12. Bolt
13. Washer
14. Spacer
15. Nut
16. Cotter pin SEE DETAIL A
17. Connector SEE DETAIL B
18. Control motion transducer
19. Support
20. Bolt
21. Spacer
22. Spacer
23. Nut
24. Cotter pin
25. Jam nut
26. Rod end
27. Bracket
28. Bolt
29. Spacer
30. Spacer
31. Washer
32. Nut
33. Cotter pin
Applicable to helicopters S/N 36087 and subsequent.

17
19
Applicable to helicopters S/N 33001 through 36086.
23 22
4 28
8 18
7 29
6 25
21
20
2 6
16 9
15 3 5 18
14

30
STA 26
16.85 31 27 17
10 31
13 STA 32
11 56.82 1 33

DETAIL B
13
12 DETAIL A

412_MM_67_0019

Figure 67-35. Collective Transducers

67-00-00
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 BHT-412-MM-8

412_MM_67_0018

Figure 67-36. Collective Jackshaft Assembly

67-00-00
30 MAR 2007 Rev. 11 Page 97
BHT-412-MM-8
67-85. Inspection
1. Inspect control motion transducers (2, 3, or 18,
Figure 67-35) for mechanical and corrosion damage.
2. Inspect bearings in transducers (2, 3, or 18) for
secure installation and wear (BHT-ALL-SPM).
3. Inspect electrical connectors (1 or 17) for bent or
corroded pins and damaged threads. Superficial
damage is acceptable without repair.
67-86. Repair
1. Control motion transducers (2, 3, or 18, Figure
67-35) are not repairable and must be replaced when
defective.
67-87. Installation (Helicopters S/N 33001 through
36086)
NOTE
Helicopters S/N 33001 through 36036 use a
single control motion transducer (2, Figure
67-35) (412-074-101-101). The transducer
(2) has one element and is installed with the
Flight Director Kit (412-706-111-103).
Helicopters S/N 36037 through 36086 use
one control motion transducer (3)
(412-074-101-103). The transducer (3) has
two elements and is installed as part of the
basic ship. Transducer’s element one is
used by Flight Director Kit
(412-706-111-107), if installed. Transducer’s
element two is used by Flight Data Recorder
(FDR), if installed.
1. Position control motion transducer (2 or 3) in
support (4) and install bolt (5), washers (6), nut (7), and
cotter pin (8).
2. Position collective stick against the up and down
stop to check the transducer (2 or 3) for bottoming out
in either direction as if it were installed. Ensure that the
transducer (2 or 3) can travel beyond the up and down
stop of the collective stick. Adjustments can be made
by loosening jam nut (9) and turn rod end (10).
67-00-00
Page 98 Rev. 12 27 FEB 2009
3. Attach transducer (2 or 3) to bracket (11) with bolt
(12), washers (13), spacer (14), nut (15), and cotter pin
(16).
NOTE
The following step is only applicable to
helicopters S/N 36037 through 36086 with
transducer P/N 412-074-101-103 installed.
4. Perform collective transducer adjustment; refer to
paragraph 67-88A.
5. Connect the electrical connectors (1).
6. Install access panel in cabin floor forward of pylon.
67-88. Installation (Helicopters S/N 36087 and
Subsequent)
NOTE
Helicopters S/N 36087 and subsequent use
two control motion transducers (18, Figure
67-35) (412-074-101-103). Each transducer
(18) has two elements. One element on
each transducer (18) is used as an input to
the autopilot and the second element of one
transducer (18) is used for Flight Data
Recorder Kit (FDR), if installed.
1. Position control motion transducers (18) in support
(19) and install bolt (20), spacers (21 and 22), nut (23),
and cotter pin (24).
2. Position collective stick against the up and down
stop to check the transducers (18) for bottoming out in
either direction, as if they were installed. Ensure that
the transducer (18) can travel beyond the up and down
stop of the collective stick. If adjustments are needed,
loosen jam nut (25) and turn rod ends (26).
3. Attach transducer’s rod ends (26) to bracket (27)
by installing bolt (28), spacers (29 and 30), washers
(31), nut (32), and cotter pin (33).
4. Perform collective transducer adjustment; refer to
paragraph 67-88A.
5. Connect electrical connectors (17).
6. Install access panel in cabin floor forward of pylon.

67-88A. Adjustment (Helicopters 36037 and
Subsequent)
SPECIAL TOOLS REQUIRED
NUMBER NOMENCLATURE
412-274-001-101 Calibration Tool
(Pot Calibrator)
NOTE
Electrical adjustment is required for dual
element control motion transducers used in
helicopters S/N 36037 and subsequent.
1. Perform collective control motion transducer (3,
Figure 67-35, Detail A or 18, Detail B) adjustment as
follows:
NOTE
Dual element control motion transducers
(412-074-101-103) are aligned and
positioned using calibration tool
(412-274-001-101) This calibration tool is
used to electrically align the control motion
transducers installed on the helicopter to be
used as control position sensors for the
flight data recorder. This tool will ensure the
control motion transducers are aligned
within ±0.5% of the prescribed position.
a. Connect hydraulic power cart and turn on.
b. Position pilot collective stick against the down
stop.
c. Using calibration tool (4, Figure 67-36A)
(412-274-001-101) (pot calibrator), turn power
calibration switch (5) to the OFF position. Connect
calibration box connector (3) to one of the collective
transducers (1) electrical connector (2). Turn selector
knob (6) to collective (CLTV) position.
d. Turn calibration power switch (5) to ON
position.
NOTE
Any time the LO BAT lamp comes on,
replace batteries (use 9 VDC alkaline
BHT-412-MM-8
batteries). Low battery is set to illuminate at
12 ±1 volt.
e. If a RED lamp comes on, the transducer (1)
shaft shall be adjusted in the direction indicated. An
extend indication means extend the transducer shaft
by screwing it into rod end bearing (10 or 26,
Figure 67-35) (in clockwise direction when looking at
rod end). A retract indication means retract the
transducer shaft by unscrewing it from the rod end
bearing (in counterclockwise direction when looking at
the rod end). Adjust transducer shaft until GREEN IN
RANGE lamp comes on.
f. Tighten jam nut (9 or 25) on transducer shaft
and verify that GREEN IN RANGE lamp is on and
RED lamps are off.
g. Move calibration power switch (5,
Figure 67-36A) to OFF position. Disconnect calibration
box connector (3) from transducer electrical connector
(2).
h. Connect transducer electrical connector (2) to
electrical connector on the bulkhead.
i. Perform calibration adjustment on remaining
collective transducer (1) using step a through step h.
2. Alternate method for collective transducer (3,
Figure 67-35, Detail A or 18, Detail B) adjustment is as
follows:
a. Connect hydraulic power cart and turn on.
b. With collective transducers (3 or 18) installed
on structure only.
c. Loosen jam nut (9 or 25) on transducer so
shaft can rotate freely.
d. Measure and record resistance (T) between
pins D and F of the transducer electrical connector.
Resistance should be 5000 ±10% ohms.
e. Multiply resistance (T) x 11.3% = __. Record
value of T.
f. Measure and record resistance (R) between
pins E and F of the transducer electrical connector.
Adjust the transducer shaft until resistance (R) equals
the value of step e ±25 ohms.
67-00-00
27 FEB 2009 Rev. 12 Page 98A
BHT-412-MM-8

g. Tighten the jam nut on the transducer shaft i. Perform calibration adjustment on remaining
and verify that the resistance is still within limits. collective transducer (1) using step a through step h.

h. Connect the transducer electrical connector to j. Turn off hydraulic power cart and disconnect
the bulkhead. from helicopter.

67-00-00
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 BHT-412-MM-8

2 3

5 4

1. Control motion transducer (Typical)

2. Electrical connector
3. Calibration box connector
4. Calibration tool (412-274-001-101)
5. Calibration power switch
6. Selector knob

412_MM_67_0024

Figure 67-36A. Control Motion Transducer Adjustment

67-00-00
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 BHT-412-MM-8

67-89. FRICTION CLAMP 4. Lightly abrade dacron surface (pink side) of liner
material with 180 grit abrasive cloth or paper (C-423).
67-90. Removal

1. Remove copilot seat and access panel below seat NOTE

(Chapter 52).
2. Remove bolt (4, figure 67-37), washers (3 and 10),
and nut (11) attaching clamp halves (5 and 8) to elbow
support assembly (12).
The dark (teflon) side of liner material is
friction side.
5. Mix adhesive (C-363) according to manufacturers
instructions.

3. Remove bolt (1), washers (2), and nut (9). NOTE

4. Remove bolt (6) and washer (7) and remove two
halves of clamp assembly from elbow support
assembly.
67-91. Inspection
Pot life of adhesive not to exceed 30 minutes
at 75°F (24°C).
6. Apply adhesive to inner surface of both clamp
halves and to dacron (pink) surface of liner material.
Install liner in clamp halves.

1. Inspect clamp assembly for cracks or deformation.

No cracks are allowed. Any deformation which prevents 7. Install clamp halves around cylindrical work aid
proper operation is cause for rejection. 2.03 to 2.09 in. (51.56 to 53.09 mm) diameter and install
bolt (6) and washer (7).
2. Inspect friction lining for excessive wear. Wear
which prevents proper operation necessitates 8. Install bolt (1), washers (2) and nut (9) through
replacement of friction liner. tongues of clamp halves (5 and 8) and tighten nut (9) to
one in.-lbs. (0.113 N-m) greater than nut tare torque.
67-92. Repair
9. Remove adhesive squeeze-out. Allow adhesive to
MATERIALS REQUIRED cure 24 hours at 75°F (24°C) or heat assembly to 175°F
to 190°F (80°C to 88°C) for one hour.
Refer to BHT-ALL-SPM for specifications and source.
10. After complete curing, remove clamp assembly
NUMBER NOMENCLATURE from work aid and scuff friction surface of liner with 180
C-309 Methyl-Ethyl-Ketone grit abrasive cloth or paper (C-423) followed by an
(MEK) abrasive pad (C-407) until a uniform finish is attained.

C-363 Adhesive
11. Wash clamp assembly with mild soap and water
C-423 Abrasive Cloth or Paper followed by rinse of MEK (C-309) to remove all grit and
C-465 Liner foreign material.

1. Remove all old liner material and adhesive from 67-93. Installation
clamp halves (5 and 8, figure 67-37) using 180 grit
abrasive cloth or paper (C-423). 1. Place clamp halves around elbow support
assembly (12, figure 67-37).
2. Rinse clamp halves in clean water and dry using
clean cloths or a heat gun. 2. Install washer (7) and bolt (6).

3. Cut liner (C-465) material to approximately 1.0 X 3. Install bolt (1), washers (2) and nut (9). Tighten nut
3.0 in. (25.4 X 76.2 mm) size to match inside areas of (9) only enough to hold clamp halves in contact with
clamp halves. elbow.

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BHT-412-MM-8

Figure 67-37. Collective Friction Clamp Assembly

67-00-00
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 BHT-412-MM-8

4. Align hole in tang on upper clamp half with hole in 5. Adjust minimum collective friction (paragraph
support and install bolt (4), washer (3) between friction 67-4).
clamp tang and support, washer (10) under nut (11).
6. Install floor access panel and seat (Chapter 52).

67-00-00
30 SEP 2003 Rev. 7 Page 101/102

CYCLIC FLIGHT CONTROLS
67-94. CYCLIC CONTROLS
The cyclic controls (figure 67-38) consists of controls
and components from pilot cyclic stick (22) up to and
including extension tubes (1 and 34).
The AFCS cyclic control system incorporates two
series actuators, one connected in roll system and one
connected in pitch system. A control tube and idler arm
are attached to series actuator in pitch system.
Four transducers, two in roll system and two in pitch
system, are used to convert mechanical movement to
electrical signals for injecting pilot control commands to
AFCS.
Two transducers are attached to right end of cyclic
jackshaft providing a fore and aft cyclic signal. Two
transducers are attached to a forward cyclic bellcrank
providing a lateral cyclic signal.
A force gradient assembly connected to an
electromechanical rotary actuator is also installed in
each cyclic system. Cyclic roll system force gradient
attaches to a bellcrank forward of jackshaft. The cyclic
pitch system force gradient attaches directly to left end
of cyclic jackshaft.
A support assembly and idler are used to connect pitch
series actuator and a pitch control tube, which is
attached to mixing lever assembly.
Two proximity switches and two cyclic centering (CYC
CTR) caution lights are installed by kit 412-704-115-101
for aid in centering swashplate. The lights are located
in pilot and copilot instrument panel. The two proximity
switches are located underneath floor near mixing lever
assembly.
NOTE
Cyclic control AFCS system components
forward of mixing lever assembly (28) are
identified as "lateral cyclic" or "fore and aft
cyclic" as applicable, i.e., "lateral cyclic force
gradient".
Cyclic control system components aft of mixing lever
assembly (28) are identified as "left cyclic" or "right
BHT-412-MM-8
cyclic" as applicable, i.e., "left cyclic flight control
cylinder".
The fore and aft control linkage and lateral control
linkage are separate from cyclic stick to mixing lever
(28). From mixing levers to swashplate effects of
control linkages are combined and cannot be
considered separately as to effect.
Actuation of pilot cyclic stick (22) causes hydraulic
power assisted cyclic pitch change of main rotor
blades.
The forward series actuators in each cyclic system are
connected to Helipilot (HP-1) system. Aft series
actuators in each cyclic system are connected to
Helipilot (HP-2) system.
Refer to Chapter 96, for AFCS system wiring diagrams.
67-95. HYDRAULIC CYLINDER EXTENSION TUBE
67-96. Removal
NOTE
The removal procedure for hydraulic
cylinder extension tube (20, figure 67-39) in
left cyclic system is given. The removal
procedure for corresponding hydraulic
cylinder extension tube (23) in right cyclic
system is the same.
1. Remove forward pylon fairing (Chapter 52).
2. Disconnect hydraulic cylinder extension tube (20)
from swashplate (1) by removing cotter pin (6), nut (5),
washers (4, 3, 2 and 21) and bolt (22).
3. Remove nut (7), thin aluminum washers (8 and 10)
and screw (11). Loosen bottom of boot (12) from lip on
mount (16) and remove boot and clamp (9) from
helicopter.
4. Remove cotter pin (19), nut (18), washers (13 and
17) and bolt (14). Separate hydraulic cylinder extension
tube (20) from hydraulic cylinder extension universal
(15).
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BHT-412-MM-8

412_MM_67_0038

Figure 67-38. Cyclic Controls

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 BHT-412-MM-8

Figure 67-39. Hydraulic Cylinder Extension Tube

67-00-00
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BHT-412-MM-8

67-97. Inspection right cyclic flight control cylinder are the

same.
NOTE
67-100. Removal
The inspection procedure for hydraulic
cylinder extension tube (20 and 23, figure
1. Remove forward pylon fairing (Chapter 52).
67-39) in left cyclic system is contained in
BHT-412-CR&O.
2. Disconnect hydraulic cylinder extension tube (20)
from swashplate horn (1) by removing cotter pin (6), nut
67-98. Installation
(5), washers (4, 3, 2 and 21) and bolt (22).

NOTE
3. Remove nut (7), thin aluminum washers (8 and 10)
The installation procedure for hydraulic and screw (11).
cylinder extension tube (20, figure 67-39) in
left cyclic system is given. The installation
4. Loosen bottom of boot (12) from mount bearing
procedure for hydraulic cylinder extension
(16) and slip boot off tube (20).
tube (23) in right cyclic system is the same.

1. Place hydraulic cylinder extension tube (20) in 67-101. Inspection

position with lower end on hydraulic cylinder extension
universal (15). Install bolt (14), washer (13), washer Inspect boot (12, figure 67-39) for tears and signs of
(17), nut (18), and cotter pin (19). deterioration. Torn or deteriorated boots are not
acceptable and shall be replaced.

2. Place boot (12) and clamp (9) over top of tube (20)
and slide down to secure bottom of boot into lip on
mount (16).
3. Place top of tube (20) on swashplate (1) and install
bolt (22), washers (21, 2, 3, and 4), nut (5), and cotter
pin (6).
4. Position top of boot (12) 22.2 in. (563.9 mm) below
centerline of bolt (22, detail B). Install clamp (9), screw
(11), washers (10 and 8), and nut (7).
5. Install forward pylon fairing (Chapter 52).
6. Verify cyclic rigging within limits (paragraph 67-6 or
67-7).
67-102. Installation
1. Slide boot (12, figure 67-39) over tube (20) and
secure lower end of boot into lip on mount (16).
2. Position tube (20) on swashplate (1). Install bolt
(22), washer (21), washers (2, 3, and 4), nut (5), and
cotter pin (6).
3. Position top of boot (12) 22.2 in. (563.9 mm) below
centerline of bolt (22) (detail B). Install clamp (9), screw
(11), washer (10), washer (8), and nut (7).
4. Install forward pylon fairing (Chapter 52).
67-103. HYDRAULIC CYLINDER EXTENSION
UNIVERSAL

67-99. HYDRAULIC SERVO CYLINDER BOOT

NOTE
The maintenance procedures for boot (12,
figure 67-39) on left cyclic flight control
cylinder is given. The procedures for boot on
NOTE
The maintenance procedures for hydraulic
cylinder extension universal (8, figure 67-40)
on right hydraulic cylinder extension tube (5)
is given. Procedures for universal on left
cylinder are the same.

67-00-00
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 BHT-412-MM-8

Figure 67-40. Hydraulic Cylinder Extension Universal

67-00-00
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BHT-412-MM-8

67-104. Removal 3. Loosen bottom of boot (5) from lip on mount (13)
and slide boot upward to expose universal assembly
1. Remove forward pylon fairing (Chapter 52). (6).

2. Remove nut (19, figure 67-40), thin aluminum
washers (2 and 18) and screw (3). Slide boot (4) and
clamp (1) upward to expose bolts (7 and 9).
3. Remove cotter pin (14), nut (13), washers (10 and
12) and bolt (9).
4. Remove cotter pin (16), nut (15), washers (8 and
14) and bolt (7).
5. Loosen nut (10). Remove piston rod clevis (9) from
piston rod (12). Remove nut (10) and lock (11) from
clevis (9).

4. Remove cotter pin (17), nut (16), washers (6 and
15) and bolt (7). Remove hydraulic cylinder extension
universal (8) from piston rod clevis (11).
67-105. Inspection
Inspect hydraulic cylinder extension universal (8, figure
67-40) for mechanical and corrosion damage
(BHT-412-CR&O).
67-110. Inspection
1. Inspect clevis (9, figure 67-41) for mechanical and
corrosion damage. Superficial mechanical and
corrosion damage is acceptable if repaired (paragraph
67-111).
2. Inspect bolt holes for elongation.

67-106. Bearing Replacement 3. Inspect threads for damage. No visible thread

damage is acceptable.
Refer to BHT-412-CR&O for bearing replacement
procedure in universal assembly P/N 205-076-381, and 67-111. Repair
in universal assembly P/N 412-076-620-101.
Repair piston rod clevis (9, figure 67-41)
67-107. Installation (BHT-412-CR&O).

1. Place universal (8, figure 67-40) in clevis of 67-112. Installation

extension tube (5).
MATERIALS REQUIRED
2. Install bolt (7), washers (6 and 15), nut (16), and
cotter pin (17).
Refer to BHT-ALL-SPM for specifications and source.
3. Place bottom of universal into piston rod clevis (11) NUMBER NOMENCLATURE
and install bolt (9), washers (10 and 12), nut (13), and
cotter pin (14). C-101 Corrosion Preventive
Compound
4. Slide boot (4) and clamp (1) down 22.2 in. (563.9
mm) from centerline of top bolt (20). Install screw (3), C-308 Adhesive
washers (2 and 18), and nut (19). C-405 Lockwire

5. Install forward pylon fairing (Chapter 52).

1. Coat threads of clevis (9, figure 67-41) with
corrosion preventive compound (C-101).
67-108. LEFT CYCLIC PISTON ROD CLEVIS

67-109. Removal
1. Remove forward pylon fairing (Chapter 52).
2. Remove nut (18, figure 67-41), thin aluminum
washers (2 and 17) and screw (3).
2. Place lock (11) into nut (10). Install nut (10) and
lock (11) on clevis (9).
3. Install clevis (9) into piston rod (12). Adjust clevis
(9) to obtain 1.75 in. (44.45 mm) from clevis bolt hole
centerline to top of piston rod (detail B).

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 BHT-412-MM-8

Figure 67-41. Left Cyclic Piston Rod Clevis

67-00-00
30 SEP 2003 Rev. 7 Page 109
BHT-412-MM-8

4. Torque nut (10) 660 to 780 in.-lbs. (74.57 to 88.13 4. Remove cotter pin (16), nut (15), washers (8 and
N-m). Secure nut with lockwire (C-405). 14) and bolt (7).

5. Loosen nut (10). Remove piston rod clevis (9) from

piston rod (12). Remove nut (10) and lock (11) from
clevis (9).
AVOID GETTING ADHESIVE (SEALANT)
O N P I S T O N R O D S U R FA C E O R
67-115. Inspection
SCRAPER AND ROD SEAL DAMAGE MAY
OCCUR.
1. Inspect piston rod clevis (9, figure 67-42) for
5. Coat nut (10), lock (11), lockwire and threads on mechanical and corrosion damage (BHT-412-CR&O).
clevis (9) with adhesive (C-308).
2. Inspect bolt holes for elongation.
6. Place universal (6) in clevis (9). Install bolt (7),
washer (8), washer (14), nut (15), and cotter pin (16).
3. Inspect threads for damage. No visible damage to
threads is acceptable.
7. Slide boot (5) down over piston rod (12) and
engage bottom of boot into lip on mount (13).
67-116. Installation
8. Position top of boot (5) 22.2 in. (563.9 mm) from
centerline of bolt (19) (detail A). MATERIALS REQUIRED

9. Secure boot to hydraulic cylinder extension tube Refer to BHT-ALL-SPM for specifications and source.
(1) with clamp (4) using screw (3), washer (2), washer
(17) and nut (18). NUMBER NOMENCLATURE

C-101 Corrosion Preventive

10. Verify cyclic rigging is within limits (paragraph 67-6 Compound
or 67-7).
C-308 Adhesive
11. Move cyclic controls through full travel and check C-405 Lockwire
for interference and binding.

12. Install forward pylon fairing (Chapter 52). 1. Coat threads of clevis (9, figure 67-42) with
corrosion preventive compound (C-101). Place lock
(11) into nut (10). Install nut (10) and lock (11) on clevis
67-113. RIGHT CYCLIC PISTON ROD CLEVIS
(9).
67-114. Removal
2. Adjust clevis (9) to obtain 1.90 in. (48.26 mm)
1. Remove forward pylon fairing (Chapter 52). between bolt hole centerline and top of piston rod (12)
(detail B).
2. Loosen bottom of boot (5, figure 67-42) from lip in
mount (13).
3. Torque nut (10) 660 to 780 in.-lbs. (74.57 to 88.13
N-m) and secure with lockwire (C-405).
3. Remove nut (18), thin aluminum washers (2 and
17) and screw (3). Slide clamp (4) and boot (5) upward
on hydraulic cylinder extension tube (1) to expose 4. Coat nut (10), lock (11), lockwire, and threads on
universal (6). clevis (9) with adhesive (C-308).

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 BHT-412-MM-8

Figure 67-42. Right Cyclic Piston Rod Clevis

67-00-00
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BHT-412-MM-8

discard packings (31, 33, 56, and 58). Plug or cap open
ports to prevent contamination.
CAUTION

5. Remove cotter pin (53), nut (52), two washers

DO NOT ALLOW SEALANT TO CONTACT (51), bolt (38), and washer (39).
PISTON ROD SURFACE OR SCRAPER
AND R OD S EA L O R DAM AG E M AY 6. Remove nuts (26 and 30) and washers (27 and 29)
OCCUR. (Detail C).

5. Place universal (6) to piston rod clevis (9). Install
bolt (7), washer (8), washer (14), nut (15), and cotter
pin (16).
6. Slide boot (5) downward and secure bottom of
boot into lip in mount (13).
7. Position top of boot (5) 22.2 inches (563.9 mm)
below centerline bolt (19) (Detail A).
8. Secure boot (5) to hydraulic cylinder extension
tube (1) with clamp (4), screw (3), washer (2), washer
(17), and nut (18).
7. Remove cotter pin (48), nut (47), washer (46), and
bolt (44).
NOTE
If tr ansmission i s installed, cylinder
assembly must be removed by rotating
support bracket (28), so it will pass
downward through support. If transmission
has been removed, cylinder assembly can
be removed upward.
8. Carefully remove left cyclic flight control cylinder
(7) from helicopter.

