BHT-212-MM-2

CHAPTER 12 — SERVICING

TABLE OF CONTENTS

Paragraph Chapter/Section Page

Number Title Number Number

SERVICING

12-1 Servicing ........................................................................................ 12-00-00 3

12-1A Servicing Tolerance ....................................................................... 12-00-00 3
12-2 Main Fuel System .......................................................................... 12-00-00 3
12-3 Main Fuel System — Fueling/Defueling Preparation................ 12-00-00 6
12-4 Main Fueling System — Fueling............................................... 12-00-00 7
12-5 Main Fueling System — Defueling ........................................... 12-00-00 7
12-6 Main Fuel System — Purging Fuel Cells .................................. 12-00-00 8
12-7 Oil System...................................................................................... 12-00-00 9
12-8 Changing Oil Types .................................................................. 12-00-00 9
12-9 Engine Oil System .................................................................... 12-00-00 10
12-10 Transmission Oil System ............................................................... 12-00-00 10
12-11 Transmission Oil System — Seepage Rates............................ 12-00-00 10
12-12 Tail Rotor Gearboxes..................................................................... 12-00-00 10
12-13 Tail Rotor and Intermediate Gearbox Oil Systems —
Seepage Rates ......................................................................... 12-00-00 10
12-14 Main Rotor Hub.............................................................................. 12-00-00 11
12-15 Stabilizer Bar Dampers .................................................................. 12-00-00 11
12-16 Hydraulic Systems ......................................................................... 12-00-00 11
12-17 Rotor Brake Servicing .................................................................... 12-00-00 11
12-17A Hydraulic Fluid Conversion — Change of Specification ................ 12-00-00 12A
12-18 Battery............................................................................................ 12-00-00 12D
12-19 Fire Extinguishers .......................................................................... 12-00-00 12D
12-20 Engine Fire Extinguisher Bottles............................................... 12-00-00 12D
12-21 Portable Fire Extinguishers....................................................... 12-00-00 12D

LUBRICATION

12-22 Lubrication ..................................................................................... 12-00-00 13

12-23 Deleted ..................................................................................... 12-00-00 14
12-24 Lubrication — Lubricant Restrictions (204-040-755-005) ......... 12-00-00 14
12-25 Flex Coupling Lubrication Log ....................................................... 12-00-00 14

FIGURES

Figure Page
Number Title Number

12-1 Servicing Points .................................................................................................. 4

12-2 Rotor Brake Servicing ......................................................................................... 12
12-3 Lubrication Chart (Sheet 1 of 4).......................................................................... 16

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TABLES

Table Page
Number Title Number

12-1 Servicing Materials and Capacities..................................................................... 5

12-2 Flex Couplings Lubrication Log (Example Only)................................................. 15

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SERVICING

12-1. SERVICING The Bell Helicopter Textron approved tolerance for

Chapter 12 servicing intervals, unless otherwise
stated, is 10% of the specified hourly or calendar time
interval, whichever is less. The tolerances are
CAUTION established for maintenance scheduling convenience
only.
STRAINED OR DISCOLORED SIGHT
GAUGE GLASSES MAY GIVE FALSE Servicing intervals required beyond the stated
INDICATION OF OIL/FLUID QUANTITY. IF tolerances must be approved by Product Support
FALSE INDICATION IS SUSPECTED, Engineering.
SHAKE HELICOPTER BY TAIL SKID AND
OBSERVE SIGHT GAUGE OIL/FLUID
MO V E M EN T. RE P LA CE A NY S I G HT
NOTE
G A U G E G L A S S T H AT D O E S N O T
PROVIDE ADEQUATE INDICATION OF The following is only applicable for those
FLUID LEVEL. operators whose governing aviation
authority requires to specifically approve
This chapter contains instructions to replenish fuel, the servicing tolerance.
lubricating oil, and hydraulic fluid, and to lubricate the
helicopter. Defueling and fuel cell purging instructions If approval of the servicing tolerance is required by the
are also included. applicable governing aviation authority, this is the
responsibility of the owner/operator.
Figure 12-1 identifies servicing points, defueling, and
drain valve locations. Table 12-1 specifies usable
materials for fuel, lubricating oil, and hydraulic fluid. Refer to the Pratt & Whitney PT6T-3/-3B Maintenance
Manual for the engine servicing tolerances.
12-1A. SERVICING TOLERANCE
12-2. MAIN FUEL SYSTEM

