BHT-41 2CAA-MM-1

all MODEL 412

MAINTENANCE
MANUAL
SUPPLEMENT FOR
C.A.A. CONFIGURATION WITH
X

APPROVED MAXIMUM GROSS WEIGHT

TO 11,900 POUNDS (5398 Kilograms).

Bell Helicopter A Subsidiary of Textron Inc.

Post Office Box 482 Fort Worth, Texas 76101

0

0
 BHT-41 2-CAA-MM-1

all MODEL 412

MAINTENANCE
MANUAL
SUPPLEMENT FOR
C.A.A. CONFIGURATION WITH
APPROVED MAXIMUM GROSS WEIGHT
TO 11,900 POUNDS (5398 Kilograms).

Bell Helicopter El I
A Subsidiary of Textron Inc.
z

Post Office Box 482 Fort Worth, Texas 76101 7 November 1988
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3
 BHT-412-CAA-MM-1

LIST OF EFFECTIVE PAGES

Insert latest revision pages; dispose of superseded pages.
CD

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a)
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NOTE: On a revised page, the portion of the text and illustration affected by the latest revision is indicated by a

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a)
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vertical line. Revisions to wiring diagrams are indicated by shaded areas.

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Original..........07 November 1988
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Page Revision
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No. No.
Cover ................0
Title .................0
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A/B..................0
LC ..................0
1-111-2 ...............0
4-1/4-2 ...............0
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4-3/4-4 ...............0
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5-1/5-2 ...............0
5-3/5-4 ...............0
5-515-6 ...............0
5-7/5-8 ...............0
5-9/5-10 ..............0
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5-11-5-12 ...........0
5-1315-14 .............0

Additional copies of this publication may be obtained by contacting:

Commercial Publication Distribution Center
Bell Helicopter Textron
P.O. Box 482
Fort Worth, Texas 76101

A/B
 BHT-412-CAA-MM-1

LIST OF CHAPTERS

Chapter

Q)
INTRODUCTION
INTRODUCTION ............................................................ 1-00-00
AIRWORTHINESS
AIRWORTHINESS LIMITATIONS AND COMPONENT
LIMITATIONS OVERHAUL OVERHAUL ..........................
AND COMPONENT 4-00-00
INSPECTIONS
INSPECTIONS ............................................................. 5-00-00

LC
 BHT-412-CAA-MM-1

TO USE, BEND BOOK SLIGHTLY AND FOLLOW MARGIN INDEX TO

PAGE WITH BLACK EDGE MARKER.

1-00-00
INTRODUCTION

4-00-00
AIRWORTHINESS
LIMITATIONS

5-00-00
INSPECTIONS

THE RIGHT INDEX COLUMN IS FRONT OF BOOK PROCEEDING TO REAR WITH EACH COLUMN.
 INTRODUCTION

GENERAL
2
r-1 CC)D.-1

This supplement pertains to CAA configured Model

0a)

a)
412 helicopters with approved maximum gross weight
to 11,900 lbs. (5398 Kg.). Only the differences
O
between standard FAA Model 412 helicopters and
CAA Model 412 helicopters are addressed in this
supplement.

The differences occur only in Chapter

Chapter 44 (Airworthiness

_:r
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a)

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c

Chapter 55 (Inspections).
Limitations) and Chapter
LC)
-

Data contained in this supplement modifies,

0

a)
supercedes, or is in addition to, that data contained in
C)

basic manual BHT-412-MM-1

BHT-412-MM-1 dated 15 January 1981
and subsequent revisions.
 BHT-412-CAA-MM-1

CHAPTER 4

AIRWORTHINESS LIMITATIONS AND COMPONENT

OVERHAUL

TABLE OF CONTENTS

Paragraph Page
Number Title Number

z
CD
AIRWORTHINESS LIMITATIONS

Refer to Mandatory Airworthiness Limitations Schedule 4-3

 BHT-412-CAA-MM-1

MANDATORY AIRWORTHINESS LIMITATIONS SCHEDULE

AIRWORTHINESS
COMPONENT PART NUMBER

TRANSMISSION

Main Input Bevel Gear 204-040-701-103

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NOTES:-

A\
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C)

REMOVE GEAR FROM SERVICE WHEN:

m

m
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m
>

>

a. Torque equals or exceeds 108%

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CD

OR

b. Airworthiness Factor equals or exceeds 1.0.