9. Verify cyclic control rigging within limits (paragraph 9. Loosen jam nut (68) and remove clevis (22) from
67-6 or paragraph 67-7). upper piston (21).

10. Move cyclic controls through full travel and check 67-119. Left Cyclic Flight Control Cylinder —
for interference and binding. Inspection

11. Install forward pylon fairing (Chapter 52). 1. Inspect cylinder (7, Figure 67-43) for damage and
signs of leakage.

6 7 - 11 7 . L E FT C Y C L I C F L I G H T C O N T R O L
2. Inspect exposed areas of piston for scratches and
CYLINDER
wear.

67-118. Left Cyclic Flight Control Cylinder —

3. Inspect bearings for looseness (BHT-ALL-SPM).
Removal

67-120. Left Cyclic Flight Control Cylinder —

1. Remove access panels that are around the pylon
Installation
support structure in aft cabin. Remove forward pylon
fairing (Chapter 52).
MATERIALS REQUIRED
2. Position bottom of boot (18, Figure 67-43) to gain
access. Remove cotter pin (25), nut (24), washers (23), Refer to BHT-ALL-SPM for specifications and source.
and bolt (20) (Detail B).
NUMBER NOMENCLATURE

3. Remove cotter pin (13), nut (12), washers (9, 10, C-002 Hydraulic Fluid
11, and 16), and bolt (17) (Detail A). Remove extension C-104 Corrosion Preventive
tube (14) with attached universal (19). Compound
C-308 Sealant
4. Disconnect hoses (37, 40, 43, and 54) (Detail D).
Remove bolts (34 and 55) and elbows (32 and 57) and C-405 Lockwire

67-00-00
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 BHT-412-MM-8

Figure 67-43. Left Cyclic Flight Control Cylinder (Sheet 1 of 3)

67-00-00
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BHT-412-MM-8

1
3

4 2
SEE DETAIL G

75 TO 95 IN-LBS 95 TO 110 IN-LBS 120 TO 160 IN-LBS 660 TO 780 IN-LBS

1 (8.47 TO 10.73 Nm) 2 (10.73 TO 12.43 Nm) 3 (13.6 TO 18.1 Nm) 4 (74.57 TO 88.13 Nm)

412_MM_67_0015_c01

Figure 67-43. Left Cyclic Flight Control Cylinder (Sheet 2 of 3)

67-00-00
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 BHT-412-MM-8

5 6

22

67
1 S

68 0.12 TO 0.15 IN.

(3.0 TO 3.8 mm)

21

SEALANT SHALL NOT EXTEND

BEYOND THIS POINT

DETAIL G

26. Nut 37. Hose 48. Cotter pin 58. Preformed packing
27. Aluminum washer 38. Bolt 49. Tube assembly 59. Actuator
28. Support bracket 39. Washer 50. Lever 60. Lower piston
29. Aluminum washer 40. Hose 51. Washer 61. Locking device
30. Nut 41. Preformed packing 52. Nut 62. Nut
31. Preformed packing 42. Bypass check valve 53. Cotter pin 63. Rod end bearing
32. Elbow 43. Hose 54. Hose 64. Nut
33. Preformed packing 44. Bolt 55. Bolt 65. Bearing nut
34. Bolt 45. Support 56. Preformed packing 66. Keyed washer
35. Preformed packing 46. Aluminum washer 57. Elbow 67. Lock
36. Bypass check valve 47. Nut 68. Jam nut

S SEALANT (C-308) 220 TO 250 IN-LBS 900 TO 1100 IN-LBS

5 (24.86 TO 28.25 Nm) 6 (101.69 TO 124.28 Nm)

NOTE
1 Apply sealant (C-308) around jam nut (68), lock (67), and exposed threads of clevis (22).

412_MM_67_0016_c01

Figure 67-43. Left Cyclic Flight Control Cylinder (Sheet 3 of 3)

67-00-00
ECCN EAR99 29 OCT 2009 Rev. 13 Page 115
BHT-412-MM-8
NOTE
When transmission is installed, insert lower
end of cylinder assembly through
passenger/cargo compartment (Chapter
52) until top surface clears access hole in
forward island then raise cylinder assembly
through cylinder support until support
bracket (28, Figure 67-43) is past
attachment studs.
1. Cut and remove lockwire, and loosen nuts (65
and 66, Figure 67-43) so support bracket (28) may be
rotated easily (Detail F).
2. Install clevis (22) with jam nut (68) and lock (67)
in upper piston (21) to dimension of 1.75 inches
(44.45 mm) between end of upper piston (21) and
center of holes in clevis (22).
3. Torque jam nut (68) 660 to 780 inch-pounds
(67.79 to 88.12 Nm) and secure with lockwire (C-405).
Cover jam nut (68), lock (67), and threads of clevis
(22) with sealant (C-308) (Detail G).
4. Place universal (19), attached to tube (14), into
clevis on upper piston (21) and install bolt (20),
washers (23), nut (24), and cotter pin (25) (Detail B).
5. Raise bottom of boot (18) to expose universal
(19) and clevises. Brush corrosion preventive
compound (C-104) on universal and clevises as
required. Brush corrosion preventive compound
(C-104) on mount bearing and in housing cavity.
Position lower end of boot in groove of support bracket
(28).
6. Guide left cyclic flight control cylinder (7) carefully
into helicopter. Place support bracket (28) over studs
in support (5) (Detail C). Install aluminum washers (27)
and torque nuts (26) 75 to 95 inch-pounds (10.73 to
12.73 Nm). Install aluminum washer (29) and torque
nut (30) 120 to 160 inch-pounds (13.6 to 18.1 Nm).
7. Pull lower piston (60) full down and push actuator
(59) full up (Detail E). If hole in rod end bearing (63)
does not align with hole in support (45), adjust rod end
bearing.
CAUTION
IMPROPER TORQUE TECHNIQUE CAN
DESTROY TAB ON LOCKING DEVICE
67-00-00
Page 116 Rev. 13 29 OCT 2009
(61). ROD END BEARING (63) MUST BE
HELD SECURE TO PREVENT DAMAGING
LOCKING DEVICE.
a. Remove lockwire and loosen nut (62), and
turn rod end bearing (63) to align with bolt hole.
b. Torque nut (62) to 200 to 250 inch-pounds
(22.60 to 28.25 Nm) and secure to locking device (61)
with lockwire (C-405).
c. Inspect locking device (61) to ensure tab is in
groove of rod end bearing (63) and that it was not
damaged when nut (62) was tightened. Replace
locking device if tab is twisted or damaged.
8. Align left cyclic flight control cylinder (7) into
support (45) as follows:
a. Move lower piston rod up and clear of support
(45). Lower piston rod must be able to be moved freely
down, up, and then down, and bolt replaced without
any pressure, forcing, binding, or bending of piston rod
in fore, aft, left, or right direction. One person must
guide extension tube (14) to prevent damage when
conducting this step and subsequent steps.
b. If cylinder meets requirements of step a, it is
considered in alignment. If cylinder is aligned,
accomplish step h through step j. If cylinder is
misaligned, accomplish step c through step j.
c. Loosen nut (64) and bearing nut (65) so
cylinder is loose.
d. Move rod end bearing (63) up approximately
0.5 inch (12.7 mm) above support (45). Rotate lower
end of cylinder in a 3.0 inch (76.2 mm) circle.
e. Position rod end bearing (63) directly over
lugs of support (45) and move piston down and
temporarily install bolt (44).
f. Tighten bearing nut (65) by hand
(approximately 70 inch-pounds (7.91 Nm)).
g. Remove bolt (44) and move rod end bearing
(64) up and out of support (45), then move down. Rod
end bearing (63) must be free of any side loading.
Repeat step c through step g until free of side loading.
ECCN EAR99

NOTE
If cylinder (7) still cannot be installed
without preload, it is permissible to add one
AN960C416L washer (maximum) on two
aft studs of support (5) between support
bracket (28) and support. Or, it is
permissible to add one AN960C416L
washer (maximum) and one AN960C516L
washer (maximum) on each of two forward
studs between support bracket and
support.
h. Install bolt (44). Torque bearing nut (65) to 200
inch-pounds (22.60 Nm).
i. If cylinder still meets requirements of step a,
install washer (46) and nut (47) and torque 95 to 100
inch-pounds (10.73 to 12.43 Nm). Install cotter
pin (48).
j. Torque bearing nut (65) 900 to 1100
inch-pounds (101.68 to 124.28 Nm). Torque nut (64)
900 to 1100 inch-pounds (101.68 to 124.28 Nm).
Secure nuts (65 and 64) to keyed washer (66) with
lockwire (C-405).
NOTE
Use washers (10 and 12) as required to
obtain proper engagement of cotter pin (13)
and nut (12).
9. Position extension tube (14) on swashplate horn
(3). Install bolt (17), washers (16, 9, 10, and 11), and
nut (12). Install cotter pin (13) (Detail A).
10. Position tube assembly (49, Detail D) into lever
(50) and secure with bolt (38), washer (39), washers
(51), nut (52), and cotter pin (53).
11. Lubricate new preformed packings (31, 33, 56,
and 58) with hydraulic fluid (C-002). Install preformed
packing (31 and 58), elbows (32 and 57), and
preformed packings (33 and 56) with bolts (34 and 55).
12. If bypass check valves have been removed,
lubricate new preformed packings (35 and 41) with
hydraulic fluid (C-002). Install preformed packings and
bypass check valves (36 and 42).
13. Connect hoses (37, 40, 43, and 54) observing
labels on hydraulic systems No. 1 and No. 2.
ECCN EAR99
BHT-412-MM-8
14. Bleed and leak check hydraulic system
(Chapter 29).
15. Energize hydraulic system and operate cyclic
controls through ten complete operations. Check for
leaks.
16. Verify cyclic control rigging is within limits
(paragraph 67-6 or paragraph 67-7).
17. Install access panel on pylon support. Install
forward pylon fairing (Chapter 52).
67-121. RIGHT CYCLIC FLIGHT CONTROL
CYLINDER
67-122. Right Cyclic Flight Control Cylinder —
Removal
1. Remove access panels that are around the pylon
support structure in aft cabin. Remove forward pylon
fairing (Chapter 52).
2. Disconnect hoses (35, 40, 46, and 52,
Figure 67-44, Detail D). Remove bolts (34 and 56) and
elbows (32 and 58). Plug or cap open ports.
3. Remove cotter pin (55), nut (49), washers (37,
50, and 51), and bolt (38). Remove tube assembly
(39) from lever (36).
4. Remove cotter pin (45), nut (44), aluminum
washer (43), and bolt (41) (Detail D).
5. Remove nuts (25 and 30) and aluminum washers
(26 and 29) (Detail C).
6. Remove cotter pin (9, Detail A), nut (10), washers
(11, 12, 13, and 14), and bolt (15).
7. Carefully remove right cyclic control cylinder (7)
and extension tube (3) from helicopter.
8. Reposition boot (16) to provide access to
universal (18) (Detail B). Remove cotter pin (23), nut
(24), washers (20), and bolt (19).
9. Remove extension tube (3) with attached
universal (18) from right cyclic control cylinder (7).
10. Loosen jam nut (70) and remove clevis (68) from
upper piston (20).
67-00-00
29 OCT 2009 Rev. 13 Page 116A
BHT-412-MM-8
67-123. Right Cyclic Flight Control Cylinder —
Inspection
Inspect right cyclic flight control cylinder in same
manner outlined for left cylinder (paragraph 67-119).
67-124. Right Cyclic Flight Control Cylinder —
Installation
MATERIALS REQUIRED
Refer to BHT-ALL-SPM for specifications.
NUMBER NOMENCLATURE
C-002 Hydraulic Fluid
C-104 Corrosion Preventive
Compound
C-308 Sealant
C-405 Lockwire
NOTE
When transmission is installed, insert lower
end of cylinder assembly through
passenger/cargo compartment until top
surface clears access hole in forward
island. Then, raise cylinder assembly
through cylinder support until support
bracket (27, Figure 67-44) is past
attachment studs.
1. Cut and remove lockwire and loosen nut (65 and
66, Figure 67-44) so support bracket (27) may be
rotated easily (Detail F).
2. Install clevis (22) with jam nut (69) and lock (68)
in upper piston (21) to dimension of 1.90 inches
(48.26 mm) between end of piston (20) and center of
holes in clevis (68).
3. Torque jam nut (69) 660 to 780 inch-pounds
(67.79 to 88.12 Nm) and secure with lockwire (C-405).
Cover jam nut (69), lock (68), and threads of clevis
(22) with sealant (C-308) (Detail G).
4. Place universal (18), attached to tube (3), into
clevis on upper piston (21) and install bolt (19),
washers (20), nut (24), and cotter pin (23) (Detail B).
5. Raise bottom of boot (16) to expose universal
(18) and clevises. Brush corrosion preventive
compound (C-104) on universal and clevises as
required. Brush corrosion preventive compound
67-00-00
Page 116B Rev. 13 29 OCT 2009
(C-104) on mount bearing and in housing cavity.
Position lower end of boot in groove of support
bracket (27).
6. Guide right cyclic flight control cylinder (7)
carefully into helicopter. Place support bracket (27)
over studs in support (28) (Detail C). Install aluminum
washers (29) and torque nuts (30) 75 to 95
inch-pounds (10.73 to 12.43 Nm). Install aluminum
washer (26) and torque nut (25) 120 to 160
inch-pounds (13.6 to 18.1 Nm).
7. Pull lower piston (61) full down and push actuator
(60) full up (Detail E). If hole in rod end bearing (64)
does not align with hole in support (42), adjust rod end
bearing.
CAUTION
IMPROPER TORQUE TECHNIQUE CAN
DESTROY TAB ON LOCKING DEVICE
(62). ROD END BEARING (64) MUST BE
HELD SECURE TO PREVENT
DAMAGING LOCKING DEVICE.
a. Remove lockwire and loosen nut (63), and
turn rod end bearing (64) to align with bolt hole.
b. Torque nut (63) to 200 to 250 inch-pounds
(22.60 to 28.25 Nm) and secure to locking device (62)
with lockwire (C-405).
c. Inspect locking device (62) to ensure tab is in
groove of rod end bearing (64) and that it was not
damaged when nut (63) was tightened. Replace
locking device if tab is twisted or damaged.
8. Align right cyclic flight control cylinder (7) into
support (28) as follows:
a. Move lower piston rod up and clear of support
(28). Lower piston rod must be able to be moved freely
down, up, and then down, and bolt replaced without
any pressure, forcing, binding, or bending of piston rod
in fore, aft, left, or right direction. One person must
guide extension tube (3) to prevent damage when
conducting this step and subsequent steps.
b. If cylinder meets requirements of step a, it is
considered in alignment. If cylinder is aligned,
accomplish step h through step j. If cylinder is
misaligned, accomplish step c through step j.
ECCN EAR99
 BHT-412-MM-8

Figure 67-44. Right Cyclic Flight Control Cylinder (Sheet 1 of 4)

67-00-00
ECCN EAR99 29 OCT 2009 Rev. 13 Page 116C/116D
 BHT-412-MM-8

16

3
17
18 19

20 20
24 22
23
3

21

8. Clevis
9. Cotter pin
10. Nut
11. Washer (AN960C516L)
12. Washer (AN960C516)
13. Washer (AN960C516)
14. Washer (AN960C516)
15. Bolt
16. Boot
17. Clevis
18. Universal
19. Bolt
20. Washer (AN960C516)
21. Upper piston
22. Clevis
23. Cotter pin
24. Nut
16
25. Nut
26. Aluminum washer
30 27. Support bracket
1 25
2 28. Support
29
26 27 29. Aluminum washer
30. Nut
28

75 TO 95 IN-LBS
1 (10.73 TO 12.43 Nm)

120 TO 160 IN-LBS

2 (13.6 TO 18.1 Nm)

660 TO 780 IN-LBS

3 (74.57 TO 88.13 Nm)

412_MM_67_0004_c01

Figure 67-44. Right Cyclic Flight Control Cylinder (Sheet 2 of 4)

67-00-00
ECCN EAR99 29 OCT 2009 Rev. 13 Page 117
BHT-412-MM-8

34
33
32
7 31 60

61
35
59 62
58 36
57 63
56 5
38 64
37

55
54

53 39

51
52 50
49
40

48 27

47

67
66
41 6
46
65
6
45
43
44
4 42

31. Preformed packing 44. Nut 56. Bolt

32. Elbow 45. Cotter pin 57. Preformed packing
33. Preformed packing 46. Hose 58. Elbow
34. Bolt 47. Bypass check valve 59. Preformed packing
35. Hose 48. Preformed packing 60. Actuator
36. Lever 49. Nut 61. Lower piston
37. Washer 50. Washer 62. Locking device
38. Bolt 51. Washer 63. Nut
39. Tube assembly 52. Hose 64. Rod end bearing
40. Hose 53. Bypass check valve 65. Nut
41. Bolt 54. Preformed packing 66. Bearing nut
42. Support 55. Cotter pin 67. Keyed washer
43. Aluminum washer

95 TO 110 IN-LBS 200 TO 250 IN-LBS 900 TO 1100 IN-LBS

4 (10.73 TO 12.43 Nm) 5 (22.60 TO 28.25 Nm) 6 (101.69 TO 124.28 Nm)
412_MM_67_0005_c01

Figure 67-44. Right Cyclic Flight Control Cylinder (Sheet 3 of 4)

67-00-00
Page 118 Rev. 13 29 OCT 2009 ECCN EAR99
 BHT-412-MM-8

22

68
1 S

69 0.12 TO 0.15 IN.

(3.0 TO 3.8 mm)

21

SEALANT SHALL NOT EXTEND

BEYOND THIS POINT

DETAIL G

68. Lock
69. Jam nut

S SEALANT (C-308)

NOTE
1 Apply sealant (C-308) around jam nut (69), lock (68), and exposed threads of clevis (22).

412_MM_67_0005a

Figure 67-44. Right Cyclic Flight Control Cylinder (Sheet 4 of 4)

67-00-00
ECCN EAR99 29 OCT 2009 Rev. 13 Page 119
BHT-412-MM-8
c. Loosen nut (65) and bearing nut (63) so
cylinder is loose.
d. Move rod end bearing (64) up approximately
0.5 inch (12.7 mm) above support (42). Rotate lower
end of cylinder in a 3.0 inch (76.2 mm) circle.
e. Position rod end bearing (64) directly over lugs
of support (42) and move piston down and temporarily
install bolt (41).
f. Tighten bearing nut (66) by hand
(approximately 70 inch-pounds (7.91 Nm)).
g. Remove bolt (41) and move rod end bearing
(64) up and out of support (42), then move down. Rod
end bearing must be free of any side loading. Repeat
step c through step g until free of side loading.
NOTE
If cylinder (7) still cannot be installed
without preload, it is permissible to add one
AN960C416L washer (maximum) on two aft
studs of support (5) between support
bracket (27) and support (28). Or, it is
permissible to add one AN960C416L
washer (maximum) and one AN960C516L
washer (maximum) on each of two forward
studs between support bracket and
support.
h. Install bolt (41). Torque bearing nut (66) to 200
inch-pounds (22.60 Nm).
i. If cylinder still meets requirements of step a,
install washer (43) and nut (44) and torque to 95 to 100
inch-pounds (10.73 to 12.43 Nm). Install cotter pin (45).
j. Torque bearing nut (66) to 900 to 1100
inch-pounds (101.68 to 124.28 Nm). Torque nut (65) to
900 to 1100 inch-pounds (101.68 to 124.28 Nm).
Secure nuts (66 and 65) to keyed washer (67) with
lockwire (C-405).
NOTE
Use washers (12 and 13) as required to
obtain proper engagement of cotter pin (9)
and nut (10).
7. Install extension tube (3) on swashplate horn (2).
Install bolt (15), washers (14, 13, 12, and 11), and nut
(10). Install cotter pin (9) (Detail A).
67-00-00
Page 120 Rev. 13 29 OCT 2009
8. Position tube assembly (39) into lever (36) and
install bolt (38), washer (37), washers (50 and 51), nut
(49), and cotter pin (55) (Detail D).
9. Lubricate new preformed packings (31, 33, 57,
and 59) with hydraulic fluid (C-002).
10. Install bolt (34), preformed packing (33), elbow
(32), and preformed packing (31).
11. Install bolt (56), preformed packing (57), elbow
(58), and preformed packing (59).
12. Lubricate new preformed packings (48 and 54)
with hydraulic fluid (C-002). Install preformed packings
and bypass check valves (47 and 53), if removed
(Detail D). Connect hoses (35, 40, 46, and 52).
13. Bleed and inspect hydraulic system (Chapter 29).
14. Energize hydraulic system and operate cyclic
controls through 10 complete operations. Check for
leaks.
15. Verify cyclic control rigging is within limits
(paragraph 67-6 or paragraph 67-7).
16. Install access panels on pylon support. Install
forward pylon fairing (Chapter 52).
67-125. RIGHT CYCLIC BOOST CYLINDER
SUPPORT
NOTE
Left cyclic and collective boost support (4,
Figure 67-38) is for the left cyclic control and
collective boost cylinders. Maintenance for
support is covered in collective controls
(paragraph 67-36).
67-126. Right Cyclic Boost Cylinder Support —
Removal
1. Remove access panel on right side and forward
side of pylon structure inside cabin (Chapter 52).
2. Remove right cyclic hydraulic flight control cylinder
(paragraph 67-122).
ECCN EAR99
 BHT-412-MM-8

3. Remove hydraulic system no. 1 hydraulic pump 9. Verify cyclic control rigging within limits (paragraph
(Chapter 29). 67-6 or 67-7).

4. Remove main rotor tachometer generator 10. Install access panel on right side of pylon structure
(Chapter 63). inside cabin (Chapter 52).

5. Remove nut (10, figure 67-45), two washers (3 and 11. Install access panel on forward side of pylon
9) and bolt (2). structure inside cabin (Chapter 52).

6. Remove nut (8), two washers (5 and 7) and bolt 67-129. CYCLIC CONTROL TUBES
(4).
67-130. Removal
7. Remove nut (15), two washers (12 and 14), bolt
(11). Remove cyclic control boost cylinder support (1)
NOTE
from lift beam (6).
The removal and installation procedures for
control tube (8, figure 67- 46) are typical for
67-127. Inspection left and right sides.

Inspect cyclic control boost cylinder support (1, figure

67-45) in accordance with BHT-412-CR&O. 1. Remove access panel from center of aft cabin floor
(Chapter 52).

67-128. Installation
2. Remove cotter pin (1) and nut (2). Remove bolt
1. Place cyclic control boost cylinder support (1, (6), and washers (3) from lever (5).
figure 67-45) into position in pylon structure (13) and lift
beam (6). 3. Remove cotter pin (13) and nut (12). Remove bolt
(10) and washers (11).
2. Install bolts (11), washers (12), washers (14), and
nuts (15).
4. Remove control tube (8).

3. Install bolts (2), washers (3), washers (9), and nuts

5. Remove cotter pin (18) and nut (19). Remove bolt
(10).
(17) and washers (16).

4. Install bolts (4), washers (5), washers (7), and nut

(8). 6. Remove cotter pin (21) and nut (22). Remove bolt
(24) and washers (23).

5. Install main rotor tachometer generator (Chapter

63). 7. Remove bellcrank (20).

6. Install no. 1 hydraulic system pump (Chapter 29). 8. Remove cotter pin (29) and nut (30). Remove bolt
(32) and washers (31).

7. Install right cyclic flight control cylinder (paragraph

67-124). 9. Loosen clamp (26) and slide forward off of boot
(27).

8. Move cyclic controls through full travel and check

for interference and binding. 10. Slide control tube (28) forward out of helicopter.