CAUTION All five interconnected cells of the main fuel system

are serviced through a single filler located on the right
side of the helicopter. A grounding jack is provided
DO NOT APPLY THESE TOLERANCES IF near the filler. Sump drains are located in the bottom of
THE HELICOPTER IS OPERATED IN the right and left fuel cells beneath the cabin floor.
EXTREME ENVIRONMENTAL System defuel valves are accessible through the
CONDITIONS REQUIRING AN bottom skin behind the aft cabin bulkhead. A system
INCREASED FREQUENCY OF filter is located ahead of each of the two engine power
SERVICING. OTHERWISE, DAMAGE TO sections. The filters are connected to the caution panel
THE PARTS MAY OCCUR. for indication of an impending bypass condition.

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Figure 12-1. Servicing Points

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Table 12-1. Servicing Materials and Capacities

MATERIAL
NOMENCLATURE CAPACITY REMARKS
SPECIFICATION

MAIN FUEL SYSTEM

Turbine Fuel BHT-212-FM 217.0 gallons All ambient temperatures.

ENGINE OIL SYSTEM

Lubricating Oil BHT-212-FM 1.60 gallons Left power section. Do not

mix oils.

Lubricating Oil 1.60 gallons Right power section. Do

not mix oils.

Lubricating Oil 1.25 gallons Combining gearbox. Do

not mix oils.

TRANSMISSION OIL SYSTEM

Lubricating Oil BHT-212-FM 11.0 quarts Do not mix oils.

INTERMEDIATE GEARBOX

Lubricating Oil BHT-212-FM 0.19 quart Do not mix oils.

TAIL ROTOR GEARBOX

Lubricating Oil 0.40 quart Do not mix oils.

MAIN ROTOR HUB BLADE GRIPS

Lubricating Oil BHT-212-MD-1 1.0 quart per grip Do not mix oils.

PILLOW BLOCKS

Lubricating Oil BHT-212-MD-1 0.12 quart per block Do not mix oils.

HYDRAULIC SYSTEM NO. 1

Hydraulic Fluid BHT-212-FM 4.7 quarts

HYDRAULIC SYSTEM NO. 2

Hydraulic Fluid 4.25 quarts

Hydraulic Fluid Reservoirs 2.64 quarts per reservoir

ROTOR BRAKE SYSTEM

Hydraulic Fluid BHT-212-FM 1.0 pint

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12-3. MAIN FUEL SYSTEM — FUELING/ 4. Do not perform fueling/defueling near a drainage
DEFUELING PREPARATION ditch or similar low place where combustible vapors
may accumulate.

WARNING 5. Do not perform fueling/defueling in a hangar.