Determine Airworthiness Factor as follows:-
'
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Duration Duration
c

(in minutes) (in minutes)

of operation of operation
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from 100.5% to from 105.1% to

0

105.0% torque + 107.9% torque = Airworthiness Factor

LC)

N
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50
0

100
 BHT-412-CAA-MM-1

CHAPTER 5

INSPECTIONS

TABLE OF CONTENTS

Paragraph Page
Number

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Number Title

5-1 Inspections 5-3

5-2 Daily Inspection 5-5
5-8 20 Hour Inspection 5-7
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5-11 Conditional Inspection 5-9

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0a)

5-12 CAA Model 412 Overtorque Conditional Inspection 5-11

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 SCHEDULED INSPECTIONS

5-1 INSPECTIONS

In addition to the scheduled inspections contained in

C)
CD
CD

CD
BHT-412-MM-1
the basic maintenance manual, BHT-412-MM-1,
accomplish the following:
 BHT-412-CAA-MM-1

5-2 CAA MODEL 412 - DAILY INSPECTION (VISUAL)

DATE
SIGNATURE
HELICOPTER REGISTRATION NO.
HELICOPTER HOURS

INITIAL EACH ITEM AFTER ACCOMPLISHMENT

INITIAL
5-3 TRANSMISSION

1. External surfaces for oil leakage or seepage and physical damage.

x

2. Oil filter for by-pass indication.

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5-4 MAIN INPUT DRIVESHAFT

External surfaces for evidence of grease leakage and overheating (refer to basic manual 20
0

HOUR INSPECTION for detailed procedures).

5-5 INTERMEDIATE GEARBOX

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External surfaces for oil leakage or seepage and physical damage.

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5-6
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TAIL ROTOR DRIVE AND COMPONENTS

-

Tail rotor gearbox, driveshafts, hangers and couplings for evidence of physical damage.
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x

Inspect hangers and couplings for grease leakage and evidence of overheating (refer to
basic manual 20 HOUR INSPECTION for detailed procedures).
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5-7 OVERTORQUE MONITORS

1. Record (or log) duration of any recorded overtorque.

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2. Reset monitors.

5-515-6
 BHT-412-CAA-MM-1

5-8 CAA MODEL 412 - 20 HOUR INSPECTION

NOTE: Accomplish the following check(s) in addition to those contained in the basic maintenance
m
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c6
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C)
4

CD
..

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o

D)

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a)
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BHT-412-MM-1
manual, BHT-412-MM-1.
CD

DATE

SIGNATURE
HELICOPTER REGISTRATION NO.
HELICOPTER HOURS

INITIAL EACH ITEM AFTER ACCOMPLISHMENT

INITIAL
5-9
m

FUSELAGE
w

Inspect transmission chip detectors for debris. Clean detectors and VERIFY PROPER

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-a'

>
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OPERATION.

5-10 TAILBOOM
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Inspect intermediate and tail rotor gearbox chip detectors for debris. Clean detectors and
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4
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a)
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VERIFY PROPER OPERATION.
 CONDITIONAL INSPECTIONS

5-11 CONDITIONAL INSPECTIONS

Accomplish the following in addition to those

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a)
inspections contained in basic maintenance manual,
.V)
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BHT-412-MM-1
BHT-412-MM-1.
 BHT-412-CAA-MM-1

5-12 CAA MODEL 412 AFTER OVERTORQUE CONDITIONAL INSPECTION.