67-00-00
30 SEP 2003 Rev. 7 Page 121
BHT-412-MM-8

Figure 67-45. Right Cyclic Control Boost Cylinder Support

67-00-00
Page 122 Rev. 7 30 SEP 2003
 BHT-412-MM-8

Figure 67-46. Right Cyclic Control Tubes and Bellcranks

67-00-00
30 SEP 2003 Rev. 7 Page 123
BHT-412-MM-8
67-131. Inspection
NOTE
The inspection procedure for control tubes
(8 and 28, figure 67-46), clevises (9 and 25),
and bellcrank (20) in left and right cyclic
system are covered in BHT-412-CR&O.
Inserts and bearings in control tubes and
bellcranks are covered in BHT-ALL-SPM.
1. Inspect bolt holes for elongation.
2. Inspect threads for damage. No visible damage to
threads is acceptable.
3. Inspect boot (27, figure 67-46) for tears and signs
of deterioration. Torn or deteriorated boots are not
acceptable and shall be replaced.
67-132. Repair
NOTE
Repair bellcranks and control tubes in
accordance with BHT-412-CR&O. Refer to
BHT-ALL-SPM for bearing replacement
procedure.
67-133. Installation
1. Slide control tube (28, figure 67-46) aft through
boot (27). Position control tube (28) and install clamp
(26) on boot (27) and tighten.
2. Install control tube (28) on mixing lever assembly
(33) with bolt (32), two washers (31), nut (30), and
cotter pin (29).
3. Install bellcrank (20) in clevis (25) of control tube
(28) with bolt (24), two washers (23), nut (22), and
cotter pin (21).
4. Install bellcrank (20) with bolt (17), two washers
(16), nut (19), and cotter pin (18).
5. Install clevis (9) of control tube (8) on bellcrank
(20) with bolt (10), two washers (11), nut (12), and cotter
pin (13).
67-00-00
Page 124 Rev. 7 30 SEP 2003
6. Install rod end bearing (7) of control tube (8) on
lever (5) with bolt (6), washers (3), nut (2), and cotter
pin (1).
7. Verify cyclic control rigging is within limits
(paragraph 67-6 or 67-7).
8. Install access panel in the center aft cabin floor
(Chapter 52).
67-134. MIXING LEVER ASSEMBLY
67-135. Removal
1. Removal access panel in center of aft cabin floor
(Chapter 52).
2. Remove flight control tube (19, figure 67-47) from
mixing lever assembly (26) by removing cotter pin (18),
nut (17), washer (16) and bolt (3).
3. Remove flight control tube (6) from mixing lever
assembly (26) by removing cotter pin (9), nut (8),
washers (7 and 5) and bolt (4).
4. Remove flight control tube (12) from mixing lever
(26) by removing cotter pin (15), nut (14), washers (13
and 11), and bolt (10).
5. Disconnect series actuator (23) by removing cotter
pin (22), nut (21), washers (20 and 24) and bolt (25)
from lever assembly (26).
6. Remove four bolts (2) and washers (1). Remove
mixing lever assembly (26).
67-136. Inspection
Inspect mixing lever (26, figure 67-47) for mechanical
and corrosion damage in accordance with
BHT-412-CR&O.
67-137. Repair
Repair mixing lever assembly (26, figure 67-47)
(BHT-412-CR&O).
67-138. Installation
1. Place mixing lever assembly (26, figure 67-47) in
position in helicopter and install bolts (2) and washers
(1).
 BHT-412-MM-8

Figure 67-47. Mixing Lever

67-00-00
30 SEP 2003 Rev. 7 Page 125
BHT-412-MM-8

2. Place flight control tube (6) on lever assembly (26) 67-143. Installation
and install bolt (4), washer (5 and 7), nut (8), and cotter
pin (9). MATERIALS REQUIRED

3. Place flight control tube (12) on lever assembly Refer to BHT-ALL-SPM for specifications and source.
(26) and install bolt (10), washers (11 and 13), nut (14),
and cotter pin (15). NUMBER NOMENCLATURE

4. Place flight control tube (19) in lever assembly (26) C-405 Lockwire
and install bolt (3), washer (16), nut (17), and cotter pin
(18).
1. Place fore and aft proximity switch (2, figure 67-48)
in support assembly (3) and loosely install nut (1). Do
5. Place series actuator (23) onto lever assembly not tighten nut at this time.
(26) and install bolt (25), washers (24 and 20), nut (21),
and cotter pin (22).
2. Connect wires at splice to switch.
6. Move cyclic controls through full travel and check
for obstructions and binding. 3. Adjust switch as required (paragraph 67-8).
Tighten nut (1) and secure with lockwire (C-405).
7. Verify cyclic rigging within limits (paragraph 67-6 or
67-7). 4. Install access panel in center of cabin floor
(Chapter 52).
8. Install access panel in center of aft cabin floor.
(Chapter 52). 67-144. LATERAL PROXIMITY SWITCH

67-139. FORE AND AFT PROXIMITY SWITCH 67-145. Removal

67-140. Removal 1. Remove access panel in center of aft cabin floor

(Chapter 52).
1. Remove access panel in center of aft cabin floor
(Chapter 52).
2. Cut lockwire and remove nut (4, figure 67-48) from
lateral proximity switch (5).
2. Cut lockwire and remove nut (1, figure 67-48) from
fore and aft proximity switch (2).
3. Separate wires at splice to switch.
3. Separate wires at splice to switch.
4. Remove switch (5) from sensor plate (6).
4. Remove switch (2) from support assembly (3).
67-146. Inspection
67-141. Inspection
1. Inspect lateral proximity switch (5, figure 67-48) for
1. Inspect fore and aft proximity switch (2, figure cracks and security.
67-48) for cracks and security.

2. Inspect wires for deterioration and looseness.

2. Inspect wires for deterioration and looseness.

67-142. Repair 67-147. Repair

1. Tighten loose connections on wires. 1. Tighten loose connections on wires.

2. Proximity switches are nonrepairable and shall be 2. Proximity switches are nonrepairable and shall be
replaced if unserviceable. replaced if unserviceable.

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 BHT-412-MM-8

Figure 67-48. Fore and Aft and Lateral Proximity Switches

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BHT-412-MM-8

67-148. Installation 67-152. Repair

MATERIALS REQUIRED NOTE

Linear actuator portions of series actuators
Refer to BHT-ALL-SPM for specifications and source. are nonrepairable and shall be replaced if
unserviceable. Clevis and couplings are
NUMBER NOMENCLATURE repairable (BHT-412-CR&O).
C-405 Lockwire
67-153. Installation

1. Place lateral proximity switch (5, figure 67-48) in
sensor plate (6), and install nut (4). Do not secure nut
at this time.
2. Connect wires at splice to switch.
3. Adjust switch as required (Paragraph 67-8).
Tighten nut (4) and secure with lockwire (C-405).
1. Place series actuator (3, figure 67-49) into position
in helicopter. Place clevis of actuator on bellcrank (7).
Install bolt (9), washer (8), washer (4), nut (5), and
cotter pin (6).
2. Place aft clevis of series actuator onto mixing lever
(15). Install bolt (14), washer (13), washer (12), nut (11),
and cotter pin (10).

4. Install access panel in center of cabin floor 3. Connect electrical connector.

(Chapter 52).
4. Install cabin floor panels. (Chapter 52).
67-149. LATERAL SERIES ACTUATOR
67-154. LONGITUDINAL SERIES ACTUATOR
67-150. Removal
67-155. Removal
1. Remove access panel in center of aft cabin floor.
(Chapter 52). 1. Remove access panel in center of aft cabin floor
(Chapter 52).
2. Disconnect electrical connector.
2. Remove panel from left side of console. (Chapter
3. Remove panel in cabin floor to provide access to 52).
lateral cyclic control bellcrank (7, figure 67-49) (Chapter
52).
3. Remove cotter pin (5, figure 67-50), nut (4),
washers (3 and 14), and bolt (15).
4. Remove series actuator (3) from mixing lever
assembly (15) by removing cotter pin (10), nut (11),
4. Remove cotter pin (7), nut (8), washers (9 and 12),
washers (12 and 13) and bolt (14).
and bolt (11).

5. Remove series actuator (3) from lateral cyclic

5. Disconnect electrical connectors. Slide series
control bellcrank (7) by removing cotter pin (6), nut (5),
actuator (13) aft and remove from helicopter.
washers (4 and 8) and bolt (9). Disconnect electrical
connector. Slide series actuator (3) forward and remove
from helicopter. 67-156. Inspection

67-151. Inspection 1. Inspect series actuator in accordance with

BHT-412-CR&O.
Inspect series actuator (3, figure 67-49) for damage,
distortion, corrosion, and security of clevis 2. Inspect rod end bearings on series actuator for
(BHT-412-CR&O). wear (BHT-ALL-SPM).

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 BHT-412-MM-8

Figure 67-49. Lateral Series Actuator and Proximity Switch

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BHT-412-MM-8

Figure 67-50. Longitudinal Series Actuator

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 BHT-412-MM-8

67-157. Repair 67-162. Installation

1. Series actuators are nonrepairable and shall be MATERIALS REQUIRED

replaced if unserviceable.
Refer to BHT-ALL-SPM for specifications and source.
2. Repairs are limited to clevis and coupling
(BHT-412-CR&O). NUMBER NOMENCLATURE

67-158. Installation C-405 Lockwire

1. Place series actuator (13, figure 67-50) into
position in helicopter. Place forward end onto arm of
tube and lever assembly (10) and install bolt (11),
washer (12), washer (9), nut (8), and cotter pin (7).
2. Place aft end into idler (2), install bolt (15), washer
(14), washer (3), nut (4), and cotter pin (5). Connect
electrical connectors.
3. Verify cyclic control rigging within limits (paragraph
67-6 or 67-7).
4. Move controls through full travel and check for
binding and obstructions.
5. Install access panel in center of cabin floor.
(Chapter 52).
6. Install panel on left side of console. (Chapter 52).
67-159. ROTARY ACTUATOR (LATERAL CYCLIC)
67-160. Removal
1. Inspect rotary actuator (7, figure 67-51) to ensure
arm (11) is installed with index mark on arm positioned
six teeth from index mark on shaft (View A). Loosen
stud locking screw (12) and reposition arm (11) if index
marks are not properly located.
2. Torque rotary actuator arm stud locking screw
(12), 12 to 15 in.-lbs. (1.35 to 1.69 N-m). Secure with
lockwire (C-405) as required.
3. Position actuator (7) on rotary actuator adapter
plate (8). Install bolts (5) and washers (6).
4. Adjust length of force gradient (2) (refer to
paragraph 67-6) for rigging instructions. After force
gradient (2) length is set, position force gradient and
tube and lever assembly (1) on arm (11). Install nut (3)
and cotter pin (4).
5. Install electrical connectors (9 and 10).
6. Move cyclic controls through full travel and check
for binding and/or obstructions.

1. Remove access panel from bottom of helicopter 7. Verify cyclic control rigging within limits (paragraph
just aft and inboard of left lower nose window (Chapter 67-6 or 67-7).
52).

8. Install access panel (Chapter 52).

2. Remove cotter pin (4, figure 67-51) and nut (3).

67-163. ROTARY ACTUATOR (FORE AND AFT

3. Disconnect electrical connectors (9 and 10) from CYCLIC)
rotary actuator (7).
67-164. Removal
4. Remove four bolts (5) and four washers (6).
Remove rotary actuator (7) and rotary actuator adapter 1. Remove access panel from cabin floor under left
plate (8). crew seat. Remove access panel from bottom of left
side of helicopter just forward of forward landing gear
67-161. Inspection crosstube (Chapter 52).

Inspect, rotary actuator for mechanical and corrosion 2. Disconnect hook (16, figure 67-52), spring (19)
damage (BHT-412-CR&O). from bolt (13).

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BHT-412-MM-8

Figure 67-51. Lateral Cyclic Rotary Actuator

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 BHT-412-MM-8

Figure 67-52. Fore and Aft Cyclic Rotary Actuator

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BHT-412-MM-8
3. Remove cotter pin (3) and nut (4) and separate
force gradient (2) from arm (6).
4. Disconnect electrical connectors (5, 11 and 12).
5. Remove bolts (10 and 13) and washers (9 and 14).
6. Remove rotary actuator (8) from structure (15).
67-165. Inspection
Inspect actuator (8, figure 67-52) for mechanical and
corrosion damage (BHT-412-CR&O).
67-166. Installation
MATERIALS REQUIRED
Refer to BHT-ALL-SPM for specifications and source.
NUMBER NOMENCLATURE
C-405 Lockwire
1. Inspect rotary actuator (8, figure 67-52) to ensure
arm (6) is installed with index mark on arm positioned
14 teeth from index mark on shaft (View A). Loosen
stud locking screw (7) and reposition arm (6) if index
marks are not properly located.
2. Torque rotary actuator arm stud locking screw (7),
12 to 15 in.-lbs. (1.35 to 1.69 N-m). Secure with
lockwire (C-405) as required.
3. Position rotary actuator (8) on structure (15).
4. Install special bolt (13) and washer (14) in lower
outboard hole.
5. Install bolts (10) and washers (9) in remaining
holes.
6. Adjust length of force gradient (2) (paragraph
67-6). After force gradient (2) length is set, position
force gradient and tube and lever assembly (1) on arm
(6).
7. Install nut (4) and cotter pin (3).
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8. Install spring (19), plate (17), and hook (16) on bolt
(13). Refer to paragraph 67-171 for procedure to
position spring (19) in correct hole in plate.
NOTE
For initial installation, install spring in fourth
hole of plate (17). With hydraulic boost on or
during ground run, adjust spring tension to
position pilot cyclic (longitudinal only)
perpendicular to deck within 2°.
9. Close loop on hook (16) on bolt (13). Secure
spring (19) to plate (15) with lockwire (C-405).
10. Install electrical connectors (5, 11 and 12).
11. Move cyclic controls through full travel and check
for binding and/or obstructions.
12. Verify cyclic rigging within limits (paragraph 67-6 or
67-7).
13. Install access panel on cabin floor under left crew
seat (Chapter 52).
14. Install access panel on bottom of helicopter
(Chapter 52).
67-167. FORCE GRADIENT (FORE AND AFT
CYCLIC)
NOTE
Following paragraphs apply to helicopters
pr io r to S /N 360 87. For pr oce dur es
applicable to S/N 36087 and subsequent
refer to paragraph 67-290.
67-168. Removal
1. Remove access panel from cabin from under left
crew seat (Chapter 52).
2. Remove access panel from bottom of helicopter
on left side forward of forward landing gear crosstube.
(Chapter 52).
3. Remove hook (7, figure 67-53) from bolt (6).
4. Disconnect electrical connector.
 BHT-412-MM-8

Figure 67-53. Fore and Aft Cyclic Force Gradient

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BHT-412-MM-8
5. Remove cotter pin (3) and nut (4) from rotary
actuator (5).
6. Remove aluminum washer (11) and bolt (12).
7. Remove fore and aft cyclic controls force gradient
(2) from tube and lever assembly (1).
67-169. Inspection
1. Inspect force gradient (2, figure 67-53) for
corrosion and mechanical damage. Superficial
mechanical damage is acceptable without repair.
Mechanical damage in excess of superficial and/or
corrosion is not acceptable and force gradient shall be
replaced.
2. Inspect clevis (13) for damaged threaded helicoil
insert and for elongated hole in bushing opposite the
threaded helicoil insert.
3. Inspect hook (7), plate (8), and spring (10) for
obvious mechanical damage and for loss of tension in
Figure 67-54. Fore and Aft Cyclic Force Gradient Assembly
67-00-00
Page 136 Rev. 7 30 SEP 2003
spring. Spring tension at 10.36 in. (263.1 mm) is 6.4 ±
0.5 lbs. (28.4 ± 2.2 N).
4. Inspect bearing for wear and for secure installation
in cylinder (5, figure 67-54) (BHT-ALL-SPM).
5. Inspect two nuts (6 and 8) for secure installation. If
adjustment of nuts (2 and 3, spring preload) is
suspected of being incorrect, adjust spring preloads
(paragraph 67-171).
6. Inspect jam nut (1) and cylinder (5) for lockwire
installation.
7. Inspect switch and electrical cable assembly (18)
for frayed wires and broken pins in connector. Check
continuity from connector pins through switch.
67-170. Repair
Repair of force gradient consists of replacement of
unserviceable components and adjustment of spring
preload (paragraph 67-171).

67-171. Installation
MATERIALS REQUIRED
Refer to BHT-ALL-SPM for specifications and source.
NUMBER NOMENCLATURE
C-405 Lockwire
NOTE
Force gradient (2, Figure 67-53) in fore and
aft cyclic controls is similar in appearance to
force gradient in lateral cyclic controls, but
the force gradients have different part
numbers. Ensure correct part number force
gradient is installed at lateral or fore and aft
positions. (BHT-412-IPB)
1. If not previously accomplished, adjust spring
preload of force gradient as follows:
a. Cut and remove lockwire, loosen jam nut (1)
and remove cap (9, Figure 67-54).
b. Remove spring assembly (4) from cylinder (5).
c. Adjust inboard nut (3) to provide 7.5 to 8.5
pounds (33.4 to 37.8 N) preload against spring
assembly (4). Tighten outboard nut (2) against inboard
nut (3).
d. Position spring assembly (4) in cylinder (5) and
install cap (9) with jam nut (1) until all end play is
eliminated. Tighten jam nut (1) and secure with lockwire
(C-405) to cylinder (5).
2. If not previously accomplished, adjust actuator (7)
on force gradient as follows:
a. Loosen nuts (6 and 8) on shaft of spring
assembly (4).
b. Ensure retainer (13) is secured by screws (15)
and washers (14).
c. Align actuator (7) on shaft of spring assembly
(4) with ball (10) and plunger of cable assembly (switch)
(18).
BHT-412-MM-8
d. Loosen screws (11), washers (12 and 16) and
nut (17) cable assembly (switch) (18) to retainer (13).
e. Push and hold actuator (7) down (180°) against
cap (9) at point opposite location of cable assembly
(18). Hold this position to initially adjust switch (18) then
adjust switch to actuate within ±0.050 inch (1.27 mm)
linear travel of spring assembly (4). Secure switch (18)
to retainer (13) with screws (11), washers (12 and 16)
and nut (17). Secure actuator (7) with nut (8).
f. Install clevis (13, Figure 67-53) on shaft of
spring assembly (4, Figure 67-54), secure with nut (6).
3. After assembly of force gradient, prior to
installation, verify spring assembly (4) preload of 7.5 to
8.5 pounds (33.36 to 37.81 N).
4. Position spring (10, Figure 67-53) on clevis (13) as
illustrated.
5. Position force gradient (2) on tube and lever (1).
Clevis (13) has a threaded helicoil insert in one side.
Position clevis with threaded insert inboard. Install bolt
(12) and washer (11). Secure bolt head to hole in clevis
(13) with lockwire (C-405).
CAUTION
ENSURE FORCE GRADIENT LENGTH IS
ADJUSTED PRIOR TO INSTALLATION OF
F O R C E G R A D I E N T O N R O TA R Y
ACTUATOR.
6. If not previously accomplished, adjust length of
force gradient as outlined in rigging instructions (<X-ref
Blue>paragraph 67-6).
7. Position force gradient (2) on rotary actuator (5).
Install nut (4) and cotter pin (3).
8. Install plate (8) on spring (10) with spring through
fourth hole in plate (8). Do not lockwire spring to plate
at this time.
9. Attach plate (8) with hook (7) to bolt (6). Do not
close loop on hook (7) at this time.
10. Connect electrical connector.
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BHT-412-MM-8

12. Apply external hydraulic power to helicopter
(Chapter 29).
13. Loosen cyclic friction and observe cyclic stick
p o s i t i o n . I f c y c l i c s t i c k i s n ot p e r p e n d i c u l a r
(longitudinally) within two degrees, move spring (10) to
different hole in plate (8) to cause cyclic stick to be
vertical (longitudinally).
14. When tension on spring (10) is correctly adjusted,
secure spring to plate (8) with lockwire (C-405) (9) and
close loop on hook (7) to prevent accidental
disengagement of hook.
15. Move cyclic controls through full travel and check
for binding and obstructions.
3. Remove cotter pin (7) and nut (6). Separate lateral
cyclic control force gradient (5) and lateral cyclic
controls rotary actuator (8).
4. Remove cotter pin (9), nut (10), aluminum
washers (3 and 11), and bolt (2). Remove lateral cyclic
control force gradient (5).
67-174. Force Gradient (Lateral Cyclic) —
Inspection
1. Inspect lateral cyclic control force gradient (5,
Figure 67-55) for corrosion and mechanical damage.
Superficial mechanical damage is acceptable without
repair. Mechanical damage in excess of superficial and/
or corrosion is not acceptable.
2. Inspect clevis on link (4) for elongated holes.

16. Verify cyclic control rigging is within limits

3. Inspect bearing for wear and for secure installation
(paragraph 67-6 or paragraph 67-7). in cylinder (5, Figure 67-56) (BHT-ALL-SPM).

17. Remove external power from helicopter.
18. Install access panel on bottom of helicopter on left
side forward of forward landing gear crosstube.
(Chapter 52).
19. Install access panel on cabin floor under left crew
seat (Chapter 52).
67-172. FORCE GRADIENT (LATERAL CYCLIC)
4. Inspect two nuts (6 and 8) for secure installation. If
adjustment of nuts (2 and 3) (spring preload) is
suspected of being incorrect, adjust spring preload
(paragraph 67-176).
5. Inspect jam nut (1) and cylinder (5) for correct
lockwire installation.
6. Inspect switch and electrical cable assembly (18)
for frayed wires and broken pins in connector. Check
continuity from connector pins through switch.

NOTE 67-175. Force Gradient (Lateral Cyclic) — Repair

The following paragraphs apply to Repair of lateral cyclic control force gradient is
he li c op ter s pr i or t o S /N 3 608 7. F or restricted to replacement of faulty parts and adjustment
procedures applicable to S/N 36087 and of spring preload.
subsequent, refer to paragraph 67-295.
67-176. Force Gradient (Lateral Cyclic) —
67-173. Force Gradient (Lateral Cyclic) — Installation
Removal
MATERIALS REQUIRED

1. Remove panel from bottom of helicopter below

lateral cyclic control force gradient (5, Figure 67-55), Refer to BHT-ALL-SPM for specifications and source.
(Chapter 52).
NUMBER NOMENCLATURE

2. Disconnect electrical connector. C-405 Lockwire

67-00-00
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 BHT-412-MM-8

NOTE
Lateral cyclic control force gradient (5,
Figure 67-55) in lateral cyclic controls is
similar in appearance to force gradient in
fore and aft cyclic controls, but the force
gradients have different part numbers.
Ensure force gradient with correct part
number is installed in lateral cyclic control
system position. (BHT-412-IPB).

67-00-00
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 BHT-412-MM-8

Figure 67-55. Lateral Cyclic Force Gradient

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BHT-412-MM-8
Figure 67-56. Lateral Cyclic Force Gradient Assembly
The instructions in step 1. are for lateral cyclic controls
force gradient (5, figure 67-55).
1. If not previously accomplished, adjust spring
preload of lateral cyclic control force gradient as
follows:
a. Cut and remove lockwire, loosen jam nut (1,
figure 67-56) and remove cap (9).
b. Remove spring assembly (4) from cylinder (5).
c. Adjust inboard nut (3) to provide 3.5 to 4.5 lbs.
(15.6 to 20.0 N) preload against spring assembly (4).
Tighten outboard nut (2) against inboard nut (3).
d. Position spring assembly (4) in cylinder (5) and
install cap (9) with jam nut (1) until all end play is
eliminated. Install jam nut (1) and secure with lockwire
(C-405) to cylinder (5).
2. If not previously accomplished, adjust actuator (7)
on force gradient as follows:
a. Loosen nuts (6 and 8) on shaft of spring
assembly (4).
67-00-00
Page 140 Rev. 7 30 SEP 2003
b. Ensure retainer (13) is secured by screws (15)
and washer (14).
c. Align actuator (7) on shaft of spring assembly
(4) with ball (10) and plunger of cable assembly (18)
(switch).
d. Loosen screws (11), washers (12 and 16) and
nut (17) mounting switch (18) to retainer (13).
e. Push and hold actuator (7) down (180°) against
cap (9) at point opposite location of cable assembly
(18). Hold this position to initially adjust switch (18) then
adjust switch to actuate within ± 0.050 in. (1.27 mm)
linear travel of spring assembly (4). Secure switch (18)
to retainer (13) with screws (11), washers (12 and 16)
and nut (17). Secure actuator (7) with nut (8).
f. Install clevis (4, figure 67-55) on shaft of spring
assembly (4, figure 67-56), secure with nut (6).
3. After assembly of force gradient, prior to
installation, verify spring assembly (4) preload of 3.5 to
4.5 pounds (15.57 to 20.02 N).
 BHT-412-MM-8

4. Position lateral cyclic control force gradient (5, 67-179. Transducers (Fore and Aft Cyclic) —
Figure 67-55) on lateral cyclic control bellcrank (1). Inspection
Install bolt (2), washer (3), washer (11), nut (10), and
cotter pin (9). 1. Inspect transducer for damage.