Position helicopter at least 50 feet (15 m) from any
building or smoking area, and at least 500 feet (152 m)
from any radar system.
USE EXTREME CAUTION DURING
FUELING/DEFUELING PROCEDURES.
FUEL IS EXTREMELY FLAMMABLE AND 6. Do not allow another aircraft to operate within 100
M AY B E I G N I T E D B Y S TAT I C O R feet (30 m) of the area.
FRICTION SPARK S, HOT EXHAUST
PIPES, LIGHTED CIGARETTES, 7. Position servicing unit as far from helicopter as
ELECTRICAL DEVICES, OR SIMILAR hose will permit, and such that it may be driven or
IGNITION SOURCES. towed away in case of an emergency. Set parking
brake.
PERSONNEL SHOULD NOT BE ABOARD
HELICOPTER DURING FUELING/ 8. Position a fully charged 50-pound (22 kg) CO2
DEFUELING PROCEDURES. fire extinguisher with an extension assembly in an
accessible place. Make sure fire extinguishers on
WHEN HELICOPTER FUEL COMES IN service unit are readily available.
C O N TA C T W I T H S K IN , A S O LV E N T
ACTION OCCURS WHICH REMOVES
9. Maintain clear paths for immediate evacuation of
NATURAL FATS AND OIL THAT MAY
personnel and vehicles in case of emergency.
EXPOSE THE SKIN TO INFECTIOUS
D E R M ATO S I S . E X T E N S I V E VA P O R
INHALATION MAY CAUSE SERIOUS 10. Do not allow other aircraft within 20 feet (6 m) of
ILLNESS. ACCIDENTAL SWALLOWING helicopter.
OF FUELS WILL RESULT IN INTERNAL
I N J U R Y A N D P O S S I B L E D E AT H . 11. If fuel cell filler cap is to be removed for any
PERSONNEL WHO ARE SUBJECTED TO reason other than fueling, grasp helicopter grounding
S P L A S H E D O R S P R AY E D F U E L jack adjacent to fuel cell filler cap with bare hand to
SHO ULD REMOV E CONTAMINATED dissipate static electricity prior to removing cap.
CLOTHING AS SOON AS POSSIBLE AND
WASH DOWN/SHOWER WITH LARGE
A M O U N T S O F WAT E R . D O N O T
REMOVE CONTAMINATED CLOTHING WARNING
NEAR POTENTIAL IGNITION SOURCES.

1. Allow only qualified personnel engaged in fueling/ ACCOMPLISH THE BONDING

defueling operations in the area. Allow no one to carry PROCEDURES IN THE FOLLOWING
matches, cigarette lighters, or other sparking or flame STEPS IN ORDER LISTED OR STATIC
producing devices in the area. ELECTRICITY MAY CAUSE FUEL TO
IGNITE AND CAUSE INJURY OR
DAMAGE TO EQUIPMENT.
2. Do not perform fueling/defueling operations when
high winds are considered hazardous or when 12. Bond fueling/defueling equipment and helicopter
electrical storms are within 3 miles (5 km) of the area. as follows prior to removing fuel hose filler dust cap
and/or helicopter fuel cell filler cap or prior to using
3. Do not allow personnel fueling/defueling the defueling valve.
helicopter to wear shoes with protruding nails or taps,
or static producing clothing such as nylon, rayon or a. Bond fueling equipment to the helicopter by
wool. use of a cable.

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b. Bond fuel hose nozzle with a nozzle bonding 11. In the event of a fire emergency, accomplish the
cable to one of the helicopter grounding jacks. following as quickly as possible:

12-4. MAIN FUELING SYSTEM — FUELING a. Stop fuel flow.

1. Accomplish fueling preparation steps outlined in b. Separate helicopter and service unit.
paragraph .
c. Sound alarm.
2. Make sure helicopter electrical power is off. If
electrical power is required, turn BATTERY BUS 1 and d. Attempt rescue and contain fire.
2 switches ON and position remaining switches as
required prior to start of fueling operation. Do not 12-5. MAIN FUELING SYSTEM — DEFUELING
accomplish further switching until fueling is complete,
except as required by an emergency condition. 1. Accomplish defueling preparation steps outlined
in paragraph .
3. Confirm fuel in fueling vehicle is correct type prior
to refueling. Refer to Table 12-1 for list of approved NOTE
fuels.
If helicopter is being defueled with
defueling type vehicle, accomplish step 2
NOTE through step 14.
Comply with bonding instructions in step 12 If helicopter is being defueled with boost
of paragraph prior to accomplishing pumps, accomplish step 15.
following steps.
2. Notify fire department of defueling operation,
4. Remove fuel hose nozzle dust cap. location, anticipated start time, and estimated time of
completion.
5. Remove fuel cell filter cap.
3. Make sure that all electrical power is off.

CAUTION NOTE
Comply with bonding instructions in step 12
of paragraph prior to accomplishing
DO NOT LEAVE NOZZLE UNATTENDED following steps.
AT A NY T IM E DUR ING R EF UE LI NG
OPERATION. 4. If helicopter is being defueled because of an
accident or incident, or if quality of fuel is questionable,
6. Fill fuel cells and then remove hose nozzle from sample and test drained fuel. Dispose of fuel or return
fuel cell. fuel to storage as test results indicate.