DATE
m

SIGNATURE
HELICOPTER REGISTRATION NO.
HELICOPTER HOURS

MAIN ROTOR BLADES SERIAL NO. HOURS

C
MAIN ROTOR HUB
TAIL ROTOR BLADES

TAIL ROTOR HUB

INTERMEDIATE GEARBOX
TAIL ROTOR GEARBOX
TAIL ROTOR DRIVESHAFTS

TAIL ROTOR DRIVESHAFT HANGERS

SWASHPLATE & SUPPORT

HUB AND SLEEVE (ROTATING CONTROLS)
MAIN ROTOR MAST
TRANSMISSION
MAIN INPUT DRIVESHAFT
POWER PLANT NO. 1
POWER PLANT NO.2
COMBINING GEARBOX

5-11
BHT-412-CAA-MM-1

5-12 CAA MODEL 412 AFTER OVERTORQUE CONDITIONAL INSPECTION (Cont).

I

INITIAL EACH ITEM AFTER ACCOMPLISHMENT

INITIAL
Overtorque is defined as any incident in which torsional loads are introduced into the helicopter
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P4
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C)
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dynamic system in excess of established limits.
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NOTE: Evaluate components removed from a helicopter following an overtorque as an interrelated

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0)00

-'.4

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CD
C

>a)
group. Make entries in component records to cross-reference part and serial numbers of other drive
CD'

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.

system components removed for evaluation.

1

1. Refer to Pratt and Whitney Aircraft of Canada PT6T-3B Maintenance Manual for engine
C)
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CD

CD
CD

CD

CD
C

a)
overtorque inspection limits.

2. When overtorque has exceeded 100.5% but did not exceed 105%, no inspection is required.
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+
C

C
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3. When overtorque has exceeded 105% but did not exceed 108%, perform a thorough visual
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a)a

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inspection of the following components: -
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E
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a. Tail rotor hub.

b. Intermediate gearbox.

c. Tail rotor gearbox.

d. Tail rotor driveshaft.

e. Tail rotor driveshaft hangers.

f. Swashplate.

g. Main driveshaft.

h. Mast.
i. Transmission.
P4

j. Chip detectors. Check transmission (3 locations), intermediate gearbox and tail rotor gearbox
0)
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3
U U

a)

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-CD

chip detectors. Clean and verify proper operations.

CD

.
 BHT-412-CAA-MM-1

5-12 CAA MODEL 412 AFTER OVERTORQUE CONDITIONAL INSPECTION (Cont).

c
INITIAL EACH ITEM AFTER ACCOMPLISHMENT

INITIAL
k. Inspect main transmission internal filter and pump inlet screen.

-
-
a
a
(1) If metal particles indicating internal failure are found, remove the transmission for overhaul
evaluation. Make entry in component record that reason for removal was overtorque. Remove all

o
<
NE-
.

transmission system oil lines and oil cooler. Replace external oil filter element. Flush and install lines.
C 0

Install new oil cooler. Tag old cooler, metal particle contaminated, and return for overhaul.
-

o
E

(2) If chip detector, internal filter and pump inlet screen appear normal, and there is no
.-Ca)a

evidence of internal failure, operate the transmission for five hours, then check chip detector, internal

-
0
<

a
filter and pump inlet screen. If chip detector, filter, and screen inspection does not reveal metal
a

particles, the transmission is satisfactory for continued service. If metal particles are found or if there is

-
>..C

an evidence of internal failure, remove the transmission for overhaul evaluation. Clean oil lines, replace
B

oil cooler, replace external oil filter element and make record entries as prescribed in preceding step (1).
=

a)
4. When overtorque has exceeded 108 percent.
<

a. Return the following components to an overhaul facility for overhaul evaluation.

-
0

a)

0
NOTE: Component removal record of dynamic components shall reflect overtorque as reason for
W

C'
<

0
0

0
°

0
C
C

>
removal.

(1) Transmission.

(2) Main driveshaft.

C

(3) Main rotor hub.

(4) Mast.
(5) Perform thorough visual inspection of other components outlined in previous step 3.
.
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C