2. Inspect electrical cable and connectors for

damage.
CAUTION
3. Inspect bearings for looseness (BHT-ALL-SPM).
ENSURE FORCE GRADIENT LENGTH IS
ADJUSTED PRIOR TO FINAL 67-180. Transducers (Fore and Aft Cyclic) —
INSTALLATION OF LATERAL CYCLIC Repair
CONTROL FORCE GRADIENT ON
ROTARY ACTUATOR. The fore and aft cyclic transducers are nonrepairable
and shall be replaced when defective.
5. If not previously accomplished, adjust length of
lateral cyclic control force gradient as outlined in rigging 67-181. Transducers (Fore and Aft Cyclic) —
instructions (paragraph 67-6). Installation

MATERIALS REQUIRED
6. Position lateral cyclic control force gradient (5) on
lateral cyclic control rotary actuator (8). Install nut (6)
and cotter pin (7). Refer to BHT-ALL-SPM for specifications and source.

7. Connect electrical connector.
8. Move lateral cyclic controls through full travel and
check for binding and/or obstructions.
9. Verify cyclic control rigging within limits (paragraph
67-6 or paragraph 67-7).
10. Install access panel on bottom of helicopter below
force gradient (Chapter 52).
NUMBER NOMENCLATURE
C-405 Lockwire
1. Position transducer (7, Figure 67-57) and
transducer (15) on support (4) and install bolt (6),
spacers (5 and 3), nut (2), and cotter pin (1).
2. Install bolt (13), spacer (14), transducer (15),
spacer (11), transducer (7), and spacer (10) on tube
and lever assembly (8). Secure with lockwire (C-405).

67-177. TRANSDUCERS (FORE AND AFT NOTE

67-178. Transducers (Fore and Aft Cyclic) —
Removal
1. Remove access panel from cabin floor under pilot
seat (Chapter 52).
2. Disconnect electrical connectors (16 and 17,
Figure 67-57).
3. Remove cotter pin (1), nut (2), spacers (3 and 5),
and bolt (6) from support (4) and transducers (7 and
15).
4. Cut and remove lockwire (12), bolt (13), spacer
(14), and spacers (10 and 11). Remove transducer (15)
and transducer (7) from tube and lever assembly (8)
and control tube (9).
If not previously accomplished, perform
transducer adjustment. For helicopters S/N
33001 through 33213 and S/N 36001
t h r o u g h 3 6 03 6 wi t h t r a n s d u c e r P / N
4 1 2 - 0 7 4 - 1 0 1 - 1 0 1 i n s ta l l e d , r e f e r t o
paragraph 67-6. For helicopters S/N 36037
and subsequent with transducer P/N
4 1 2 - 0 7 4 - 1 0 1 - 1 0 3 i n s ta l l e d , r e f e r t o
paragraph 67-278B.
3. Connect electrical connectors (16 and 17).
4. Move controls through full travel and check for
binding and obstructions.
5. Install access panel on cabin floor under pilot seat
(Chapter 52).

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BHT-412-MM-8

Figure 67-57. Fore and Aft Cyclic Transducers

67-00-00
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67-182. JACKSHAFT (FORE AND AFT) TUBE AND
LEVER ASSEMBLY (RIGHT SIDE)
67-183. Removal
1. Remove access panel from cabin floor under pilot
seat. Remove access panel from cabin floor at aft end
of console. Remove access panel from left side of
console. Remove oval access panel from right side of
helicopter below pilot door (Chapter 52).
2. For removal of control motion transducers refer to
paragraph 67-177.
3. Remove cotter pin (18, figure 67-58), nut (19),
washers (20 and 2) and bolt (1) from tube and lever
assembly (right) (3) and flight control tube (21).
4. Remove cotter pin (7), nut (8), washers (9 and 11)
and bolt (12) from series actuator (10) and arm
assembly (14).
5. Remove two nuts (17), two washers (16) two bolts
(6), bushings (5 and 15). Index bushings for
reinstallation in original location.
6. Tap on tube and lever assembly (3) with a plastic
mallet to loosen inboard joint and to slide tube and lever
assembly (3) outboard.
7. Carefully work tube and lever assembly (3)
outboard to disengage arm assembly (14) and housing
(4). Remove tube and lever assembly (3) from
helicopter.
67-184. Inspection
1. Inspect tube and lever assembly (3, figure 67-58)
for mechanical and corrosion damage.
2. Inspect bolt holes for elongation.
3. Inspect bearing for secure installation in tube and
for wear (BHT-ALL-SPM).
BHT-412-MM-8
67-185. Installation
MATERIALS REQUIRED
Refer to BHT-ALL-SPM for specifications and source.
NUMBER NOMENCLATURE
C-204 Primer
SPECIAL TOOLS REQUIRED
NUMBER NOMENCLATURE
T27872-2 Reamer
NOTE
Inspect tube and lever (3, figure 67-58) to
determine whether holes for bolts (6) have
been drilled. If holes have been drilled and
reamed, proceed to step 14. If tube and lever
(3) has not been drilled and reamed,
accomplish steps 1. through 13.
1. Measure and record gap between arm assembly
(1, figure 67-59) and tube and lever assembly (3).
2. Remove arm assembly (1) from helicopter to use
as an aid in drilling new tube and lever assembly
(paragraph 67-195).
3. Fit arm assembly (1) into tube and lever assembly
(4) and establish dimension obtained in step 1. Set
angle between arm assembly (1) and tube and lever
assembly (3).
4. Holding lateral and angular dimensions, mark and
center punch top holes in tube and lever assembly (4).
5. Drill through top surface of tube and lever
assembly (4) using a No. 20 drill (0.161 in.) as a pilot.
Insert drill through top of tube and lever assembly (4)
and drill bottom hole using a No. 20 drill (0.161 in.).
6. Turn tube and lever assembly (4) and arm
assembly over, keeping everything aligned and redrill
bottom hole with an F drill (0.257 in.).
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BHT-412-MM-8

Figure 67-58. Fore and Aft Cyclic Jackshaft Tube and Lever Assembly (Right Side)

67-00-00
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 BHT-412-MM-8

Figure 67-59. Fore and Aft Cyclic Jackshaft Tube and Lever Assembly (Right Side) Alignment

67-00-00
30 SEP 2003 Rev. 7 Page 145
BHT-412-MM-8
7. Inspect hole in top of tube and lever assembly (4).
Verify hole is centered in existing hole in arm assembly
(1). If hole is not centered, use a small grinder or a
router bit in a drill motor to center hole. Redrill top hole
with an F drill (0.257 in.).
8. Insert reamer (T27872-2) through hole so pilot
projects through far side and ream hole to a smooth
finish and until tapered bushings extend 0.030 to 0.060
in. (0.762 to 1.524 mm) (figure 67-59).
9. Turn arm assembly (1) and tube and lever
assembly (4) over. Place one tapered bushing in hole
already reamed and insert reamer (T27872-2) so pilot
projects into bushing. Ream hole to a smooth finish.
Remove all burrs.
10. Repeat steps 4. through 11. to drill and ream holes
for remaining bolt.
11. Temporarily install bolts (6, figure 67-58), tapered
bushings (5 and 15), washers (16), and nuts (17).
Ensure bushings protrude 0.030 to 0.060 in. (0.762 to
1.524 mm) out of tube and lever assembly (3). Remove
and retain bolts (6), washers (16), nuts (17), and
bushings (5 and 15).
12. Place arm assembly (14) in position and mount to
tube and lever assembly (13), being sure washer
bonded to arm assembly (14) is on left side.
13. Apply primer (C-204) to end of arm assembly (14)
and tube and lever assembly (3) being sure to coat all
holes and bare surfaces.
14. Install tube and lever assembly (3) in helicopter,
guiding it through housing (4) and aligning holes in tube
and lever assembly (3) and arm assembly (14).
NOTE
After final installation of hardware, bushings
(5 and 15) must protrude from jackshaft tube
within the 0.030 to 0.060 in. (0762 to 1.524
mm) limits shown in figure 67-59 view A-A.
15. Install bolts (6), bushings (5 and 15), washers (16),
and nuts (17).
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16. Place tube (21, figure 67-58) onto tube and lever
assembly (3) and install bolt (1), washers (2 and 20),
nut (19), and cotter pin (18).
17. Place series actuator (10) on arm assembly (14)
and install bolt (12), washers (11 and 9), nut (8), and
cotter pin (7).
18. Move cyclic controls through full travel and check
for interference and binding.
19. For installation of control motion transducers refer
to paragraph 67-177.
20. Verify cyclic rigging within limits (paragraph 67-6 or
67-7).
21. Install access panel on cabin floor under pilot seat.
Install access panel on cabin floor aft of console. Install
access panel on left side of console. Install oval access
panel on right side of helicopter below pilot door
(Chapter 52).
67-186. JACKSHAFT (FORE AND AFT) TUBE AND
LEVER ASSEMBLY (LEFT SIDE)
67-187. Removal
1. Remove access panel from cabin floor under
copilots seat, access panel from under aft end of
console and oval access panel from lower left side of
helicopter under left crew door (Chapter 52).
2. Remove lockwire, bolt (15, figure 67-60) and
washers (14) from force gradient (13).
3. Remove cotter pin (8), nut (7), washers (4 and 6)
and bolt (3) from series actuator (5) and arm (19).
4. Remove bolts (9), tapered bushings (10 and 16),
washers (17), and nuts (18). Index bushings (10 and
16) for reinstallation in same location.
5. If copilot cyclic controls are installed, disconnect
control tube (not illustrated) from tube and lever
assembly (11).
6. Tap tube and lever assembly (11) with a plastic
mallet to loosen it from arm assembly (19). Carefully
work tube and lever assembly outboard and out of
helicopter.
 BHT-412-MM-8

Figure 67-60. Fore and Aft Cyclic Jackshaft Tube and Lever Assembly (Left Side)

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BHT-412-MM-8

67-188. Inspection 5. Drill a pilot hole through top surface of tube and
lever assembly (8) with a No. 20 drill (0.161 in.) for bolts
1. Inspect tube and lever assembly (11, figure 67-60) (9 and 10). Drill holes in bottom of tube and lever
for mechanical and corrosion damage. assembly (8) using a No. 20 drill (0.161 in.).

2. Inspect bearings for freedom of movement and 6. Turn over tube and lever assembly (8) and arm
excessive wear. assembly (1) and redrill the holes in bottom of tube and
lever assembly (8) using an F drill (0.257 in.).
67-189. Installation
7. Verify holes in top of tube and lever assembly (8)
MATERIALS REQUIRED are centered with existing holes in arm assembly (1). If
not centered, use a small hand grinder or a router bit to
Refer to BHT-ALL-SPM for specifications and source. center holes. Redrill holes with an F drill (0.257 in.).

NUMBER NOMENCLATURE 8. Insert reamer (T27872-2) so end of pilot projects

through opposite side of tube and lever assembly (8).
C-204 Primer
C-405 Lockwire 9. Ream one side to a smooth finish. Remove all
burrs. Install a tapered bushing and insert reamer
(T27872-2) so end of pilot projects into tapered
SPECIAL TOOLS REQUIRED bushing.

NUMBER NOMENCLATURE
T27872-2 Reamer
NOTE
Inspect tube and lever assembly (11, figure
67-60) to determine whether holes for two
bolts (9) have been drilled. If holes have
been drilled and reamed, proceed to step
14. If tube and lever assembly (11) has not
been drilled and reamed, accomplish steps
1. through 13.
1. Measure distance between inboard end of tube
and lever assembly (8, figure 67-61) and arm assembly
(1).
2. Remove arm assembly (1) from helicopter
(paragraph 67-195).
3. Fit arm assembly (1) into end of new tube and
lever assembly (8). Set distance between inboard end
of tube and lever assembly (8) and arm assembly (1) to
correspond with dimension obtained in step 1.
4. Set arm assembly (1) at angle shown. Holding
angular and lateral dimension, measure holes for bolts
(9 and 10) to pick up existing holes in arm assembly.
Center punch top holes for bolts (9 and 10).
10. Ream opposite side to a smooth finish. Remove all
burrs.
11. Repeat steps 4 through 10 to drill and ream holes
for remaining bolts.
12. Temporarily install bolt (9, figure 67-60), tapered
bushings (10 and 16), washer (17) and nut (18). Check
tapered bushings (10 and 16) protrude 0.030 to 0.060
in. (0.762 to 1.524 mm). Remove bolts (9), washers
(17), nuts (18), and bushings (10 and 16).
13. Coat inboard end of tube and lever assembly (23)
and arm assembly (19) with primer (C-204). Insert arm
assembly (19) into tube and lever assembly (23) with
washer on left side of arm. Install bolts (2), bushings (1
and 22), washers (21), and nuts (20).
14. Coat inside of inboard end of tube and lever
assembly with primer (C-204). Carefully guide tube and
lever assembly (11) into helicopter through housing
(12) and onto end of arm assembly (19).
NOTE
After final installation of hardware, bushings
(10 and 16) must protrude from jackshaft
tube within the 0.030 to 0.060 in. (0.762 to
1.524 mm) limits shown in figure 67-59 view
A-A.

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 BHT-412-MM-8

Figure 67-61. Fore and Aft Cyclic Jackshaft Tube and Lever Assembly (Left Side) Alignment

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BHT-412-MM-8
15. Install bolts (9, figure 67-60), bushings (10 and
16), washers (17), and nuts (18).
16. Install series actuator (5) on arm assembly (19)
and secure with bolt (3), washers (4 and 6), nut (7), and
cotter pin (8).
17. Place clevis of force gradient (13) on tube and
lever assembly (11), install bolt (15) and washer (14).
Secure bolt (15) with lockwire (C-405).
18. Attach control tube (not illustrated) from copilot
cyclic controls to tube and lever assembly (11) arm
adjacent to force gradient (13).
19. Move cyclic controls through full travel and check
for interference and binding.
20. Verify cyclic rigging within limits (paragraph 67-6 or
67-7).
21. Install access panel from cabin floor under copilots
seat, access panel from under aft end of console and
oval access panel from lower left side of helicopter
under left crew door (Chapter 52).
67-190. JACKSHAFT HOUSING
67-191. Removal
1. Remove access panel from cabin floor under pilot
seat. Remove access panel from cabin floor at aft end
of console. Remove access panel from left side of
console. Remove oval access panel from right side of
helicopter below pilot door. Remove access panel from
cabin floor under copilots seat, access panel from
under aft end of console and oval access panel from
lower left side of helicopter under left crew door
(Chapter 52).
2. Remove left tube and lever assembly (7, figure
67-62) (paragraph 67-187).
3. Remove nuts (6), washers (2 and 5) and bolts (1).
Remove housing (4) from structure (3). Remove
housing (4) from tube and lever assembly (7).
67-192. Inspection
1. Inspect housing (4, figure 67-62) for mechanical
and corrosion damage.
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2. Inspect bearing for secure installation in housing
and for wear (BHT-ALL-SPM).
67-193. Installation
1. Place housing (4, figure 67-62) on structure (3)
and install bolts (1), washers (2 and 5), and nuts (6).
2. Install tube and lever assembly (7) (paragraph
67-189).
3. Move cyclic controls through full travel and check
for interference and binding.
4. Verify cyclic rigging within limits (paragraph 67-6 or
67-7).
5. Install access panel from cabin floor under pilot
seat. Install access panel from cabin floor at aft end of
console. Install access panel from left side of console.
Install oval access panel from right side of helicopter
below pilot door. Install access panel from cabin floor
under copilots seat, access panel from under aft end of
console and oval access panel from lower left side of
helicopter under left crew door (Chapter 52).
67-194. ARM ASSEMBLY
67-195. Removal
1. Remove access panel from cabin floor under pilot
seat. Remove access panel from left side of pedestal
(Chapter 52).
2. Remove cotter pin (21, figure 67-63), nut (22),
washers (23 and 26) and bolt (25). Remove flight
control tube (24) from tube and lever assembly (1).
3. Remove cotter pin (9), nut (8), washers (5 and 7)
and bolt (4). Remove series actuator (6) from arm
assembly (16).
4. Remove bolts (10), tapered bushings (11 and 13),
washers (14) and nuts (15). Index tapered bushings (11
and 13) for reinstallation in same location.
5. Remove nuts (20), tapered bushings (2 and 18),
washers (19) and bolts (3). Index tapered bushings (2
and 18) for reinstallation in same location.
 BHT-412-MM-8

Figure 67-62. Cyclic Jackshaft Housing

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BHT-412-MM-8

6. Tap tube and lever assembly (1) with a plastic
mallet to slide out of arm assembly (16). Tap arm
assembly (16) with a plastic mallet to disengage it from
tube and lever assembly (12). Remove arm assembly.
67-196. Inspection
1. Inspect arm assembly (16, figure 67-63) for
mechanical and corrosion damage (BHT-412-CR&O).
2. Inspect washer (17) for secure installation on arm
(16).
5. Center punch top bolt holes in center of existing
holes in tube and lever assemblies (5 and 8).
6. Drill a pilot hole through top surface of tube and
lever assembly (3) with a No. 20 drill (0.161 in.) for bolts
(9 and 10). Drill holes in bottom of tube and lever
assembly (3) using a No. 20 drill (0.161 in.).
7. Turn over tube and lever assembly (3) and arm
assembly (1) and redrill the holes in bottom of tube and
lever assembly (3) using an F drill (0.257 in.).

8. Verify holes in top of tube and lever assembly (3)

3. Inspect bearing in arm assembly (16) for secure
installation in arm and for wear (BHT-ALL-SPM).
67-197. Installation
MATERIALS REQUIRED
are centered with existing holes in arm assembly (1). If
not centered, use a small hand grinder or a router bit to
center holes. Redrill holes with an F drill (0.257 in.).
9. Insert reamer (T27872-2) so end of pilot projects
through opposite side of tube and lever assembly (5).

Refer to BHT-ALL-SPM for specifications and source. 10. Ream four top bolt holes so tapered bushings
extend 0.030 to 0.060 in. (0.762 to 1.524 mm) as
NUMBER NOMENCLATURE illustrated.
C-204 Primer
11. Insert a tapered bushing into top holes and insert
reamer (T27872-2) so pilot projects into bushing. Ream
SPECIAL TOOLS REQUIRED the four bottom holes to same dimension described in
preceding step.
NUMBER NOMENCLATURE
12. Fit tube and lever assembly (1) and tube and lever
T27872-2 Reamer assembly (12) into arm assembly (16). Install bolts (10),
bushings (11), bushings (13), washers (14), and nuts
NOTE (15).
If arm assembly is being replaced, tube and
lever assemblies must be used as a jig to 13. Fit flight control tube (24) on tube and lever
drill and ream holes for tapered bushings. assembly (1). Install bolt (25), washers (23 and 26), nut
(22), and cotter pin (21).
1. Remove tube and lever assembly (1, figure 67-63)
(paragraph 67-183). 14. Install bolts (3), bushings (2), bushings (18),
washers (19), and nuts (20).
2. Remove tube and lever assembly (12) (paragraph
67-187). 15. Install series actuator (6) on arm and washer
assembly (16) using bolt (4), washers (5 and 7), nut (8),
3. Fit new arm assembly (1, figure 67-64) into tube and cotter pin (9).
and lever assemblies (5 and 8) with washer (2) on left
side. 16. Move cyclic controls through full travel and check
for obstructions and binding.
4. With levers (3 and 7) vertical and arm assembly (1)
6° aft, establish lateral dimensions as shown. Clamp all 17. Verify cyclic rigging within limits (paragraph 67-6 or
components in place. 67-7).

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 BHT-412-MM-8

Figure 67-63. Cyclic Controls Arm

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BHT-412-MM-8

Figure 67-64. Cyclic Controls Arm and Washer Positioning

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 BHT-412-MM-8

18. Install access panel on cabin floor under pilot seat 4 1 2 - 0 7 4 - 1 0 1 - 1 0 1 i n s ta l l e d , r e f e r t o

(Chapter 52). paragraph 67-6. For helicopters S/N 36037
and subsequent, with transducer P/N
67-198. LATERAL TRANSDUCERS (CYCLIC 4 1 2 - 0 7 4 - 1 0 1 - 1 0 3 i n s ta l l e d , r e f e r t o
CONTROLS) paragraph 67-278.

67-199. Removal 3. Connect electrical connectors.

1. Remove access panel from bottom of helicopter 4. Move controls through full travel and check for
immediately aft of lower nose window line and right of binding and obstructions.
helicopter centerline (Chapter 52).

2. Disconnect electrical connector. 5. Install access panel on bottom of helicopter aft of

lower nose window line and to right of helicopter
centerline (Chapter 52).
3. Remove bolt (3, Figure 67-65) by removing cotter
pin (14), nut (15). Remove spacer (2) and spacer (16).
67-203. CYCLIC STICK BOOT
4. Remove bolt (6) by removing cotter pin (12), and
67-204. Removal
nut (11). Remove spacers (5 and 10).
1. Unsnap buttons (1, Figure 67-66).
5. Remove transducer (4) with spacer (7) and
transducer (13) with spacer (9).
2. Remove screws (5) and washers (4).
67-200. Inspection
3. Remove boot (2) from pilot cyclic control stick (3).
1. Inspect transducer for damage.
67-205. Inspection
2. Inspect electrical cable and connectors for
damage. 1. Inspect boot (2, Figure 67-66) for tears,
deterioration, and defective buttons.
3. Inspect bearings for looseness (BHT-ALL-SPM).
2. Replace boot if unserviceable.
67-201. Repair

Lateral cyclic transducers are nonrepairable and shall 67-206. Installation

be replaced when defective.
1. Slide boot (2, Figure 67-66) down over cyclic stick
(3).
67-202. Installation

1. Position transducer (4, Figure 67-65) and
transducer (13) on support (1) and install bolt (3),
spacer (2), spacer (16), nut (15), and cotter pin (14).
2. Position spacer (7) and spacer (9) on bellcrank (8).
Install transducer (4) and transducer (13) onto bellcrank
(8) with bolt (6), spacer (5), spacer (10), nut (11), and
cotter pin (12).
NOTE
If not previously accomplished, perform
transducer adjustment. For helicopters S/N
33001 though 33213 and S/N 36001 through
36036, with transducer P/N
2. Align holes in boot (2) and in floor and install
screws (5) and washers (4).
3. Snap buttons (1) around stick (3).
67-207. PILOT CYCLIC CONTROL STICK
ASSEMBLY
67-208. Removal
1. Remove access panel from bottom of helicopter
under pilot cyclic stick (Chapter 52).
2. Remove boot (paragraph 67-204).