7. Install filler cap and nozzle dust cap.

NOTE
8. Place BATTERY BUS switches and required Comply with bonding instructions in step 12
system switches to OFF, if required. of paragraph prior to accomplishing
following steps.
9. Remove fuel hose nozzle bonding cable from 5. Make sure that all helicopter electrical power is
helicopter grounding jack. off. If electrical power is required, turn BATTERY BUS
switches ON and position other switches as required
10. Remove bonding cable from helicopter and prior to starting defueling operation. Do not
fueling equipment. accomplish additional switching until defueling is

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complete, except as required by an emergency 12-6. MAIN FUEL SYSTEM — PURGING FUEL
condition. CELLS

6. Remove filler cap and insert defueling tube/hose

into helicopter fuel cell. MATERIALS REQUIRED

7. Pump fuel from helicopter. Stop pump as soon as Refer to BHT-ALL-SPM for specifications.
fuel flow stops.
NUMBER NOMENCLATURE

8. Remove defueling tube/hose and replace filler C-009 Lubricating Oil

cap. Disconnect defuel tube/hose ground wire from
helicopter.

WARNING
9. Remove access plates under fuel cell sumps.

10. Position suitable container under helicopter. ON A STILL DAY (NO WIND CONDITION),
FUEL VAPOR CAN ACCUMULATE IN
11. Remove plugs from defuel valves. AREA OF HELICOPTER (EVEN IN AN
OPEN AREA), POSSIBLY PRODUCING
AN EXPLOSIVE MIXTURE. UNDER THIS
12. Disconnect cable from helicopter and defueler CONDITION, PERSONNEL SHOULD BE
equipment. Move defueler away from helicopter. CLEARED FROM AREA EVEN AFTER
PURGE LINES ARE INSTALLED AND
13. Dispose of fuel as noted in step 4. INERT GAS IS FLOWING UNTIL 8
HOURS OF PURGING IS COMPLETED.
14. Purge fuel cells as outlined in paragraph 12-6.
1. Defuel helicopter (paragraph 12-5).

15. Defuel with helicopter boost pumps as follows:

NOTE
a. Accomplish step 2 through step 5. Use dry, filtered compressed air or inert gas
(nitrogen or carbon dioxide) as outlined in
b. Disconnect engine fuel pressure hose above step 2 and step 3.
engine deck. Connect a suitable hose to engine fuel
pressure connection that will transfer fuel to a suitable 2. Purge fuel cells using dry, filtered, compressed air
container or servicing unit. as follows:

c. Open fuel cell interconnect valves and actuate a. Open all sump drains and drain lines.
appropriate boost pump to pump fuel out of helicopter.
b. Insert compressed air hose in cell filler inlet
d. Shut off boost pump as soon as fuel flow under cap and seal with masking tape.
stops.
c. Blow air through cell at 60 to 100 PSI (414 to
e. Install hose disconnected in step b. 689 kPa) for a period of 8 hours.

f. Disconnect grounding cables. d. Remove air hose from cell inlet. Wait 1 hour.

g. Dispose of fuel as noted in step 4. e. Check interior of fuel cell with explosimeter
(combustible gas indicator calibrated for fuel vapors)
h. Purge fuel cells (paragraph 12-6). for level of vapors.

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f. Explosimeter reading shall be less than 20%. 12-7. OIL SYSTEM

If reading is more than 20%, repeat step a through
step c until reading is less than 20%.
The engine, transmission, tail rotor drive gearboxes,
and main rotor hub may be serviced with
3. Purge fuel cells using inert gas (nitrogen or MIL-PRF-7808. MIL-PRF-23699, or DOD-PRF-85734
carbon dioxide) as follows: (C-030) (except engine) lubricating oil. Refer to the
BHT-212-FM for a list of approved oils and restrictions.