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BHT-412-MM-8

Figure 67-65. Lateral Transducer

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 BHT-412-MM-8

Figure 67-66. Cyclic Stick Boot

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BHT-412-MM-8
3. Remove bolt (7, figure 67-67) by removing cotter
pin (2) and nut (3). Remove washers (4 and 6). Remove
flight control tube (5) clevis from control stick (1).
4. Remove cotter pin (8), nut (9) and washer (10).
Remove bolt (13) and washer (12). Remove flight
control tube (11) clevis from control stick (1).
5. Disconnect electrical connector (14).
6. Remove bolts (16) and washers (15). Remove
pilot cyclic control stick (1).
67-209. Inspection
1. Inspect stick assembly (1, figure 67-67) for
mechanical and corrosion damage. Superficial
mechanical and corrosion damage is acceptable if
repaired in accordance with BHT-412-CR&O.
2. Inspect bearings for secure installation in stick and
for wear (BHT-ALL-SPM).
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Page 158 Rev. 7 30 SEP 2003
3. Inspect electrical connector (14) and wiring for
security.
67-210. Installation
1. Place stick (1, figure 67-67) in position and install
bolts (16) and washers (15).
2. Place tube (5) on arm on stick (1) and install bolt
(7), washers (6 and 4), nut (3) and cotter pin (2).
3. Place tube (11) on arm of stick (1) and install bolt
(13), washers (12 and 10), nut (9) and cotter pin (8).
4. Connect electrical connector (14) to airframe
mounted receptacle.
5. Verify cyclic rigging within limits (paragraph 67-6 or
67-7).
6. Install boot (paragraph 67-206).
7. Install access panel on bottom of helicopter under
pilot control stick (Chapter 52).
 BHT-412-MM-8

Figure 67-67. Pilot Cyclic Stick

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 BHT-412-MM-8

ANTI-TORQUE CONTROLS

67-211. ANTI-TORQUE CONTROLS
The anti-torque control system (figure 67-68) consists
of control linkage and components from pilot pedals
(23) aft to tail rotor assembly. The AFCS provides a
single electrical series actuator and a transducer.
Series actuator is located forward of cylinder and
support (15). A transducer is connected to airframe
structure and bellcrank located aft of pedals.
2. Place tube (14) onto bellcrank (3). Install bolt (16),
washer (15), washer (12), nut (10), and cotter pin (11).
3. Place link (7) onto anti-torque control bellcrank (3).
Install bolt (1), washer (2), washer (4), torque nut (6)
and torque to 60 to 110 in.-lbs. (6.78 to 12.42 N-m), and
secure with cotter pin (5).
67-217. ANTI-TORQUE CONTROL TUBE GUIDES

Movement of pedals causes a hydraulic power assisted 67-218. Removal

pitch change of tail rotor blades to offset main rotor
torque and to control directional heading of helicopter. NOTE
Maintenance procedures for guide (5, figure
67-212. PITCH CHANGE CONTROL BELLCRANK 67-70) is given. Maintenance for remaining
guides is similar with the exception that
67-213. Removal appropriate flight control tube(s) (1, 11, or
16) must be removed.
1. Remove cotter pin (11, figure 67-69), nut (10), and
washers (12 and 15), and bolt (16). Remove flight 1. Remove access door from lower side of tailboom
control tube (14). (Chapter 52).

2. Remove cotter pin (5), nut (6), washers (2 and 4), 2. Remove flight control tube (11) (paragraph
and bolt (1). Remove link (7). 67-222).

3. Remove cotter pin (8), nut (9), washer (13), and 3. Remove two screws (7) and two washers (6).
bolt (17). Remove anti-torque control bellcrank (3). Remove guide (5).

67-214. Inspection 67-219. Inspection

1. Inspect guide (figure 67-70) for wear, distortion

1. Inspect anti-torque control bellcrank (3) for
corrosion and mechanical damage (BHT-412-CR&O).
2. Inspect bearings in bellcrank (BHT-ALL-SPM).
67-215. Repair
1. Repair anti-torque control bellcrank (3, figure
67-69) in accordance with BHT-412-CR&O.
67-216. Installation
1. Place anti-torque control bellcrank (3, figure
67-69) into position on fin. Install bolt (17), washer (13),
nut (9) and torque to 60 to 110 in.-lbs. (6.78 to 12.4
N-m), and secure with cotter pin (8).
and cracks. Damage that can be detected visually is
cause to replace guide. Guides are fabricated from
nylatron material and are not repairable.
67-220. Installation
1. Position guide (5) on bulkhead (4). Install two
screws (7) and two washers (6).
2. Install flight control tube (11) (paragraph 67-224).
3. Verify anti-torque rigging within limits (paragraph
67-9).
4. Install access door on lower side of tailboom
(Chapter 52).

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BHT-412-MM-8

Figure 67-68. Anti-Torque Controls

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 BHT-412-MM-8

Figure 67-69. Pitch Change Control Bellcrank

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BHT-412-MM-8

Figure 67-70. Control Tube Guides

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 BHT-412-MM-8

6 7 - 2 2 1 . F L I G H T C O N T R O L TU B E S A N D 67-227. Inspection and Repair

BELLCRANKS
1. Inspect and repair support (1, figure 67-71)
Anti-torque control tubes and bellcranks transmit pilot mechanical and corrosion damage (BHT-412-CR&O).
motion at the tail rotor pedals to pitch change
mechanism at tail rotor gearbox (figure 67-68). 2. Inspect bolt holes for elongation
(BHT-412-CR&O). Damage which can be detected
67-222. Removal visually is not acceptable and is cause for replacement
of support.
1. Remove appropriate access panel(s) and door(s)
to gain access to desired control tube or bellcrank
(Chapter 52). 3. Inspect pressure-sensitive tape (C-430) for
adhesion to mating surface of support (1).

2. Remove cotter pins, nuts, washers, and bolts and

remove desired component. 67-228. Installation

MATERIALS REQUIRED
67-223. Inspection

1. Inspect components for corrosion and mechanical Refer to BHT-ALL-SPM for specifications and source.
damage (BHT-412-CR&O).
NUMBER NOMENCLATURE
2. Inspect abrasion strip(s) for wear and for secure C-430 Tape
installation on flight control tube(s).

1. Apply pressure-sensitive tape (C-430) to mating

3. Inspect clevises for secure installation on tubes.
surface of support (1, figure 67-71).

67-224. Installation
2. Place support (1) in position on structure (4).
Install bolts (3) and washers (2).
1. Position control tube (or bellcrank) in fuselage or
tailboom as appropriate.
3. Install walking beam (paragraph 67-242).
2. Retain component in position with bolts, washers,
and nuts. Secure with cotter pins. 4. Move anti-torque pedals through full range of
travel and check for interference and binding.
3. Install components, panels, or doors removed for
access (Chapter 52). 5. Verify anti-torque rigging within limits (paragraph
67-9).
4. Move anti-torque controls through full travel and
check for interference and binding. 67-229. CONTROL CYLINDER

67-230. Removal
5. Verify anti-torque control rigging within limits
(paragraph 67-9).
1. Open door on aft right side of fuselage.

67-225. WALKING BEAM SUPPORT ASSEMBLY

NOTE
67-226. Removal Refer to Chapter 29 for general
maintenance practices when in hydraulic
1. Remove walking beam (paragraph 67-239). areas.

2. Remove bolts (3, figure 67-71) and washers (2). 2. Disconnect hoses (7 and 9, figure 67-72). Plug or
Remove anti-torque controls support (1). cap open ports to prevent contamination.

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BHT-412-MM-8
Figure 67-71. Anti-Torque Control Support
3. Remove bolt (4) by removing cotter pin (29), nut
(30), and washers (3 and 31).
4. Remove cotter pin (18), nut (17), washer (16), and
remove bolt (21) and washer (20), including spacer
(15).
5. While supporting cylinder (6), remove nut (27), bolt
(11) with washers (10 and 26). Remove nut (25), bolt
(13) with washers (12 and 24).
6. Disengage trunnion plates (22 and 28) from
trunnion (8). Remove cylinder (6).
7. If cylinder (6) is being replaced, loosen nut (5) and
remove clevis (2).
67-231. Inspection
1. Inspect cylinder (6, figure 67-72) for damage and
signs of leakage.
67-00-00
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2. Inspect trunnion (8) and plates (22 and 28) for
wear. Fit plates onto trunnion and feel for looseness
and smoothness of movement.
3. Inspect bearing in lever (14) for freedom of
movement.
4. Perform the following inspections only when high
frequency vibrations due to anti-torque controls are
suspected and/or anti-torque controls series actuator
motors. Refer to troubleshooting chart in Chapter 29.
a. Grasp cylinder (6, figure 67-72) just below
plates (22 and 28) and move cylinder laterally. Lateral
movement of cylinder should be 0.003 to 0.050 in.
(0.076 to 1.27 mm). If binding is noted, refer to
paragraph 67-232. There should not be any evidence
of binding.
b. Inspect bearing in lever (14) for freedom of
movement. Maximum acceptable force to rotate
bearing is eight oz. (2.22 N).
 BHT-412-MM-8

412_MM_67_0072_c01

Figure 67-72. Anti-Torque Hydraulic Cylinder

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ECCN EAR99 29 OCT 2009 Rev. 13 Page 167
BHT-412-MM-8

(1) Remove cotter pin (18), nut (17), washer 2. Thoroughly clean and dry trunnion (8) and plates
(16), and bolt (21) with washer (20). Separate bellcrank (22 and 28) with aliphatic naphtha (C-305) and lint-free
(19) from lever (14). cloth (C-516).

(2) Install bolt (21) in bearing in lever (14).
(3) Attach a spring scale to bolt (21) (Figure
67-73). Measure force required to rotate bearing. If
force required to rotate bearing is in excess of value
shown on illustration, refer to paragraph 67-232.
67-232. Repair
MATERIALS REQUIRED
3. Place plates (22 and 28) over trunnion (8) and
position plates onto support (23). Install bolts (11 and
13), washers (10 and 12), washers (24 and 26), and
nuts (25 and 27).
4. Position bellcrank (19) onto lever (14). Install
spacer (15), bolt (21), washer (20), washer (16), nut
(17), and cotter pin (18).
5. Position tube (1) into clevis (2). Install bolt (4),
washer (3), washer (31), nut (30), and cotter pin (29).

Refer to BHT-ALL-SPM for specifications and source. 6. Remove plugs or caps and connect hoses (7 and
9).
NUMBER NOMENCLATURE
7. Service hydraulic system reservoir.
C-407 Abrasive pad

8. Pressurize hydraulic system 1 and operate

1. If binding was noted during accomplishment of anti-torque controls through ten complete cycles
step 4 of paragraph 67-231, clean trunnion plates (22 (Chapter 29).
and 28, Figure 67-72) with abrasive pad (C-407).
9. Verify anti-torque rigging within limits (paragraph
2. If force to rotate bearing during accomplishment of 67-9). Bleed hydraulic system (Chapter 29).
step 4 above exceeds value shown on illustration,
attach an air drill motor to bolt as shown on Figure 10. Close door on right aft side of fuselage (Chapter
67-73. Spin bearing with drill to loosen bearing until it 52).
will rotate within limits.
67-234. SERIES ACTUATOR
67-233. Installation

MATERIALS REQUIRED CAUTION

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

DISASSEMBLY OF SERVO ACTUATOR
(5, FIGURE 67-74) IS NOT PERMITTED.
NUMBER NOMENCLATURE

C-305 Aliphatic Naphtha 67-235. Removal

C-516 Cloth 1. Remove large round access panel from bottom of

aft fuselage. Open access door on right lower side of aft
fuselage (Chapter 52).
1. If cylinder (6, Figure 67-72) is a replacement,
install clevis (2) in top of piston to obtain 1.22 inches
(30.99 mm) S/N 33001 through 33213 and 36001 2. Remove tailboom assembly (Chapter 53).
through 36086 (on 36087 through Subs) obtain 1.29
inches (32.76 mm) from bolt hole centerline to top of 3. Disconnect electrical connector (15, Figure
piston. Secure with nut (5). 67-74).

67-00-00
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 BHT-412-MM-8

Figure 67-73. Anti-Torque Hydraulic Cylinder Bearing Inspection Tool

4. Remove cotter pin (14), nut (13), washer (12), and 3. Install bolt (4), washer (3), washer (6), nut (7) and
remove bolt (9) and washer (10). cotter pin (8).

5. Remove cotter pin (8), nut (7), washer (6), and bolt 4. Place forward end of series actuator (5) on
(4) with washer (3). anti-torque controls lever (11).

6. Remove series actuator (5).

5. Install bolt (9), washer (10), washer (12), nut (13),
and cotter pin (14).
67-236. Inspection

1. Inspect series actuator (5, Figure 67-74) 6. Move anti-torque controls through full travel and
(BHT-412-CR&O). check for obstructions and binding.

7. Connect electrical connector (15).

CAUTION
8. Install tailboom assembly (Chapter 53).
DISASSEMBLY OF SERVO ACTUATOR
(5, FIGURE 67-74) IS NOT PERMITTED. 9. Verify anti-torque rigging within limits (paragraph
67-9).
67-237. Installation

1. Establish overall dimensions shown in Figure 10. Install large round access panel on bottom of aft
67-75. fuselage (Chapter 52).

2. Place series actuator (5, Figure 67-74) into 11. Close access door on lower right side of aft
position with rod end bearing in bellcrank (2). fuselage (Chapter 52).

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27 FEB 2009 Rev. 12 Page 169
BHT-412-MM-8

SEE DETAIL A

14
8
13
12 7
2
10 6 3
9
5 4

11 15

DETAIL A

1. Directional hydraulic flight control cylinder 9. Bolt

2. Bellcrank 10. Aluminum washer
3. Aluminum washer 11. Anti-torque control lever
4. Bolt 12. Aluminum washer
5. Servo actuator 13. Nut
6. Aluminum washer 14. Cotter pin
7. Nut 15. Connector
8. Cotter pin

412_MM_67_0074

Figure 67-74. Directional Series Actuator

67-00-00
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 BHT-412-MM-8

Figure 67-75. Directional Series Actuator Assembly

67-00-00
30 SEP 2003 Rev. 7 Page 171
BHT-412-MM-8
67-238. WALKING BEAM AND FRICTION CLAMP
67-239. Removal
1. Remove access panel from center of aft cabin
floor. Remove access panel from bottom of helicopter
under walking beam (19, Figure 67-76) (Chapter 52).
2. Disconnect flight control tube (24) by removing
cotter pin (23), nut (22), washer (21). Remove bolt (26)
and washer (25).
3. Disconnect flight control tube (14) by removing
cotter pin (16), nut (17), and washer (15). Remove bolt
(12) and washer (13).
4. Remove nut (11) and washer (10). Remove bolt (4)
and washer (5).
5. Remove cotter pin (28), nut (27), and washer (29).
Remove bolt (3) and washer (2).
6. Remove walking beam (19) and friction clamp (8)
with spacer (9).
7. Loosen screw (6) and remove clamp (8) from
walking beam (19).
67-240. Inspection
1. Inspect walking beam (19, Figure 67-76) for
mechanical and corrosion damage. Superficial
mechanical and corrosion damage is acceptable if
repaired (BHT-412-CR&O).
2. Elongated bolt hole damage which can be
detected visually is cause to replace walking beam.
3. Inspect bearings for secure installation in beam
and for wear (BHT-ALL-SPM).
4. Inspect friction clamp (8) for mechanical and
corrosion damage and for elongated bolt holes.
67-241. Repair
Repair walking beam (19, Figure 67-76) and clamp (8)
in accordance with BHT-412-CR&O.
67-00-00
Page 172 Rev. 12 27 FEB 2009
67-242. Installation
1. Place friction clamp (8, Figure 67-76) onto walking
beam (19). Place walking beam and clamp into
structure (1). Install bolt (3) and washer (2) to hold
walking beam in position.
2. Install bolt (4), washer (5), spacer (9), washer (10),
and nut (11). Install washer (29), nut (27), and cotter pin
(28) on bolt (3).
3. Place tube (24) on walking beam (19). Install bolt
(26), washer (25), washer (21), nut (22), and cotter pin
(23).
4. Disconnect force gradient (paragraph 67-254).
5. Adjust friction screw (6) in clamp (8) until force of
4.25 to 4.75 pounds (18.90 to 21.13 N) is measured at
pedals when moved through neutral position.
6. Install force gradient (paragraph 67-257).
7. Place tube (14) onto walking beam (19). Install bolt
(12), washer (13), washer (15), nut (17), and cotter pin
(16).
8. Move anti-torque controls through full travel and
check for interference and binding.
9. Verify anti-torque rigging within limits (paragraph
67-9).
10. Install access panel on bottom of helicopter under
walking beam (19) (Chapter 52).
11. Install access panel in center of aft cabin floor
(Chapter 52).
67-243. MAGNETIC BRAKE
NOTE
The following procedure is applicable to
magnetic brakes used in the anti-torque
system. For anti-torque rotary actuators
used when the optional 4-axis AFCS/Flight
Director kit is installed, refer to paragraph
67-313.
 BHT-412-MM-8

Figure 67-76. Walking Beam and Friction Clamp Assembly

67-00-00
27 FEB 2009 Rev. 12 Page 173
BHT-412-MM-8

Figure 67-77. Magnetic Brake

67-244. Removal 2. Inspect stud (4) for damaged threads. No damage

1. Remove access panel from cabin floor under pilot
seat (Chapter 52).
2. Disconnect electrical connector (6, Figure 67-77).
that can be visually detected is acceptable.
3. Inspect electrical receptacle for bent pins and
damaged threads. Superficial damage is acceptable
without repair.

67-246. Repair
3. Remove cotter pin (2) and nut (3).
1. Refer to vendor manual for magnetic brake repair
4. Lift force gradient (1) off arm (10). instructions.

5. Remove four bolts (9) with washers (8). NOTE

6. Remove magnetic brake (7) from structure (5).
67-245. Inspection
1. Inspect magnetic brake (7, Figure 67-77) for
mechanical and corrosion damage. Superficial
mechanical damage is acceptable without repair.
Mechanical damage in excess of superficial and/or
corrosion damage is not acceptable.
The following procedure is applicable to
magnetic brakes used in the anti-torque
system. For anti-torque rotary actuators
used when the optional 4-axis AFCS/Flight
Director kit is installed, refer to paragraph
67-316.
67-247. Installation
1. Inspect magnetic brake (7, Figure 67-77) to
ensure arm (10) is installed on magnetic brake with

67-00-00
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 BHT-412-MM-8

letter "D" positioned in relation to index mark (11) (detail 67-250. Inspection
B). Reposition arm (10) on magnetic brake (7) if index
mark (11) is not properly aligned. 1. Inspect transducer for damage.

2. Position magnetic brake (7) on structure (5). Install 2. Inspect electrical cable and connectors for
four bolts (9) and washers (8) as follows: damage.

a. Install washer (8) with each bolt (9).

3. Inspect bearings for looseness (BHT-ALL-SPM).

NOTE
67-251. Repair
Three different length bolts are required.
Install bolts of correct length to obtain proper
1. Transducer is nonrepairable and shall be replaced
thread engagement.
when unserviceable.

b. Install bolts (9) with drilled heads in two inboard

holes in magnetic brake (7). 67-252. Installation

3. Adjust length of force gradient (1) (paragraph 1. Place transducer (13, Figure 67-78) into helicopter
67-9, rigging instructions). After force gradient (1) onto airframe structure. Install bolt (14) with washer
length is set, position force gradient on arm (10). Install (15), washer (16), nut (17), and secure with cotter pin
nut (3) and cotter pin (2). (18).

4. Install electrical connector (6).
5. Move anti-torque controls through full travel and
check for binding and obstructions.
2. Place spacer (22) and rod end bearing of
transducer on pedal adjuster assembly (23). Install bolt
(11), spacer (12), washer (21), nut (19) and cotter pin
(20).

6. Verify anti-torque rigging is within limits; refer to NOTE

paragraph 67-9 for helicopters prior to S/N 36087, and
paragraph 67-279 for helicopters S/N 36087 and
subsequent.
7. Install access panel on cabin floor under pilot seat
(Chapter 52).
If not previously accomplished, perform
transducer adjustment. For helicopters S/N
33001 through 33213 and S/N 36001
through 36036 refer to paragraph 67-9. For
helicopters S/N 36037 and subsequent,
refer to paragraph 67-279.

67-248. CONTROL TRANSDUCER 3. Connect electrical connector.

67-249. Removal 4. Install access panel on floor under pilot seat

(Chapter 52).
1. Remove access panel from cabin floor under pilot
seat (Chapter 52).
67-253. FORCE GRADIENT

2. Disconnect electrical connector.

3. Remove cotter pin (20, Figure 67-78), nut (19) with
washer (21) and remove bolt (11) and spacer (12).
4. Remove bolt (14) and washer (15) by removing
cotter pin (18), nut (17), and spacer (16). Remove
transducer (13).
NOTE
The following procedure is applicable to
anti-torque force gradients not incorporating
a detent switch for anti-torque force
gradients (incorporating a detent switch)
used when the optional 4-axis AFCS/Flight
Director kit is installed, refer to paragraph
67-308.

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27 FEB 2009 Rev. 12 Page 175
BHT-412-MM-8

5
4
3
1

2
6
25
8
24 7
9

10

11

23 12
22

13
16 17
18
21
19

20

15
14

24. Clevis
25. Nut
412_MM_67_0078

Figure 67-78. Control Transducer and Force Gradient

67-00-00
Page 176 Rev. 12 27 FEB 2009

67-254. Removal
1. Remove access panel from cabin floor under pilot
seat (Chapter 52).
2. Remove cotter pin (10, Figure 67-78), nut (9),
washer (8), and bolt (1) with washer (2) from pedal
adjuster (23).
3. Remove cotter pin (5) and nut (4) from stud (6).
4. Remove force gradient (3) from magnetic
brake (7).
5. Record length of force gradient assembly.
6. Loosen nut (25) and remove clevis (24).
67-255. Inspection
1. Inspect force gradient assembly (Figure 67-79) for
corrosion and mechanical damage. Superficial
mechanical damage is acceptable without repair.
Mechanical damage in excess of superficial and/or
corrosion damage is not acceptable and shall be
repaired or unit replaced.
2. Inspect bearing (5, Figure 67-79) and sleeve (4)
for secure installation in housing (2) and for wear
(BHT-ALL-SPM).
3. Inspect cap (3) for correct two way lockwire
installation.
67-256. Repair
Repair of force gradient consists of replacement of
unserviceable components and adjustment of spring
preload in accordance with paragraph 67-257.
NOTE
The following procedure is applicable to
anti-torque force gradients not incorporating
a detent switch for anti-torque force
gradients (incorporating a detent switch)
used when the optional 4-axis AFCS/Flight
Director kit is installed, refer to paragraph
67-311.
BHT-412-MM-8
67-257. Force Gradient — Installation
MATERIALS REQUIRED
Refer to BHT-ALL-SPM for specifications and source.
NUMBER NOMENCLATURE
C-405 Lockwire
NOTE
Force gradient (3, Figure 67-78) is similar in
appearance to force gradients used in cyclic
controls but has a different part number.
Ensure force gradient with correct part
number is installed for anti-torque control
system. Refer to the BHT-412-IPB.
1. If not previously accomplished, adjust spring
preload on force gradient as follows:
a. Cut and remove lockwire from cap (3, Figure
67-79).
b. Remove cap (3) and spring assembly (1) from
housing (2).
c. Adjust inboard nut (6) to provide 2.5 to 3.0
pounds (11.12 to 13.34 N) preload against spring
assembly (1). Tighten outboard nut (6) against inboard
nut (6).
d. Position spring assembly (1) in housing (2).
Install cap (3). Tighten cap until end play of spring is
eliminated. Secure cap with lockwire (C-405) to prevent
turning in either direction (Figure 67-79).
CAUTION
ENSURE FORCE GRADIENT LENGTH IS
ADJUSTED PRIOR TO INSTALLATION ON
MAGNETIC BRAKE.
2. Install clevis (13, Figure 67-78) on shaft of force
gradient (3), adjust to previously recorded length, and
secure with nut (25).
3. Position force gradient (3) on pedal adjuster
assembly (23).
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BHT-412-MM-8

Figure 67-79. Force Gradient Assembly

67-00-00
Page 178 Rev. 12 27 FEB 2009

4. Install bolt (1), aluminum washer (2), aluminum
washer (8), nut (9), and cotter pin (10).
5. If not previously accomplished, adjust length of
force gradient as outlined in rigging instructions
(paragraph 67-9).
6. Position force gradient (3) on stud (6) of magnetic
brake (7). Install nut (4) and cotter pin (5).
7. Move anti-torque controls through full travel and
check for obstructions and binding.
8. Verify anti-torque rigging is within limits; refer to
paragraph 67-9 for helicopters prior to S/N 36087 and
paragraph 67-279 for helicopters S/N 36087 and
subsequent.
9. Install access panel on cabin floor under pilot seat
(Chapter 52).
67-258. PEDAL ADJUSTER ASSEMBLY
67-259. Pedal Adjuster Assembly — Removal
1. Remove access panel from cabin floor under pilot
seat (Chapter 52).
2. Remove access panel from bottom of helicopter
under pilot cyclic control stick (Chapter 52).
3. Remove pilot cyclic stick boot (paragraph
67-178).
4. Disconnect flight control tube (3, Figure 67-80)
from anti-torque control pedal adjuster assembly (41),
as follows:
a. Remove cotter pin (6), nut (5), and aluminum
washer (4).
b. Remove bolt (1) with aluminum washer (2)
and disconnect flight control tube (3).
5. Disconnect force gradient tube (9), as follows:
a. Remove cotter pin (11), nut (12), and
washer (10).
b. Remove bolt (7) with aluminum washer (8)
and disconnect force gradient tube (9).
BHT-412-MM-8
6. Disconnect transducer (15) from adjuster, as
follows:
a. Remove cotter pin (31), nut (29), and
washer (28).
b. Remove bolt (13), spacer (14), and spacer
(21). Disconnect transducer (15).
7. Disconnect flight control tube (32), as follows:
a. Remove cotter pin (30), nut (27), and
washer (26).
b. Remove bolt (22) with washer (23) and
disconnect flight control tube (32).
8. Disconnect flight control tube (35), as follows:
a. Remove cotter pin (36), nut (40), and
aluminum washer (37).
b. Remove bolt (39) with aluminum washer (38)
and disconnect flight control tube (35).
9. Remove nuts (24), washers (25 and 33), and
bolts (34).
10. Remove anti-torque control pedal adjuster
assembly (41) from helicopter.
67-260. Pedal Adjuster Assembly — Inspection
1. Inspect components of anti-torque control pedal
adjuster assembly (41, Figure 67-80) for mechanical
and corrosion damage (BHT-412-CR&O).
2. Inspect chain for wear. Wear that can be detected
visually is not acceptable.
3. Inspect gears for wear. Wear that can be detected
visually is not acceptable.
4. Inspect bearings for secure installation and for
wear (BHT-ALL-SPM).
5. Inspect bolt holes for elongation. Elongation that
can be detected visually is not acceptable.
67-00-00
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 BHT-412-MM-8

Figure 67-80. Pedal Adjuster

67-00-00
30 SEP 2003 Rev. 7 Page 179
BHT-412-MM-8
67-261. Installation
1. Place adjuster assembly (41, figure 67-80) in
position in helicopter. Install four bolts (34), washers (33
and 25), and nuts (24).
2. Place tubes (35 and 32) in pedal adjuster
assembly (41). Install bolts (39 and 22), washers (38
and 23), washers (37 and 26), nuts (40 and 27), and
cotter pins (36 and 30).
3. Place force gradient (9) on adjuster assembly (41).
Install bolt (7), washers (8 and 10), nut (12), and cotter
pin (11).
4. Place control tube (3) on pedal adjuster assembly
(41). Install bolt (1), washers (2 and 4), nut (5), and
cotter pin (6).
5. Place spacer (21) and rod end bearing of
transducer (15) on pedal adjuster assembly (41). Install
bolt (13), spacer (14), washer (28), nut (29) and cotter
pin (31).
6. Install pilot cyclic stick boot (paragraph 67-206).
7. Move anti-torque controls through full travel and
check for interference and binding.
8. Verify anti-torque rigging within limits (paragraph
67-9).
9. Install access panel on bottom of helicopter below
pilot seat (Chapter 52).
10. Install access panel on cabin floor under plot seat
(Chapter 52).
67-00-00
Page 180 Rev. 7 30 SEP 2003
67-262. PEDALS
NOTE
Maintenance procedure for anti-torque
control right pedal is given. The procedure
for left pedal is similar.
67-263. Removal
1. Remove cotter pin (4, figure 67-81), nut (5),
washer (3), and bolt (12) with washer (13).
2. Remove cotter pin (8), nut (7), washer (6) and bolt
(11) with washer (10). Remove anti-torque control
pedal (1).
67-264. Inspection
1. Inspect pedal (1, figure 67-81) for mechanical and
corrosion damage. Superficial mechanical damage is
acceptable without repair. Superficial corrosion
damage is acceptable if repaired (BHT-412-CR&O).
2. Inspect bushings for elongation and security.
Damage that can be detected visually is not acceptable.
67-265. Installation
1. Place pedal (1, figure 67-81) on anti-torque pedal
support (9). Install bolt (11), washers (10 and 6), nut (7),
and cotter pin (8).
2. Place tube (2) into pedal (1). Install bolt (12),
washers (13 and 3), nut (5), and cotter pin (4).
 BHT-412-MM-8

Figure 67-81. Anti-Torque Pedals

67-00-00
30 SEP 2003 Rev. 7 Page 181/182

AERODYNAMICALLY ACTUATED ELEVATOR
67-266. AERODYNAMICALLY ACTUATED
ELEVATOR
67-267. DESCRIPTION
The aerodynamically actuated elevator installation
(figure 67-82) consists of left and right elevator
assemblies (2 and 17), a horn assembly (15), two horn
support sets (10 and 26), and spring-loaded control
tube (20). The horn is mounted in the support set which
secures horn to tailboom structure and permits horn to
move to the extent allowed by the spring-loaded control
tube. Each elevator is built up on a spar tube which is
inserted into end of horn and is secured by two bolts
(27). Each of the two bolts is installed into holes drilled
through both the elevator spar and the horn assembly
to provide a fail safe condition for the elevator.
67-268. Removal
NOTE
Perform inspections described in steps 1.
through 4. of paragraph 67-269 prior to
removing elevators.
1. Remove access panels from tailboom in area
below elevators (Chapter 52).
2. Remove bolt (3, figure 67-82) and washer (4).
3. Remove cotter pin (30), nut (29), washers (28),
bolt (27) and washer (31) from horn (15).
4. Pull elevator (2) straight outboard until spar tube
(5) disengages from elevator horn (15).
5. Remove elevator (17) in same manner outlined in
steps 2, 3, and 4.
6. Remove cotter pin (23), nut (22), washer (21), and
bolt (18) with washer (19). Disconnect tube (20).
BHT-412-MM-8
HANDLE SUPPORTS (10 AND 26) WITH
CARE AFTER REMOVAL TO AVOID
DAMAGE TO BUSHINGS THAT ARE
BONDED TO SUPPORTS.
7. Remove self-locking nuts (13), washers (12) and
bolts (8) and washers (9). Remove bolts (24) and
washers (25).
8. Remove supports (10 and 26) and shims (7 and
11). Index shims (7 and 11) and supports (10 and 26)
for installation as set in same location.
9. Remove supports on opposite end of horn (15).
Index shims and supports as a set in same manner
outlined in step 8.
10. Remove horn (15) from helicopter.
67-269. Inspection
NOTE
Prior to removal of elevator, perform
inspection outlined in steps 1. through 4.
1. Inspect for loose rivets and/or cracks in skin at
attachment points for bracket (6, figure 67-82) and
similar bracket on opposite side. Press down on each
elevator (2 and 17) trailing edge to cause elevator to
defect maximum of 0.040 in. (1.02 mm) and at same
time inspect for loose rivets. It is recommended that a
dial indicator be used to measure deflection. If loose
rivets or cracks are found, refer to paragraph 67-270 for
repair procedure.
2. Measure axial play of elevator horn (15) as follows:
a. Mount dial indicator on tailboom so stylus of
indicator touches inboard edge of elevator near bolt (3).
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BHT-412-MM-8

1
2
3 T3
4

16
5
6 ADJUST TO
7 26 TO 32 LBS DRAG
8 (2.9 TO 3.6 N)
9
10
11
12
13
14
15
1. Tip cap 29 T1
2. Right elevator
3. Bolt 28
4. Aluminum washer
5. Spar tube 30
6. Tailboom bracket
7. Shim set
8.
9.
Bolt
Thin aluminum washer
26 24 T2 31
25
10. Upper support (matched wet)
11. Shim
12. Thin aluminum washer
13. Self-locking nut 23
14. Horn mounting lug
15. Elevator horn
16. Stop 22
17. Left elevator 27
18. Bolt
19. Steel washer 21 20 19 18 17
20. Control tube
21. Steel washer
22. Nut
23. Cotter pin
10 IN-LBS
24. Bolt T1 (1.13 Nm) MAXIMUM
25. Thin aluminum washer
26. Lower support (matched set)
50 TO 70 IN-LBS
27. Bolt T2 (5.7 TO 7.9 Nm)
28. Aluminum washer
29. Nut 100 TO 140 IN-LBS
30. Cotter pin T3 (11.3 TO 15.8 Nm)
31. Thin aluminum washer

412_MM_67_0025

Figure 67-82. Aerodynamically Actuated Elevator and Horn

67-00-00
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 BHT-412-MM-8

b. Apply light force to move elevator inboard and b. Inspect tip cap (1) and similar tip cap on left
outboard spanwise, as shown in Figure 67-83. Record elevator for security.
dial indicator reading. Acceptable axial play is 0.005 to
0.030 inch (0.127 to 0.762 mm). If axial play is not within 6. For detailed inspection criteria, refer to the
limits, adjust shims (7, Figure 67-82), as outlined in BHT-412-CR&O.
paragraph 67-271.
67-270. Aerodynamically Actuated Elevator —
c. Remove dial indicator. Repair

3. Measure radial play at elevator horn (15) as MATERIALS REQUIRED

follows:
Refer to BHT-ALL-SPM for specifications and source.
a. Mount dial indicator on tailboom, so stylus of
indicator touches upper surface of right elevator (2)
NUMBER NOMENCLATURE
near bolt (3).
C-305 Aliphatic Naphtha
NOTE
C-306 Toluene
Do not use heavy force to move elevator up
and down when accomplishing the following C-310 Adhesive
step or false dial indicator readings will
result. 1. Repair minor damage to skins and structure. Refer
to the BHT-412-CR&O for materials.
b. Apply light force to move elevator up and down
to measure radial play, as shown in Figure 67-83.
Record dial indicator reading. Maximum acceptable 2. Repair loose or missing elevator tip cap (1, Figure
radial play is 0.010 inch (0.254 mm). 67-82) and similar tip cap on left elevator (17) as
follows:
c. Measure radial play on opposite elevator in
same manner outlined in step a and step b. Remove a. Clean bonding area on elevator tip using
dial indicator. aliphatic naphtha (C-305).

d. If radial play on either elevator exceeds limits,
adjust shims (11, Figure 67-82) as outlined in
paragraph 67-271.
4. Inspect spring action of control tube assembly
(20). Refer to paragraph 67-274 for inspection
procedure.
5. Inspect elevators (2 and 17) as follows:
b. Clean inside of tip cap (1) using toluene
(C-306).
c. Brush thin coat of thermosetting adhesive
(C-310) about 0.010 inch (0.254 mm) thick inside tip
cap (1).
d. Allow about 1 hour drying time for adhesive to
get tacky, then install tip cap (1).

a. Inspect for loose and/or missing rivets, cracks, e. Hold tip cap (1) in place at least 15 seconds.
and holes in skin. Minor damage that does not result in
distortion of elevator surface is acceptable if repaired as f. Allow to dry at least 24 hours prior to flight or
outlined in paragraph 67-270. operation.

67-00-00
30 MAR 2007 Rev. 11 Page 185
BHT-412-MM-8

Figure 67-83. Elevator Inspection (Installed)

67-00-00
Page 186 Rev. 11 30 MAR 2007
 BHT-412-MM-8

67-271. Aerodynamically Actuated Elevator — SPECIAL TOOLS REQUIRED

Installation

MATERIALS REQUIRED NUMBER NOMENCLATURE

DPPH200 Push-Pull Dial Gauge

Refer to BHT-ALL-SPM for specifications and source. (Spring Scale)

NUMBER NOMENCLATURE NOTE

C-104 Corrosion Preventive If horn (15, Figure 67-82) and control tube
Compound (20) were previously installed, proceed to
step 12.
C-202 Primer
C-204 Primer 1. Place horn (15) in tailboom with horn arm on right
side and pointing down, as illustrated.
C-304 Solvent

C-309 MEK

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30 MAR 2007 Rev. 11 Page 186A/186B

HANDLE SUPPORTS (10 AND 26)
CAREFULLY TO AVOID DAMAGE TO
BUSHINGS, THAT ARE BONDED TO
SUPPORTS.
2. Install supports (10 and 26), and shims (11) on
horn (15) with two bolts (8), washers (9 and 12), and
nuts (13). Install nuts snugly but do not torque at this
time.
3. Install supports and shims on opposite end of horn
in same manner outlined in step 2.
4. Position shim set (7) and supports (10 and 26) on
bracket (6) and install bolts (24) and washers (25).
Install bolts snugly but do not torque at this time.
5. Install supports and shims on opposite end of horn
(15) in same manner outlined in step 4.
6. Measure axial play of horn (15) as outlined in
paragraph 67-269, step 2. If play is not within
acceptable limits, adjust thickness of shim set (7). Snug
bolts (24) but do not torque at this time.
7. Install two nuts (13). Loosen two similar nuts in
opposite end of horn (15).
8. Attach spring scale to hole in arm of horn (15)
where control tube (20) is normally installed. Pull scale
at right angle to arm and record force required to rotate
horn. Acceptable force is 13 to 16 lbs. (57.82 to 71.17
N). If force is not within limits, adjust thickness of shims
(11) (add shims if force is too great, subtract shims if
force is less than acceptable).
9. After shims (11) are adjusted within acceptable
limits, tighten two nuts corresponding to nut (13), but on
left end of horn (15).
10. Repeat force check with spring scale as outlined
in step 8, but now acceptable force to rotate horn with
both supports tight is 26 to 32 lbs. (115.65 to 142.34 N).
If force is not within limits, adjust thickness of shims on
BHT-412-MM-8
left end of horn (15) that are opposite shims (11) (add
shims if force is too great, subtract shims if force is less
than acceptable).
11. After shims (11) are adjusted within acceptable
limits as specified in step 10, torque bolts (24) 50 to 70
in.-lbs. (5.7 to 7.9 N-m).
NOTE
If forward end of control tube (20) has not
been previously installed on tube support
fitting on bulkhead, install tube (20) on fitting
(paragraph 67-275).
12. Position control tube (20) on elevator horn (15).
Install bolt (18), washers (19 and 21), and nut (22).
Install cotter pin (23).
NOTE
The only authorized organic finishes for
elevator spar tubes (5) are primer (C-202)
and primer (C-204).
13. Prior to installation, clean both elevator spar tubes
(5) and horn (15) as follows:
a. If either tube (5) has been erroneously painted
or primed with primer (C-201) or any material other than
primer (C-202) or primer (C-204), remove all traces of
existing paint or primer with clean cloth moistened with
MEK (C-309). Also, clean portion of horn (15) that is
contacted by either tube (5). If bare metal is exposed,
touch up with primer (C-202) or primer (C-204). Allow
primer to thoroughly and completely dry before
installing elevator into horn.
b. If tubes (5) are coated only with primer (C-202),
clean tubes (5) and portion of horn (15) that is contacted
by either tube (5) with solvent (C-304).
14. Apply thin coat of corrosion preventive compound
(C-104) to spar tube (5) on elevators and to internal
surfaces of horn (15).
15. Insert spar tube (5) into horn and align horn
mounting lug (14) for bolt (3). Install bolt (3) and washer
(4). Torque bolt 100 to 140 in.-lbs. (11.3 to 15.8 N-m).
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30 SEP 2003 Rev. 7 Page 187
BHT-412-MM-8
16. Install bolt (27) with washer from horn (15), washer
(28), and nut (29). Torque nut (29) to 10.0 in.-lbs. (1.13
N-m) maximum. Install cotter pin (30).
17. Install elevator (17) in same manner outlined in
steps 13. through 16.
18. Inspect spring action of control tube (20)
(paragraph 67-274).
19. Install access doors on bottom of tailboom below
elevators (Chapter 52).
67-272. ELEVATOR CONTROL TUBE
67-273. Removal
1. Remove access door from tailboom in area below
elevators (Chapter 52).
2. Remove cotter pin (14, figure 67-84), nut (15),
washer (16) and bolt (2) and washer (3).
3. Remove cotter pin (11), nut (10), washer (12), bolt
(4), and washer (5) and remove control tube (13) from
helicopter.
67-274. Inspection
NOTE
Perform inspections described in step 1. of
paragraph 67-273 prior to removing
elevators.
1. Inspect operation of tube (13, figure 67-84). Move
elevator to approximately 3° nose down position and
slowly release. Spring action of tube (13) should return
elevator to original position. Failure to return to original
position, binding, and/or lock-up are not acceptable. If
any of these conditions exist, adjust length of tube as
67-00-00
Page 188 Rev. 7 30 SEP 2003
shown in detail A. If this does not correct discrepancy,
replace tube (13).
2. Inspect support (9, figure 67-84)
(BHT-412-CR&O).
67-275. Installation
MATERIALS REQUIRED
Refer to BHT-ALL-SPM for specifications and source.
NUMBER NOMENCLATURE
C-104 Corrosion Preventive
Compound
1. If control tube (13, figure 67-84) was not previously
installed in same helicopter, adjust length of control
tube (13) to dimensions shown on detail A. Align clevis
(17) and clevis (20) so bolt holes are parallel. Tighten
nut (19) but do not install lockwire (22) at this time.
2. Apply corrosion preventive compound (C-104) to
nut (19) and adjacent threads.
3. Position tube (13) in tailboom with non-adjustable
clevis (20) on elevator horn (1). Install bolt (2), washers
(3 and 16) and nut (15). Install cotter pin (14).
4. Align adjustable clevis (17) on tube support (9) and
install bolt (4), washers (5 and 12), and nut (10). Do not
install cotter pin (11) at this time.
5. Rig elevator controls (paragraph 67-10).
6. After rigging is complete, ensure cotter pins (11
and 14) and lockwires (21 and 22) are installed.
7. Install access doors (Chapter 52).
 BHT-412-MM-8

Figure 67-84. Elevator Control Tube

67-00-00
30 SEP 2003 Rev. 7 Page 189/190

FLIGHT CONTROLS — DIGITAL AFCS
67-276. DIGITAL AFCS FLIGHT CONTROLS
(SN 36087 AND SUBSEQUENT)
67-277. DESCRIPTION
The following paragraphs contain information and
instructions for maintenance of the Digital Automatic
Flight Control System (DAFCS) which includes the
standard flight controls with added components in the
cyclic, directional and collective control systems.
Cyclic control system incorporates four electrical servo
actuators, four transducers, a force gradient assembly
and an electromechanical rotary actuator.
Anti-toque directional system incorporates two
electrical servo actuators, two transducers, a force
gradient assembly and a magnetic brake.
There are two transducers in the collective control
system.
Forward electrical servo actuators in the cyclic and
directional systems are controlled by Autopilot Flight
Control Computer (FCC) number 1 (AP1). Aft actuators
are controlled by AP2.
BHT-412-MM-8
If the optional 3-axis Flight Director Kit is installed there
are no changes to the flight control system.
If the optional 4-axis Flight Director kit is installed: It
includes a collective trim system consisting of an
electromechanical rotary actuator and a force gradient
with a detent switch connected in parallel to the primary
collective controls. The rotary actuator repositions the
collective controls in response to a signal from either
the pilot or the AFCS system. Actuation of the force
gradient detent switch either by the rotor actuator
driving to its internal stop or by a pilot control input will
disengage the rotary actuator. In the directional control
system the standard force gradient is replaced by a
force gradient incorporating a detent switch and the
magnetic brake is replaced by an electromechanical
rotary actuator.
Refer to Chapter 96 for further description of the Digital
Automatic Flight Control System and Chapter 98 for
DAFCS system wiring diagrams.
For additional information on the Digital Automatic
Flight Control System refer to Honeywell SPZ-7600
Integrated Flight Control System Bell 412 System
Maintenance Manual.
67-00-00
27 FEB 2009 Rev. 12 Page 191/192

FLIGHT CONTROLS RIGGING — S/N 36087 AND SUBSEQUENT
67-278. FLIGHT CONTROLS RIGGING (S/N
36087 AND SUBSEQUENT)
Rigging procedures for 412EP (S/N 36087 and
subsequent) incorporating the digital automatic flight
control system (DAFCS) are the same as AFCS rigging
except where noted. Refer to paragraph 67-3.
67-278A. COLLECTIVE CONTROLS (S/N
36087 AND SUBSEQUENT)
Basic rigging procedures for the collective control
system in helicopters S/N 36087 and subsequent are
the same as rigging instructions in paragraph 67-4.
Adjustment of the dual element control motion
transducers is accomplished in accordance with
paragraph 67-88A.
67-278B. CYCLIC CONTROLS (S/N 36087
AND SUBSEQUENT)
NOTE
Basic rigging procedures for the cyclic
Digital Automatic Flight Control System
(DAFCS) are the same as AFCS rigging
except where noted. Refer to paragraph
67-5.
SPECIAL TOOLS REQUIRED
NUMBER NOMENCLATURE
412-274-001-101 Calibration Tool
(Pot Calibrator)
NOTE
For maintenance procedures of cyclic dual
controls, refer to the BHT-412-SI-13 and to
the BHT-412-IPB for illustrated parts list.
1. Perform fore and aft cyclic control motion
transducer (2, Figure 67-85, Detail A) adjustment as
follows:
a. Position pilot cyclic stick (1) perpendicular to
the deck within degree longitudinally. Loosen jam nut
(5) on fore and aft cyclic transducer (2) so the
transducer shaft (7) can rotate freely.
BHT-412-MM-8
NOTE
Dual element control motion transducers
(412-074-101-103) are aligned and
positioned using calibration tool
(412-274-001-101). This calibration tool is
used to electrically align the control motion
transducers installed on the helicopter to be
used as control position sensors for the flight
data recorder. This tool will ensure the
control motion transducers are aligned
within ±0.5% of the prescribed position. Fore
and aft position is set at 50%. Lateral
position is set at 50%.
b. Using calibration tool (9) (412-274-001-101)
(pot calibrator) turn calibration power switch (10) to the
off position. Connect calibration box connector (8) to
one of the fore and aft cyclic transducers (2) electrical
connector (6). Turn selector knob (11) to fore and
aft (F/A) position.
c. Turn calibration power switch (10) to on
position.
NOTE
Any time the LO BAT lamp comes on,
replace batteries (use 9 VDC alkaline
batteries). Low battery is set to illuminate at
12 ±1 volt.
d. If a RED lamp comes on, the transducer shaft
(7) shall be adjusted in the direction indicated. An
extend indication means extend the transducer shaft
(7) by screwing it into rod end bearing (4) (in clockwise
direction when looking at rod end). A retract indication
means retract the transducer shaft by unscrewing it
from the rod end bearing (in counterclockwise direction
when looking at the rod end). Adjust transducer shaft
until GREEN IN RANGE lamp comes on.
e. Tighten jam nut (5) on transducer shaft (7) and
verify that GREEN IN RANGE lamp is on and RED
lamps are off.
f. Move calibration power switch (10) to off
position. Disconnect calibration box connector (8) from
transducer electrical connector (6).
g. Connect transducer electrical connector (6) to
electrical connector on the bulkhead.
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BHT-412-MM-8

Figure 67-85. Cyclic Controls Rigging (36087 and Subsequent) (Sheet 1 of 4)

67-00-00
Page 194 Rev. 7 30 SEP 2003
 BHT-412-MM-8

412_MM_67_0085b

Figure 67-85. Cyclic Controls Rigging (36087 and Subsequent) (Sheet 2 of 4)

67-00-00
ECCN EAR99 29 OCT 2009 Rev. 13 Page 195
BHT-412-MM-8

Figure 67-85. Cyclic Controls Rigging (36087 and Subsequent) (Sheet 3)

67-00-00
Page 196 Rev. 7 30 SEP 2003
 BHT-412-MM-8

Figure 67-85. Cyclic Controls Rigging (36087 and Subsequent) (Sheet 4)

67-00-00
30 SEP 2003 Rev. 7 Page 197
BHT-412-MM-8
h. Perform calibration adjustment on remaining
fore and aft cyclic transducer (2) using step a through
step g.
2. Alternate method for fore and aft cyclic
transducer (2) adjustment is as follows:
a. Connect hydraulic power cart and turn on.
b. Install fore and aft cyclic transducers (2) on
structure only. Place pilot cyclic stick (1) against
extreme forward stick stop, then to extreme aft stick
stop and check to see if transducers would bottom out
if they were connected to jackshaft. If bottoming would
occur, adjust rod end bearings (4) on transducers until
bottoming is eliminated, then connect transducers to
the jackshaft. Overtravel of transducers should be
approximately equal.
c. Position pilot cyclic stick perpendicular to the
deck within 0.5° longitudinally and laterally. Loosen jam
nut on transducer so shaft can rotate freely.
d. Measure and record resistance (T) between
pins D and F of the transducer electrical connector.
Resistance should be 5000 ± 10% ohms.
e. Multiply resistance (T) x 50% = __. Record
value of T.
f. Measure and record resistance (R) between
pins E and F of the transducer electrical connector.
Adjust the transducer shaft until resistance (R) equals
the value of step e ± 25 ohms.
g. Tighten jam nut on the transducer shaft and
verify that the resistance is still within limits.
h. Connect the transducer electrical connector to
the bulkhead.
i. Turn off hydraulic power cart and disconnect
from helicopter.
3. Perform lateral cyclic transducer (3) adjustment as
follows:
a. Position pilot cyclic stick (1) perpendicular to
deck within 0.5° longitudinally and laterally. Loosen jam
nut (5) on lateral cyclic transducer (3) so transducer
shaft (7) can rotate freely.
67-00-00
Page 198 Rev. 12 27 FEB 2009
b. Using calibration tool (412-274-001-101) (pot
calibrator) turn calibration power switch (10) to off
position. Connect calibration box connector (8) to one
of the lateral cyclic transducer (3) electrical connectors
(6). Turn selector knob (11) to LAT position.
c. Perform calibration adjustment on lateral cyclic
transducer (3) by repeating step 1c through step 1g.
d. Perform calibration adjustment on remaining
lateral cyclic transducer (3) by repeating step 1c
through step 1g.
4. Alternate method for lateral cyclic transducer (3)
adjustment is as follows:
a. Connect hydraulic power cart and turn on.
b. Install lateral cyclic transducers (3) on structure
only. Place pilot cyclic stick against extreme left lateral
stick stop and check to see if lateral cyclic transducers
would bottom out if they were connected to bellcrank. If
bottoming would occur, adjust rod end bearings on
lateral cyclic transducers until bottoming is eliminated,
then connect lateral cyclic transducers to the bellcrank.
Overtravel of lateral cyclic transducers should be
approximately equal.
c. Position pilot cyclic stick perpendicular to the
deck within 0.5° longitudinally and laterally. Loosen jam
nut on lateral cyclic transducer (3) so shaft can rotate
freely.
d. Measure and record resistance (T) between
pins D and F of the lateral cyclic transducer (3)
electrical connector (6). Resistance should be 5000 ±
10% ohms.
e. Multiply resistance (T) x 49.7% = __. Record
value of T.
f. Measure and record resistance (R) between
pins E and F of the lateral cyclic transducer (3) electrical
connector (6). Adjust the transducer shaft until
resistance (R) equals the value of step e ± 25 ohms.
g. Tighten jam nut on the lateral cyclic transducer
(3) shaft and verify that the resistance is still within
limits.
h. Connect the lateral cyclic transducer (3)
electrical connector (6) to bulkhead.
 BHT-412-MM-8

i. Turn off hydraulic power cart and disconnect 6. Install cyclic lateral force gradient and adjust
from helicopter. spring preload (paragraph 67-21).