WARNING
NOTE
Transmissions modified to
REMOVE FIBER HORN WHEN USING A 212-040-001-131 require DOD-PRF-85734
FIRE EXTINGUISHER BOTTLE AS A (C-030) lubricating oil or MIL-PRF-7808
SOURCE OF CARBON DIOXIDE (CO 2 ) lubricating oil (C-010) only. Helicopters
FOR PURGING FUEL CELLS. GROUND using 212-040-001-131 transmission may
NOZZLE TO HELICOPTER. DISCHARGE also use DOD-PRF-85734 (C-030)
C O 2 I N T O F U E L C E L L S L O W LY ( 1 lubricating oil in intermediate and tail rotor
POUND PER MINUTE). RAPID PASSAGE gearboxes (BHT-212-FM).
OF GAS THROUGH A HOSE CAN
G E N E R AT E S TAT I C E L E C T R I C A L It is recommended when systems are serviced, either
CHARGES. RAPID DISCHARGE OF GAS for an oil change or routine quantity serving, that the
ALLOWS RAPID EXPANSION OF GAS
oil container be agitated prior to opening. If oil
(LOWERING THE TEMPERATURE WITH
pressure fluctuation is accompanied by foaming, drain
PO SSIB LE DA MAG E TO CE LL A S A
and service with agitated oil. When using quart cans,
RESULT). NITROGEN OR OTHER INERT
open end that has been on bottom during storage.
GAS MAY BE USED WITH THE SAME
PRECAUTIONARY MEASURES
OUTLINED ABOVE. 12-8. CHANGING OIL TYPES

a. Open all sump drains and drain lines.

NOTE
b. Insert gas hose in cell filler inlet and seal with An appropriate entry shall be made in
masking tape. helicopter and engine logbooks. The entry
shall show type and brand name of oil to
c. Blow inert gas through cells for a period of 8 prevent inadvertent mixing of lubricating
hours. oils. Refer to engine manufacturer’s
manual for additional information, and oil
change intervals for the engine.
d. Shut off inert gas flow and remove gas hose
from cell inlet. Wait 1 hour.
NOTE
e. Check interior of fuel cell with explosimeter Do not use MIL-PRF-23699 (C-011) or
(combustible gas indicator calibrated for fuel vapors) DOD-PRF-85734 (C-030) lubricating oil
for level of fuel vapors. when ambient temperature falls below
-40°F (-40°C).
f. Explosimeter reading shall be less than 20%.
If reading is more than 20%, repeat step a through 1. Before changing types of lubricating oil from
step c until reading is less than 20%. MIL-PRF-7808 (C-010) to MIL-PRF-23699 (C-011) or
DOD-PRF-85734 (C-030), replace decals shown in
4. Fog interior of fuel cell with lubricating oil (C-009). Chapter 11 with appropriate decals denoting type of
Close drains and replace filler cap. Do not close vents. lubricating oil in system.

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strainer may be drained by opening the drain valve

NOTE
located on the engine deck. Avoid excessive oil
MIL-PRF-7808 (C-010), MIL-PRF-23699 spillage if the chip detector plug is removed to
(C-011), or DOD-PRF-85734 (C-030) completely drain the system.
lubricating oils shall not be mixed. If this
should occur, drain system and refill with Engine oil system maintenance practices are
approved lubricating oil. contained in Chapter 79. Refer to the BHT-212-FM for
a list of approved oils.
2. To change oil type, perform the following steps:
12-10. TRANSMISSION OIL SYSTEM
a. Drain lubricating oil from system. Inspect and
clean filter and strainers as required. The transmission sump case serves as the reservoir
for this system. The filler is located on the upper right
b. Fill oil system with specification of lubricating side of the transmission and is accessible when the
oil to be used. forward pylon fairing is opened. Oil level sight gauges
may be viewed through the right side of the pylon
c. Operate system for a period of 30 minutes to support structure in the cabin with the aid of a light
1 hour to heat oil to operating temperature. Shut down controlled by a pushbutton switch. A sump drain valve
engine. is located directly beneath the sump. An external filter,
in return line from the oil cooler, is located inside the
d. Inspect and clean system oil filters and pylon structure at the right side and has a red indicator
strainers. If heavy contamination of filters and that will be visible when the filter is in an impending
strainers is noted, proceed with step e through step h. bypass condition. Drain valves in the oil collector lines
If little or no contamination of filters and strainers is are accessible through the bottom fuselage skin
noted, release helicopter for service and proceed with inboard of F.S. 169.0. Refer to the BHT-212-FM for a
step g and step h. list of approved oils and for the location of the filler.
Maintenance practices are contained in Chapter 63.
e. Drain lubricating oil from oil system and
discard oil. 12-11. TRANSMISSION OIL SYSTEM —
SEEPAGE RATES
f. Refill oil system with specification of
lubricating oil to be used and release helicopter for Main transmission oil seepage shall not exceed two
service. drops per minute from any single source or shall not
exceed a total of 15 drops per minute from all sources
g. Inspection and cleaning of oil system fillers on transmission.
and strainers is required after 5 and 15 hours of
operating time. 12-12. TAIL ROTOR GEARBOXES