5. Install cyclic fore and aft force gradient and adjust

spring preload (paragraph 67-16).

67-00-00
27 FEB 2009 Rev. 12 Page 198A/198B
 BHT-412-MM-8

Figure 67-86. Anti-Torque Controls Rigging (36087 and Subsequent) (Sheet 1 of 4)

67-00-00
30 SEP 2003 Rev. 7 Page 199
BHT-412-MM-8

Figure 67-86. Anti-Torque Controls Rigging (36087 and Subsequent) (Sheet 2)

67-00-00
Page 200 Rev. 7 30 SEP 2003
 BHT-412-MM-8

412_MM_67_0086c

Figure 67-86. Anti-Torque Controls Rigging (36087 and Subsequent) (Sheet 3 of 4)

67-00-00
ECCN EAR99 29 OCT 2009 Rev. 13 Page 201
BHT-412-MM-8

24 13
38

12
39

(T103206-101)

Magnetic brake/rotary actuator 1

NOTE
1 Rotary actuator used when optinal 4-axis AFCS/flight director kit installed.
412_MM_67_0086d_c01

Figure 67-86. Anti-Torque Controls Rigging (36087 and Subsequent) (Sheet 4 of 4)

67-00-00
Page 202 Rev. 13 29 OCT 2009 ECCN EAR99
 BHT-412-MM-8

67-279. ANTI-TORQUE CONTROLS (SN after adjustment. If control tubes have inspection holes,
36087 AND SUBSEQUENT) threads shall be engaged sufficiently to cover holes.

MATERIALS REQUIRED d. Apply corrosion preventive compound (C-104)

to threads of all adjustable rod bearings and clevises
after adjustment.
Refer to BHT-ALL-SPM for specifications and source.
e. Torque control jam nuts to 80 to 100
NUMBER NOMENCLATURE inch-pounds (9.04 to 11.30 Nm) after adjustment unless
other torque is specified.
C-104 Corrosion Preventive
Compound
f. Control tubes must be free to rotate several
C-308 Adhesive degrees about longitudinal axis. Loosen jam nuts,
adjust end fittings, and torque jam nuts if necessary.
C-405 Lockwire
2. Disconnect the following control tubes and force
SPECIAL TOOLS REQUIRED gradient.

a. Disconnect anti-torque force gradient (14,

NUMBER NOMENCLATURE
Figure 67-86) (paragraph 67-254) and anti-torque
T103206-101 Tail Rotor Rigging Tool transducers (20) (paragraph 67-249) from pilot pedal
adjuster (21).
Commercial Spring
Scale (Range to b. Disconnect control tube (24) from pilot pedal
measure 4 to 5 pounds/ adjuster (21) (paragraph 67-261).
17.80 to 22.24 N)
c. Disconnect control tube (26) from bellcrank
412-201-700-101 Tool Assembly
(25) (paragraph 67-9).
412-201-701-101 Tool Assembly
d. Disconnect link (4) from lever (3) (paragraph
67-213).
NOTE
Rigging procedures contained herein, 3. Verify length of centered series actuator (10),
pertain to helicopters with DAFCS and dual 62.865 to 62.915 inches (1596.77 to 1598.04 mm).
controls installed in basic controls systems.
4. Connect hydraulic power cart to helicopter
Refer to Chapter 52 for removal of required (Chapter 29). Do not turn on the hydraulic power cart
access panel. until directed.

1. Comply with the following general procedures 5. Deleted.

when rigging anti-torque controls:
a. When a rigging procedure requires a specific
position to accomplish following steps, manually hold
controls in position or secure controls in position with
pilot friction adjustment.
b. Tolerance for rigging dimensions is ±0.03 inch
(0.76 mm).
6. Position pilots left directional pedals (18 and 22)
against extreme forward stop. Adjust control tube (16)
to fit, torque jam nut, and install control tube (16).
7. Connect control tube (24) to pilot pedal adjuster
(21) (paragraph 67-261).
8. Retract two stop bolts on bellcrank (9, Detail A).

c. All adjustable control tubes must have a 9. Install tool assembly (27, Detail B)
maximum of 1.0 inch (2.54 mm) of exposed threads (412-201-701-101) on pilot pedals (22 and 23).

67-00-00
ECCN EAR99 29 OCT 2009 Rev. 13 Page 203
BHT-412-MM-8
10. Remove bolt (28, Detail A) which secures series
actuator (10) to bellcrank (9).
11. Remove bolt (31) which secures bellcrank (9) to
support (8).
12. Retract both anti-rotation screws (32) in tool
assembly (29) (412-201-700-101).
13. Position tool assembly (29) (412-201-700-101)
against the inboard surface of support (8). Install bolt
(NAS6604-30D) through tool assembly (29), support
(8), and bellcrank (9) as shown in detail A, but do not
completely tighten at this time. Rotate tool assembly
(29) body until the indexing pin (30) engages the center
slot of the tool assembly (29).
14. Adjust both tool assembly (29) anti-rotation screws
(32) to make contact with the support (8) as shown in
detail A. As the screws (32) are tighten, ensure indexing
pin (30) is free to disengage and re-engage the center
slot in the tool assembly (29) body, then tighten bolt
(NAS6604-30D).
15. Remove tool assembly (27) (412-201-701-101)
from the pilots left and right pedals (22 and 23, Detail
C).
16. Retract indexing pin (30) until it clears tool
assembly (29) (412-201-700- 101) body.
17. Slowly move pilots left pedal (22) forward until
indexing pin (30) engages the forward slot in tool
assembly (29) body. Adjust lower forward stop bolt in
bellcrank (9) to the left pedal stop within 0.000 to 0.002
inch (0.000 to 0.051 mm) as shown in Detail A.
18. Retract indexing pin (30) until it clears tool
assembly (29) body.
19. Slowly move pilots right pedal (23) forward until
indexing pin (30) engages the aft slot in tool assembly
(29) body. Adjust upper aft stop in bellcrank (9) to the
right pedal stop within 0.000 to 0.002 inch (0.000 to
0.051 mm) as shown in Detail A.
20. Remove tool assembly (29) (412-201-700-101)
and install bolt (28) and bolt (31) that were removed in
step 10 and step 11.
21. Position and hold pilots left pedal (22) forward
against stop.
67-00-00
Page 204 Rev. 12 27 FEB 2009
22. Check two pitch links (2, Detail E) for 6.180 ±0.010
inches length (156.97 ±0.254 mm) between bolt hole
centers.
23. Remove bolt (34) retaining pitch link to
crosshead (1).
24. Install tail rotor rigging tool (35) (T103206-101) to
crosshead (1) and retain with bolt (34). Position tool
(35) as shown in Figure 67-86 against tail rotor hub
trunnion (37). Hold in this position by pushing inboard
on tail rotor crosshead.
NOTE
If tail rotor rigging tool (35) (T103206-101) is
not available, position crosshead (1) to
trunnion (37) to 4.334 ±0.010 inches (110.08
±0.254 mm).
25. Adjust link (4, Detail F) to obtain 0.58 inch (14.73
mm) clearance with bellcrank (6). Torque jam nut on link
(4), and install link (4) on bellcrank (6) and lever (3).
Turn hydraulic power cart on.
26. With pilots left pedal (22) positioned (per step 21),
and link (4) adjusted (per step 25), adjust tube (26) to
fit to bellcrank (25). Torque jam nut and install control
tube (26). Turn hydraulic power cart off and disconnect
from helicopter.
NOTE
Alternate method of rigging directional
controls without pressurizing the hydraulic
system: With pilots left pedal (22) positioned
(per step 21), the hydraulic series actuator
valve bottomed by pushing down on
actuator piston rod, and link (4) adjusted
(per step 25), adjust tube (26) to fit to
bellcrank (25), then shorten one half turn of
clevis. Torque jam nut and install control
tube (26).
27. Remove tail rotor rigging tool (35) and install pitch
link (2) to crosshead (1).
28. Rig anti-torque trim system as follows:
a. Install tool assembly (27) (412-201-701-101)
on pilot left and right pedals (22 and 23, Detail B).

b. Position output arm (33) on magnetic brake or
rotary actuator (15), as shown in Detail C.
c. Place output arm (33) of magnetic brake or
rotary actuator(15) at center of travel, adjust force
gradient (14) to fit the pilot pedal adjuster (21). Torque
jam nut and install force gradient (14) on pedal adjuster
(21).
d. Check clearance between force gradient (14)
and structure at extreme position of the output arm (33).
Re-index output arm (33) relative to shaft by one
serration, if required for clearance, then repeat step b
through step d.
e. Remove tool assembly (27) from pilot left and
right pedals (22 and 23, Detail B).
29. Perform anti-torque control motion transducer (20,
Detail D) adjustment as follows:
a. Install transducers (20) to structure only. Place
pilots pedal against one stop, then the other and check
to see if transducers would bottom out in either
retracted or extended position if transducers were
connected to bellcrank (48). If bottoming would occur,
adjust rod end bearing (46) on transducers until
bottoming is eliminated. Then connect transducers to
bellcrank. Overtravel of transducers should be
approximately equal.
NOTE
Dual element control motion transducers
(412-074-101-103) are aligned and
positioned using calibration tool
(412-274-001-101).
b. Position pilot left pedal forward against left
pedal stop.
NOTE
This calibration tool (412-274-001-101) is
used to electrically align the control motion
transducers installed on the helicopter. The
transducers are used as control position
sensors for the flight data recorder. This tool
will insure that the control motion
transducers are aligned within ±0.5% of the
prescribed position. Pedal position is set at
12%.
c. Using calibration tool (9, Figure 67-85)
(412-274-001-101) (pot calibrator) turn calibrator power
BHT-412-MM-8
switch (10) to the off position. Connect calibrator box
connector (8) to one of the transducers (20, Figure
67-86) electrical connector (42). Turn selector knob (11,
Figure 67-85) to pedal position.
d. Turn calibrator power switch (10) to on position.
NOTE
Any time the LO BAT lamp comes on,
replace batteries (use 9 VDC alkaline
batteries). Low battery is set to illuminate at
12 ±1 volt.
e. If a RED lamp comes on, the transducer shaft
shall be adjusted in the direction indicated. An extend
indication means extend the transducer shaft by
screwing it into rod end bearing (46, Figure 67-86)
(clockwise looking at rod end). A retract indication
means retract the transducer shaft by unscrewing it
from the rod end bearing. Adjust transducer shaft until
GREEN, IN RANGE lamp comes on.
f. Tighten jam nut (41) on transducer shaft (7,
Figure 67-85) and verify that GREEN, IN RANGE lamp
is on and RED lamps are off.
g. Move calibrator power switch (10) to off
position. Disconnect calibrator box connector (8) from
transducer electrical connector (42, Figure 67-86).
h. Connect transducer electrical connector (42) to
electrical connector on the bulkhead.
i. Perform calibration adjustment on remaining
transducer (20) using step a through step h above.
30. Ensure that all anti-torque controls bolts are
installed and cotter pins, adhesive (C-308), lockwire
(C-405) is installed where applicable.
31. Alternate method anti-torque control motion
transducer (20, Detail D) adjustment as follows:
a. Install transducers (20) to structure only. Place
pilots pedal against one stop, then the other and check
to see if transducers would bottom out in either
retracted or extended position if transducers were
connected to bellcrank (48). If bottoming would occur,
adjust rod end bearing (46) on transducers until
bottoming is eliminated. Then connect transducers to
bellcrank. Overtravel of transducers should be
approximately equal.
67-00-00
27 FEB 2009 Rev. 12 Page 205
BHT-412-MM-8
b. Position pilot left pedal forward against left
pedal stop.
c. Measure and record resistance (T) between
pins D and F of the transducer electrical connector.
Resistance should be 5000 ± 10 percent ohms.
d. Multiply resistance (T) x 12.0 percent = .
Record value of T.
e. Measure and record resistance (R) between
pins E and F of the transducer electrical connector.
Adjust the transducer shaft until resistance (R) equals
the value of step d. ± 25 ohms.
f. Tighten jam nut on the transducer shaft and
verify that the resistance is still within limits.
g. Connect the transducer electrical connector to
bulkhead.
32. Adjust anti-torque minimum friction as follows:
67-00-00
Page 206 Rev. 7 30 SEP 2003
a. Disconnect force gradient (14) from pedal
adjuster (21).
b. Disconnect control tube (12) from walking
beam (13).
c. Attach spring scale to one pilot anti-torque
pedal. Measure force required to move pedal through
neutral. Acceptable force range is 4.25 to 4.75 lbs.
(18.91 to 21.13 N). Adjust screw (39, detail G) on clamp
(38) to obtain friction within acceptable range.
d. Install control tube (12) on walking beam (13).
e. Install force gradient (14) on pedal adjuster
(21).
33. Move anti-torque controls through full travel and
check for binding and/or obstruction of control
movement.
34. Ensure that all anti-torque controls bolts are
installed and cotter pins, adhesive (C-308), lockwire
(C-405) is installed where applicable.

CYCLIC CONTROLS — DIGITAL AFCS
67-280. CYCLIC CONTROLS (SN 36087 AND
SUBSEQUENT)
67-281. DESCRIPTION
The cyclic controls installation (figure 67-87) consist of
the controls and components from the pilot and copilot
cyclic stick (15 and 7) up to but not including the
swashplate (1).
The cyclic control system incorporates two cyclic series
actuators (6, fore and aft and 17, lateral), one
connected in roll system and one connected in pitch
system. A control tube and idler (19) are attached to
series actuators (6) in pitch system.
Four transducers, two lateral cyclic transducers (13) in
roll system and two fore and aft cyclic transducers (16)
in pitch system, are used to convert mechanical
movement to electrical signals for injecting pilot and
copilot control commands to the DAFCS.
Two fore and aft cyclic transducers (16) are attached to
right end of cyclic jackshaft (8) providing a fore and aft
cyclic signal. Two lateral cyclic transducers (13) are
attached to a forward cyclic bellcrank (14) providing a
lateral cyclic signal.
A force gradient assembly connected to an
electromechanical rotary actuator is also installed in
each cyclic system. Cyclic roll system force gradient
attaches to a bellcrank forward of jackshaft. The cyclic
pitch system force gradient attaches directly to the left
end of cyclic jackshaft.
A support assembly and idler (19) are used to connect
the fore and aft cyclic series actuators (6) and pitch
control tube which is attached to the lever assembly
(21).
Two proximity switches (18, fore and aft and 20, lateral),
and two cyclic centering (CYC CTR) caution lights are
installed for aid in centering cyclic sticks. The lights are
located in the pilots and copilots instrument panel. The
two proximity switches (18 and 20) are located
underneath the floor near the mixing lever assembly
(21).
BHT-412-MM-8
NOTE
Cyclic control system components forward
of mixing lever assembly (21) are identified
as lateral cyclic or fore and aft cyclic as
applicable, i.e., lateral cyclic force gradient.
Cyclic control system components aft of
mixing lever assembly (21) are identified as
left cyclic or right cyclic as applicable, i.e.,
left cyclic flight control cylinder.
The fore and aft control linkage are separate from the
cyclic stick to the mixing lever assembly (21). From the
mixing lever assembly (21) to the swashplate (1) the
effects of the control linkage are combined and cannot
be considered separately as to effect.
Actuation of the pilot and copilot cyclic sticks (15 and 7)
causes hydraulic power assisted cyclic pitch change of
the main rotor blades.
Dual controls are installed for copilot control of the
helicopter. Operation of dual controls system is
basically the same as operation of single system. Refer
to Flight Manual for operating procedures.
67-282. ROTARY ACTUATOR (FORE AND AFT
CYCLIC)
67-283. Removal
1. Remove access panel from cabin floor under left
crew seat. Remove access panel from bottom left side
of helicopter just forward of front landing gear crosstube
(Chapter 52).
2. Disconnect electrical connector (11, figure 67-88).
3. Remove cotter pin (3), nut (4) and separate force
gradient (2) from arm (5).
4. Disconnect hook (13) from bolt (9).
5. Remove three bolts (8) and washers (7).
6. Remove one bolt (9) and washer (10).
7. Remove rotary actuator (6).
67-00-00
30 SEP 2003 Rev. 7 Page 207
BHT-412-MM-8

Figure 67-87. Cyclic Controls (36087 and Subsequent)

67-00-00
Page 208 Rev. 7 30 SEP 2003
 BHT-412-MM-8

Figure 67-88. Fore and Aft Cyclic Rotary Actuator Removal/Installation (36087 and Subsequent)

67-00-00
30 SEP 2003 Rev. 7 Page 209
BHT-412-MM-8
67-284. Inspection
1. Inspect rotary actuator (6, figure 67-88) for
mec hani cal a nd cor r osi on dama ge and wear
(BHT-ALL-SPM).
2. Inspect rotary actuator arm (5) stud for damaged
threads. No damage that can be detected visually is
acceptable.
3. Inspect electrical receptacle for bent pins and
damaged threads. Superficial damage is acceptable
without repair.
67-285. Installation
MATERIALS REQUIRED
Refer to BHT-ALL-SPM for specifications and source.
NUMBER NOMENCLATURE
C-405 Lockwire
1. Inspect rotary actuator (6, figure 67-88) to ensure
arm (5) is installed on rotary actuator with index mark
on arm position 14 teeth from index mark on rotary
actuator shaft shown on view A. Reposition arm (5) on
rotary actuator if index marks are not properly located.
2. Position rotary actuator (6) on structure (12).
Install special bolt (9) and aluminum washer (10) in
lower out board hole. Install three bolts (8) and
aluminum washers (7) in remaining holes.
3. Position force gradient (2) on arm (5) stud. Install
nut (4) and cotter pin (3).
4. Install spring (16), plate (14), and hook (13) on bolt
(9). Refer to paragraph 67-166 for procedure to position
spring (16) in correct hole in plate (14).
NOTE
For initial installation, install spring in fourth
hole of plate (14). With hydraulic boost on,
or during ground run, adjust spring tension
to position pilot control stick (longitudinal
cyclic only) perpendicular to deck within 2
degrees.
67-00-00
Page 210 Rev. 7 30 SEP 2003
5. When tension on spring (16) is correctly adjusted,
secure spring to plate (8) with lockwire (C-405) (15).
6. Close loop on hook (13) through bolt (9).
7. Install electrical connector (11).
8. Move cyclic controls through full travel and check
for binding and/or obstructions.
9. Verify that cyclic control rigging is within limits
(paragraph 67-278).
10. Install access panel on cabin floor under left crew
seat (Chapter 52).
11. Install access panel bottom left side of helicopter
just forward of forward landing gear crosstube (Chapter
52).
67-286. ROTARY ACTUATOR (LATERAL CYCLIC)
67-287. Removal
1. Remove access panel from bottom of helicopter
just aft and inboard of left lower nose window (Chapter
52).
2. Disconnect electrical connector (9, figure 67-89)
from rotary actuator (7).
3. Remove cotter pin (4) and nut (3) and separate
force gradient (2) from arm (10).
4. Remove four bolts (5) and washers (6).
5. Separate rotary actuator (7) from rotary actuator
adapter plate (8).
67-288. Inspection
1. Inspect rotary actuator (7, figure 67-89) for
mec hani ca l and cor r osi on dama ge and wear
(BHT-ALL-SPM).
2. Inspect rotary actuator arm (10) stud for damaged
threads. No damage that can be detected visually is
acceptable.
 BHT-412-MM-8

Figure 67-89. Lateral Cyclic Rotary Actuator Removal/Installation (36087 and Subsequent)

67-00-00
30 SEP 2003 Rev. 7 Page 211
BHT-412-MM-8
3. Inspect electrical connector (9) and receptacle for
bent pins and damaged threads. Superficial damage is
acceptable without repair.
67-289. Installation
1. Inspect rotary actuator (7, figure 67-89) to ensure
that arm (10) is installed on rotary actuator with index
mark on arm positioned six teeth from index mark on
rotary actuator shaft as shown in view A. Reposition
arm (10) on rotary actuator if index marks are not
properly located.
2. Position rotary actuator (7) on adapter plate (8).
Install four bolts (5) and four aluminum washers (6).
3. Position force gradient (2) on arm (10). Install nut
(3) and cotter pin (4).
4. Install electrical connector (9).
5. Move cyclic controls through full travel and check
for binding and/or obstructions.
6. Verify that cyclic control rigging is within limits
(paragraph 67-278).
7. Install access panel on bottom of helicopter just aft
and inboard of left lower nose window (Chapter 52).
67-290. FORCE GRADIENT (FORE AND AFT
CYCLIC)
67-291. Removal
1. Remove access panel from cabin floor under left
crew seat (Chapter 52).
2. Remove access panel from bottom of helicopter
on left side forward of forward landing gear crosstube
(Chapter 52).
3. Disconnect electrical connector (5, figure 67-90).
4. Remove hook (8) from bolt (7).
5. Remove cotter pin (3) and nut (4) from rotary
actuator (6).
67-00-00
Page 212 Rev. 7 30 SEP 2003
6. Cut and discard lockwire. Remove bolt (12) and
washer (11) from clevis (13).
7. Remove fore and aft cyclic force gradient (2),
spring assembly (10) and plate (9) from jackshaft (1).
Measure and record overall length of force gradient.
67-292. Inspection
1. Inspect force gradient (2, figure 67-90) for
corrosion and mechanical damage. Superficial
mechanical damage is acceptable without repair.
Mechanical damage in excess of superficial and/or
corrosion is not acceptable.
2. Inspect for thread damage in threaded hole and for
elongation of hole in opposite side of clevis (13).
3. Inspect hook (8), plate (9), and spring (10) for
obvious mechanical damage and for loss of tension in
spring. Spring tension at 10.36 in. (263.14 mm) is 6.4 ±
0.5 lbs. (28.47 ± 2.22 kg).
4. Inspect bearings for wear and secure installation
in cylinder (5). Refer to Bearing Wear Limit Table in
BHT-ALL-SPM for acceptable limits.
5. Inspect jam nut (1) and cylinder (5) for secure
installation.
6. Inspect switch and electrical cable assembly (18,
figure 67-91) for frayed wires and broken pins in
connector. Check continuity from connector pins
through switch.
67-293. Repair
Repair of force gradient consists of replacement of
unserviceable components and adjustment of spring
preload in accordance with paragraph 67-294.
67-294. Installation
MATERIALS REQUIRED
Refer to BHT-ALL-SPM for specifications and source.
NUMBER NOMENCLATURE
C-405 Lockwire
 BHT-412-MM-8

Figure 67-90. Fore and Aft Cyclic Force Gradient Removal/Installation (36087 and Subsequent)

67-00-00
30 SEP 2003 Rev. 7 Page 213
BHT-412-MM-8

Figure 67-91. Fore and Aft Cyclic Force Gradient (36087 and Subsequent)

NOTE d. Position spring assembly (4) in cylinder (5) and

Force gradient (2, Figure 67-90) in the fore
a n d a ft c y c l i c c o nt r ol s i s s i m i l a r i n
appearance to the force gradient in lateral
cyclic controls, but has different part
numbers. Ensure that correct part number
force gradient is installed in the fore and aft
position. Refer to BHT-412 IPB.
1. If not previously accomplished, adjust spring
preload of force gradient as follows:
a. Cut and remove lockwire, loosen jam nut (1,
Figure 67-91) and remove cap (9).
b. Remove spring assembly (4) from cylinder (5).
c. Adjust inboard nut (3) to provide 8.0 to 11.0 lbs.
(35.59 to 48.93 N) preload against spring assembly (4).
Tighten outboard nut (2) against inboard nut (3).
install cap (9) with jam nut (1) until all end play is
eliminated. Tighten jam nut (1) and secure with lockwire
(C-405) to cylinder (5).
2. If not previously accomplished, adjust actuator (7)
on force gradient as follows:
a. Loosen nuts (6 and 8) on shaft of spring
assembly (4).
b. Ensure retainer (13) is secured by screws (15)
and washers (14).
c. Align actuator (7) on shaft of spring assembly
(4) with ball (10) and plunger of cable assembly (switch)
(18).
d. Loosen screws (11), washers (12 and 16), and
nut (17) cable assembly (switch) (18) to retainer (13).

67-00-00
Page 214 Rev. 12 27 FEB 2009

e. Push and hold actuator (7) down (180°) against
cap (9) at point opposite location of cable assembly
(18). Hold this position to initially adjust switch (18) then
adjust switch to actuate within ±0.050 inch (1.27 mm)
linear travel of spring assembly (4). Secure switch (18)
to retainer (13) with screws (11), washers (12 and 16),
and nut (17). Secure actuator (7) with nut (8).
f. Install clevis (13, Figure 67-90) on shaft of
spring assembly (4, Figure 67-91), secure with nut (6).
3. After assembly of force gradient, prior to
installation, verify spring assembly (4) preload of 8.0 to
11.0 pounds (35.59 to 48.93 N).
4. Position spring (10, Figure 67-90) on clevis (13).
5. Position force gradient (2) on jackshaft (1). Clevis
(13) has a threaded hole in one side. Position the clevis
with the threaded hole inboard. Install bolt (12) and
aluminum washer (11). Secure bolt head to hole in
clevis (13) with lockwire (C-405).
CAUTION
ENSURE FORCE GRADIENT LENGTH IS
ADJUSTED TO RECORDED LENGTH
PRIOR TO INSTALLATION OF FORCE
GRADIENT ON ROTARY ACTUATOR.
6. Position force gradient (2) on rotary actuator (6).
Install nut (4) and cotter pin (3).
7. Install plate (9) on spring (10) with spring through
fourth hole in plate (9). Do not lockwire spring to plate
at this time.
8. Attach plate (9) with hook (8) to bolt (7). Do not
close loop on hook (8) at this time.
9. Connect electrical connector (5).
10. Move fore and aft cyclic controls through full travel
and check for binding and obstructions.
11. Apply external hydraulic power to helicopter
(Chapter 29).
BHT-412-MM-8
12. Loosen cyclic friction and observe cyclic stick
position. If cyclic stick is not perpendicular
(longitudinally) within two degrees, move spring (10) to
different hole in plate (9) to cause cyclic stick to be
vertical (longitudinally).
13. When tension on spring (10) is correctly adjusted,
secure spring to plate (9) with lockwire (C-405). Close
loop on hook (8) to prevent accidental disengagement
of hook.
14. Move fore and aft cyclic controls through full travel
and check for binding and obstructions.
15. Confirm that cyclic control rigging is within limits
(paragraph 67-278).
16. Remove external power from helicopter.
17. Install access panel on bottom of helicopter on left
side forward of forward landing gear crosstube
(Chapter 52).
18. Install access panel on cabin floor under left crew
seat (Chapter 52).
67-295. FORCE GRADIENT (LATERAL CYCLIC)
67-296. Removal
1. Remove access panel from bottom of helicopter
below lateral cyclic force gradient (5, Figure 67-92)
(Chapter 52).
2. Disconnect electrical connector (8).
3. Remove cotter pin (7) and nut (6).
4. Remove cotter pin (10), nut (11), and washer (12).
5. Remove bolt (2) with washer (3) from lateral cyclic
control bellcrank (1).
6. Remove force gradient (5).
7. Record over all length of force gradient.
67-00-00
27 FEB 2009 Rev. 12 Page 215
BHT-412-MM-8

Figure 67-92. Lateral Cyclic Force Gradient Removal/Installation (36087 and Subsequent)

67-00-00
Page 216 Rev. 7 30 SEP 2003

67-297. Inspection
1. Inspect force gradient (5, Figure 67-92) for
corrosion and mechanical damage. Superficial
mechanical damage is acceptable without repair.
Mechanical damage in excess of superficial and/or
corrosion is not acceptable.
2. Inspect clevis (4) for damage.
3. Inspect bearings for wear and secure installation
in cylinder (5, Figure 67-93). Refer to Bearing Wear
Limit Table in BHT-ALL-SPM for acceptable limits.
4. Inspect jam nut (1) and cylinder (5) for secure
installation.
5. Inspect switch and electrical cable assembly (18,
Figure 67-93) for frayed wires and broken pins in
connector. Check continuity from connector pins
through switch.
67-298. Repair
Repair of force gradient consists of replacement of
unserviceable components and adjustment of spring
preload in accordance with paragraph 67-299.
67-299. Installation
MATERIALS REQUIRED
Refer to BHT-ALL-SPM for specifications and source.
NUMBER NOMENCLATURE
C-405 Lockwire
NOTE
Force gradient (5, Figure 67-92) in the
lateral cyclic controls is similar in
appearance to the force gradient in the fore
and aft cyclic controls, but the force gradient
has different part numbers. Ensure that
correct part number force gradient is
installed in lateral position. Refer BHT-412
IPB.
BHT-412-MM-8
1. If not previously accomplished, adjust spring
preload on force gradient as follows:
a. Cut and remove lockwire, remove cap (9,
Figure 67-93).
b. Remove spring assembly (4) from cylinder (5).
c. Adjust inboard nut (3) to provide 6.0 to 7.0
pounds (26.7 to 31.1 N) preload against spring
assembly (4). Tighten outboard nut (2) against inboard
nut (3).
d. Position spring assembly (4) in cylinder (5) and
install cap (9) with jam nut (1) until all end play is
eliminated. Tighten jam nut (1) and secure with lockwire
(C-405) to cylinder (5).
2. If not previously accomplished, adjust actuator (7)
on force gradient as follows:
a. Loosen nuts (6 and 8) on shaft of spring
assembly (4).
b. Ensure retainer (13) is secured by screws (15)
and washers (14).
c. Align actuator (7) on shaft of spring assembly
(4) with ball (10) and plunge of cable assembly
(switch) (18).
d. Loosen screws (11), washers (12 and 16), and
nut (17) cable assembly (switch) (18) to retainer (13).
e. Push and hold actuator (7) down (180°) against
cap (9) at point opposite location of cable assembly
(18). Hold this position to initially adjust switch (18) then
adjust switch to actuate within ±0.050 inch (1.27 mm)
linear travel of spring assembly (4). Secure switch (18)
to retainer (13) with screws (11), washers (12 and 16),
and nut (17). Secure actuator (7) with nuts (6 and 8).
f. Install clevis (4, Figure 67-92) on shaft of spring
assembly (4, Figure 67-93), adjust to length recorded
during removal, and secure with nut (8).
3. After assembly of force gradient, prior to
installation, verify spring assembly (4) preload of 6.0 to
7.0 pounds (26.69 to 31.14 N).
67-00-00
27 FEB 2009 Rev. 12 Page 217
BHT-412-MM-8

15 16
14 17

12 18 4
11 2 3
1
13
10
9

7
6
8
18

1. Jamnut
2. Outboard nut
3. Inboard nut
4. Spring assembly
5. Cylinder
6. Nut
7. Actuator
8. Nut
9. Cap
10. Ball
11. Screw
12. Washer
13. Retainer
14. Washer
15. Screw
16. Washer
17. Nut
18. Cable assembly (switch)

412_MM_67_0093

Figure 67-93. Lateral Cyclic Force Gradient (36087 and Subsequent)

67-00-00
Page 218 Rev. 12 27 FEB 2009

4. Position force gradient (5, Figure 67-92) on lateral
cyclic control bellcrank (1). Install bolt (2), washers (3
and 12), nut (11) and cotter pin (10).
CAUTION
E N S U R E T H AT F O R C E G R A D I E N T
LENGTH IS ADJUSTED TO RECORDED
LENGTH PRIOR TO INSTALLATION OF
F O R C E G R A D I E N T O N R O TA R Y
ACTUATOR.
5. Position force gradient (5) on rotary actuator (9).
Install nut (6) and cotter pin (7).
6. Connect electrical connector (8).
7. Apply external hydraulic power to helicopter
(Chapter 29).
8. Move cyclic controls through full travel and check
for binding and/or obstructions.
9. Verify that cyclic control rigging is within limits
(paragraph 67-278).
10. Remove external hydraulic power from helicopter.
11. Install access panel on bottom of helicopter below
force gradient (Chapter 52).
67-300. ANTI-TORQUE CONTROLS (SN
36087 AND SUBSEQUENT)
67-301. DESCRIPTION
The anti-torque control system consists of control
linkage and components from pilot and copilot pedals
(9, 10, 6, and 7, Figure 67-94) aft to crosshead (1) on
tail rotor. The DAFCS incorporates electromechanical
series actuators (3), magnetic brake (5), force gradient
(4), and two transducers (8). The series actuators (3) is
located forward of anti-torque hydraulic cylinder (2) and
support. The magnetic brake (5) is located on main
bulkhead under access panel below pilot seat. The
force gradient (4) is connected to magnetic brake (5)
and directional control bellcrank. The two transducers
(8) are connected to directional control bellcrank
BHT-412-MM-8
located aft of pilot left and right pedals (9 and 10) and
to main beam of airframe structure.
When the optional 4-axis AFCS/Flight Director kit is
installed, the force gradient (3, Figure 67-96)
incorporates a detent switch and the magnetic brake is
replaced by an electromechanical rotary actuator (8).
Actuation of the pilot or copilot pedals causes a
hydraulic power assisted pitch change of the tail rotor
blades to offset main rotor torque and to control the
directional heading of the helicopter.
Dual controls are installed for copilot control of
helicopter.
Operation of anti-torque dual controls system is
basically the same as operation of single system. Refer
to Flight Manual for operating procedures.
67-302. ANTI-TORQUE TRANSDUCERS
67-303. Removal
1. Remove access panel from cabin floor under pilot
seat (Chapter 52).
2. Disconnect electrical connectors (9 and 17, Figure
67-95).
3. Remove cotter pin (18), nut (19), washer (20),
spacers (10) and bolt (1) with washer (2).
4. Remove cotter pin (6), nut (5), spacer (4) washer
(7) and bolt (8).
5. Remove cotter pin (11), nut (12), washers (13 and
15) and bolt (16).
6. Remove transducers (3 and 14).
67-304. Inspection
1. Inspect transducers (3 and 14, Figure 67-95) for
damage and secured electrical plugs.
2. Inspect bearings for looseness (BHT-ALL-SPM).
67-305. Repair
anti-torque control transducers are nonrepairable and
must be replaced when defective.
67-00-00
27 FEB 2009 Rev. 12 Page 219
BHT-412-MM-8

1. Crosshead
2. Antitorque hydraulic
cylinder
3. Series actuator
4. Force gradient
5. Magnetic brake 1
6. Copilot left pedal
7. Copilot right pedal
8. Transducers
9. Pilot left pedal
10. Pilot right pedal

STA 3
151.50

10
STA
98.20
9
5 STA
63.33
SEE DETAIL A
8 FWD
8

DETAIL A
VIEW LOOKING DOWN

412_MM_67_0020

Figure 67-94. Anti-Torque Controls (36087 and Subsequent)

67-00-00
Page 220 Rev. 11 30 MAR 2007
 BHT-412-MM-8

Figure 67-95. Anti-Torque Transducer Removal/Installation (36087 and Subsequent)

67-00-00
30 SEP 2003 Rev. 7 Page 221
BHT-412-MM-8

SEE
DETAIL B

1. Bolt 7. Stud
2. Aluminum washer 8. Rotary actuator
3. Force gradient 9. Aluminum washer
4. Electrical connector 10. Nut
5. Nut 11. Cotter pin
6. Cotter pin 12. Pedal adjuster
13. Clevis

412_MM_67_0095a

Figure 67-96. Anti-Torque Force Gradient (4-Axis Configuration) (Sheet 1 of 2)

67-00-00
Page 222 Rev. 12 27 FEB 2009
 BHT-412-MM-8

28 29
27 30

25 31 17
24 15 16
14
26
23
22
21

20

19

18

DETAIL B

14. Jam nut

15. Outboard nut
16. Inboard nut
17. Spring assembly
18. Cylinder
19. Nut
20. Actuator
21. Nut
22. Cap
23. Ball
24. Screw
25. Washer
26. Retainer
27. Washer
28. Screw
29. Washer
30. Nut
31. Cable assembly (switch)

412_MM_67_0095b

Figure 67-96. Anti-Torque Force Gradient (4-Axis Configuration) (Sheet 2 of 2)

67-00-00
27 FEB 2009 Rev. 12 Page 223
BHT-412-MM-8
67-306. Installation
NOTE
If not previously accomplished perform
transducer adjustment, refer to paragraph
67-279.
1. Position transducers (3 and 14, Figure 67-95) on
bracket of main beam of airframe structure.
2. Install bolt (8), washer (7), spacer (4), nut (5), and
cotter pin (6).
3. Install bolt (16), aluminum washers (13 and 15),
nut (12), and cotter pin (11).
4. Position transducers (3 and 14) on pedal adjuster
(21) bellcrank.
5. Install bolt (1), washer (2), spacers (10), washer
(20), nut (19), and cotter pin (18).
6. Connect electrical connectors (9 and 17).
7. Install access panel on floor under pilot seat
(Chapter 52).
67-307. ANTI-TORQUE FORCE GRADIENT
NOTE
The following procedure is applicable to
anti-torque force gradients (incorporating a
detent switch) used when the optional 4-axis
AFCS/Flight Director kit is installed. For
anti-torque force gradients not incorporating
a detent switch, refer to paragraph 67-254.
67-308. Removal
1. Remove access panel from cabin floor under pilot
seat (Chapter 52).
2. Remove cotter pin (11, Figure 67-96), nut (10),
washer (9) and bolt (1) with washer (2) from pedal
adjuster (12).
3. Remove cotter pin (6) and nut (5) from stud (7).
4. Remove force gradient (3) from magnetic brake
(8).
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Page 224 Rev. 12 27 FEB 2009
5. Record length of force gradient assembly.
6. Loosen nut (19) and remove clevis (13) from
spring assembly (17).
67-309. Inspection
1. Inspect force gradient (3, Figure 67-96) for
corrosion and mechanical damage (BHT-412-CR&O).
Superficial mechanical damage is acceptable without
repair. Mechanical damage in excess of superficial and/
or corrosion damage is not acceptable.
2. Inspect bearing for secure installation in housing
and for wear (BHT-ALL-SPM).
67-310. Repair
Repair of force gradient consists of replacement of
unserviceable components and adjustment of spring
preload in accordance with paragraph 67-299.
NOTE
The following procedure is applicable to
anti-torque force gradients (incorporating a
detent switch) used when the optional 4-axis
AFCS/Flight Director kit is installed. For
anti-torque force gradients not incorporating
a detent switch, refer to paragraph 67-257.
67-311. Installation
CAUTION
E N S U R E T H AT F O R C E G R A D I E N T
LENGTH IS ADJUSTED TO RECORDED
LENGTH PRIOR TO INSTALLATION ON
MAGNETIC BRAKE.
NOTE
Force gradient is similar in appearance to
the force gradients used in the cyclic
controls but has a different part number.
Ensure that correct part number force
gradient is installed for the anti-torque
control system. Refer to BHT-412 IPB.
1. If not previously accomplished, adjust spring
preload of force gradient (3, Figure 67-96) as follows:
 BHT-412-MM-8

a. Cut and remove lockwire, loosen jam nut (14), 6. Install bolt (1), aluminum washers (2 and 9), nut
and remove cap (22). (10), and cotter pin (11).

b. Remove spring assembly (17) from 7. Position force gradient (3) on stud (7) of magnetic
cylinder (18). brake (8).

c. Adjust inboard nut (16) to provide 18 to 20 8. Install nut (5) and cotter pin (6).
pounds (80.06 to 88.96 N) preload against spring
assembly (17). Tighten outboard nut (15) against
9. Move anti-torque controls through full travel and
inboard nut (16).
check for obstruction and/or binding.

d. Position spring assembly (17) in cylinder (18)

10. Confirm that anti-torque control rigging is within
and install cap (22) with jam nut (14) until all end play is
limits. Refer to paragraph 67-279.
eliminated. Tighten jam nut (14) and secure with
lockwire (C-405) to cylinder (18).
11. Install access panel on cabin floor under pilot seat
(Chapter 52).
2. If not previously accomplished, adjust actuator
(20) on force gradient as follows:
67-312. ANTI-TORQUE ROTARY ACTUATOR
a. Loosen nuts (19 and 21) on shaft of spring
assembly (17). NOTE
The following procedure is applicable to
b. Make sure retainer (26) is secured by screws anti-torque rotary actuators used when the
(28) and washers (27). optional 4-axis AFCS/Flight Director kit is
installed. For magnetic brakes used in the
anti-torque system, refer to paragraph
c. Align actuator (20) on shaft of spring assembly
67-244.
(17) with ball (23) and plunger of cable assembly
(switch) (31).
67-313. Removal
d. Loosen screws (24), washers (25 and 29), and 1. Remove access panel from cabin floor under pilot
nut (30) cable assembly (switch) (31) to retainer (26). seat (Chapter 52).

e. Push and hold actuator (20) down (180°) 2. Disconnect electrical connector (6, Figure 67-97).
against cap (22) at point opposite location of cable
assembly (31). Hold this position to initially adjust
switch (31), then adjust switch to actuate within ±0.050 3. Remove cotter pin (2) and nut (3) from stud (4).
inch (1.27 mm) linear travel of spring assembly (17).
Secure switch (31) to retainer (26) with screws (24), 4. Lift force gradient (1) off arm (10).
washers (25 and 29), and nuts (30). Secure actuator
(20) with nut (21).
5. Remove bolts (9) and aluminum washers (8).

3. Install clevis (13) on shaft of spring assembly (17),

6. Remove rotary actuator (7) from structure (5).
adjust to previously recorded length, and secure with
nut (19).
67-314. Inspection
4. After assembly of force gradient, prior to
1. Inspect rotary actuator (7, Figure 67-97) for
installation, verify spring assembly (17) preload of 18 to
corrosion and mechanical damage. Superficial
20 pounds (80.06 to 88.96 N).
mechanical damage is acceptable without repair.
Mechanical damage in excess of superficial damage
5. Position force gradient (3) on pedal adjuster (12). and/or corrosion damage is not acceptable.

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BHT-412-MM-8

2
1
3

10 5

8
9

412_MM_67_0097

Figure 67-97. Anti-Torque Rotary Actuator (4-Axis Configuration)

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 BHT-412-MM-8

2. Inspect stud (4) for damaged threads. No damage 6. Install access panel on cabin floor under pilot seat
that can be detected visually is acceptable. (Chapter 52).

3. Inspect electrical receptacle for bent pins and 67-317. ANTI-TORQUE SERIES ACTUATORS
threads. Superficial damage is acceptable without
repair.

CAUTION
67-315. Repair

Refer to vendor manual for magnetic brake repair DISASSEMBLY OF SERVO ACTUATOR
instructions. (7, FIGURE 67-98) IS NOT PERMITTED.

NOTE 67-318. Removal

The following procedure is applicable to
anti-torque rotary actuators used when the 1. Remove large round access panel from bottom of
optional 4-axis AFCS/Flight Director kit is aft fuselage. Open access door on right lower side of aft
installed. For magnetic brakes used in the fuselage (Chapter 52).
anti-torque system, refer to paragraph
67-247.
2. Remove tailboom assembly (Chapter 53).

67-316. Installation
3. Disconnect electrical connectors (8, Figure
67-98).
NOTE
Ensure arm (10, Figure 67-97) is properly
4. Remove cotter pin (1), nut (2), washer (3), bolt (6),
installed on rotary actuator (7) as outlined in
and washer (5).
paragraph 67-279 rigging instructions.

1. Position rotary actuator (7) on structure (5). Install 5. Remove cotter pin (14), nut (13), washers (10 and
four bolts (9) and four aluminum washers (8) as follows: 12), and bolt (9).

a. Install aluminum washers (8) with each bolt (9). NOTE

The removal of clamps that secure the
b. Install four bolts (9) of correct length to obtain electrical cable assemblies will allow
proper thread engagement. Three different length bolts sufficient deflection of cables for actuator
are required. removal.

c. Install bolts (9) with drilled heads in two inboard 6. Remove cotter pin (15), nut (16), washer (17), and
holes in rotary actuator (7) and structure (5). bolt (18).

2. Position force gradient (1) on stud (4) of arm (10). 7. Remove cotter pin (19), nut (20), washer (21),
Install nut (3) and cotter pin (2). spacer (22), and bolt (23). Remove bellcrank (24).

3. Install electrical connector (6). 8. Disconnect clamps securing electrical cable

4. Move anti-torque controls through full travel and
check for binding and/or obstructions.
5. Confirm that anti-torque control rigging is within
limits in paragraph 67-279.
assemblies, located aft of servo actuator.
9. Pull servo actuator aft as far as possible, then
change angle and reposition actuator as necessary to
allow for removal through round access panel at bottom
of aft fuselage. Remove servo actuator (7).

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BHT-412-MM-8

Figure 67-98. Anti-Torque Servo Actuator Removal/Installation (36087 and Subsequent)

67-00-00
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 BHT-412-MM-8

67-319. Inspection 5. Install bolt (9), washer (10), washer (12), nut (13),
and cotter pin (14).
1. Inspect servo actuators (7, Figure 67-98) in
accordance with procedures in BHT-412-CR&O.
6. Re-install clamps to secure cable assemblies.

2. Inspect bellcrank sleeve (25) and bearing (26) for

wear, damage, or corrosion. 7. Install bellcrank (24) and attach with bolt (23),
spacer (22), washer (21), nut (20), and cotter pin (19).

8. Attach bolt (18), washer (17), nut (16), and cotter

CAUTION pin (15).

DISASSEMBLY OF SERVO ACTUATOR 9. Move anti-torque controls through full travel and
(7, FIGURE 67-98) IS NOT PERMITTED. check for obstructions and/or binding.

67-320. Installation 10. Connect electrical connectors (8).

1. Establish overall dimensions of servo actuators (7,

11. Install tailboom assembly (Chapter 53).
Figure 67-98) as shown in Figure 67-94.

2. Place servo actuator (7, Figure 67-98) into position 12. Confirm that anti-torque rigging is within limits
with rod end bearing in bellcrank (4). (paragraph 67-274).

3. Install bolt (6), washer (5), washer (3), nut (2), and 13. Install access panel on bottom aft fuselage
cotter pin (1). (Chapter 52).

4. Place forward end of servo actuator (7) on 14. Close access door on right side of aft fuselage
anti-torque control lever (11). (Chapter 52).

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BHT-412-MM-8

Figure 67-99. Anti-Torque Series Actuator (36087 and Subsequent)

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