h. After 15 hour inspection of oil system filters Oil level in the intermediate and tail rotor gearboxes
and strainers, revert to normal inspection interval. may be checked on the sight gauges and replenished,
as required. Intermediate gearbox and tail rotor
12-9. ENGINE OIL SYSTEM gearbox maintenance practices are contained in
Chapter 63. Refer to the BHT-212-FM for a list of
The engine assembly has three independent oil approved oils.
systems, each with its own filler and oil level sight
gauge. Fillers and gauges for left and right engine 12-13. TAIL ROTOR AND INTERMEDIATE
power sections are outboard of the accessory GEARBOX OIL SYSTEMS — SEEPAGE
gearboxes and are accessible by opening engine RATES
cowling. The third gauge is on the aft side of the
reduction gearbox, with access through the aft right Gearbox oil seepage shall not exceed two drops per
engine cowl below the exhaust ejectors. The third minute from any single source or shall not exceed a
system oil filler is located in the aft top fairing between total of six drops per minute from all sources on a
the exhaust ejectors. The third oil system cooler and gearbox.

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12-14. MAIN ROTOR HUB A supplemental indicator is located to the right of the
helicopter centerline at W.L. 22.00, and is visible
Transparent plastic sight gauges are on grip and pillow through the lower right nose window. With the engine
block reservoirs for checking oil level. Oil level shall be running and hydraulic circuit breakers closed, a green
maintained at one-half indication. Refer to indication verifies that systems are operating without
BHT-212-MD-1 for approved lubricants. clogging. Under the same circumstances, a red
indication warns there is an impending bypass
12-15. STABILIZER BAR DAMPERS condition. Refer to the BHT-212-FM for approved
hydraulic fluid type.

The rotor brake hydraulic system is a separate

CAUTION self-contained system. Refer to Figure 12-1 for the
location of the filler, and to the BHT-212-MD-1 for
approved lubricating fluids.
ONLY USE HYDRAULIC FLUID (C-002)
MIL-PRF-5606 WHEN SERVICING THE
12-17. ROTOR BRAKE SERVICING
STABILIZER BAR DAMPERS. USE OF
HYDRAULIC FLUID (C-072)
MIL-PRF-87257 IS NOT AUTHORIZED. MATERIALS REQUIRED

Check timing and service only as necessary Refer to BHT-ALL-SPM for specifications.
(Chapter 62).
NUMBER NOMENCLATURE
12-16. HYDRAULIC SYSTEMS
C-002 or C-072 Hydraulic Fluid
Access to hydraulic reservoirs is gained by opening
the forward pylon fairing. The hydraulic system No. 1 The rotor brake hydraulic system is a separate,
reservoir is on the right side and the hydraulic system self-contained system. Refer to paragraph 12-1 for
No. 2 reservoir is on the left side. Pressure and return approved hydraulic fluid and for location of fillers.
filters, with red pop-out indicators that will be visible
when filter requires change, are located in the
1. Fully apply rotor brake.
integrated valve and filter assemblies in the pylon. The
hydraulic system No. 1 integrated valve and filter
assembly is located at the lower front center of the lift 2. Remove reservoir filler cap (1, Figure 12-2) of
beam. The hydraulic system No. 2 integrated valve rotor brake master cylinder (3), located on top, right
and filter assembly is located aft of the lift beam on the forward area of cabin roof.
left side of the pylon.
3. Check fluid level of reservoir is 0.50 inch (12.7
mm) below bottom of filler neck.
NOTE
When adding hydraulic fluid, the same
specification of hydraulic fluid already used NOTE
in the system shall be used. However, in
circumstances where emergency top-off or When adding hydraulic fluid, the same
inadvertent mixing may occur, it is specification of hydraulic fluid already used
acceptable to use hydraulic fluid of the in the system shall be used. However, in
other approved specification. No further circumstances where emergency top-off or
maintenance action will be required. To inadvertent mixing may occur, it is
change the specification of hydraulic fluid acceptable to use hydraulic fluid of the
used in the system, refer to paragraph other approved specification. No further
12-17A. maintenance action will be required. To
change the specification of hydraulic fluid
Filters may be checked from inside cabin through an used in the system, refer to paragraph
access door on the forward side of the pylon structure. 12-17A.

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SEE DETAIL A

1
0.5 IN.
(12.7 mm)

B
3
SECTION B-B
FLUID LEVEL

B 4

DETAIL A
1. Reservoir filler cap
2. Packing
3. Rotor brake master cylinder
4. Rotor brake handle

412_MM_12_0002+
Figure 12-2. Rotor Brake Servicing

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4. If fluid level is low, replenish with hydraulic fluid Complete each of the three hydraulic fluid conversion
(C-002) or hydraulic fluid (C-072). phases as follows:

5. Install reservoir filler cap (1). PHASE 1:

6. Release rotor brake by returning rotor brake NOTE

handle (4) of rotor brake master cylinder (3) to stow
position. The hydraulic cart must conform to the
requirements of Chapter 29.
12-17A.HYDRAULIC FLUID CONVERSION — 1. Prepare the hydraulic cart as follows:
CHANGE OF SPECIFICATION

MATERIALS REQUIRED NOTE

If the hydraulic cart does not have dual
Refer to BHT-ALL-SPM for specifications. system hoses, do the following procedure
before doing step 2 for the hydraulic system
NUMBER NOMENCLATURE
No. 1 and before doing step 2 for the
C-002 Hydraulic Fluid hydraulic system No. 2.

C-072 Hydraulic Fluid (a) Drain the hydraulic cart until 50% of
the hydraulic fluid (C-002) stays in the cart. Add
hydraulic fluid (C-072) in the hydraulic cart until it is
NOTE
full.
Hydraulic fluid (C-002) and hydraulic fluid
(C-072) are compatible and can be mixed.
NOTE

NOTE If the hydraulic cart does not have dual

system hoses, do the following on the
Hydraulic fluid (C-072) MIL-PRF-87257 hydraulic system No. 1 and then repeat the
was introduced as a customer option per procedure on the hydraulic system No. 2.
TB 212-12-213. If a conversion from
hydraulic fluid (C-002) MIL-PRF-5606 to 2. Do the following steps on the hydraulic system
hydraulic fluid (C-072) MIL-PRF-87257 is No. 1 and No. 2 and the flight controls:
being accomplished for the first time, and
as decal changes are required, accomplish a. Connect the hydraulic cart to the hydraulic test
the conversion in accorance with couplings of the hydraulic system No. 1 and No. 2
TB 212-12-213. under the left sliding door of the helicopter.

NOTE b. Turn electrical power on or apply external

In the event operators subsequently wish to power to the helicopter.
convert their hydraulic systems to use
hydraulic fluid (C-002) MIL-PRF-5606 or c. Turn the hydraulic cart on and apply 1000 PSI
hydraulic fluid (C-072) MIL-PRF-87257, the (6895 kPa) of pressure to both hydraulic systems.
following procedure is provided. Although
the procedure is written with respect to d. Let the hydraulic cart run for 30 minutes.
converting from hydraulic fluid (C-002)
MIL-PRF-5606 to hydraulic fluid (C-072) e. Move the collective stick, cyclic stick, and
MIL-PRF-87257, the hydraulic fluid types pedals to operate all the flight control actuators
specified in each step may be reversed to through full travel for a minimum of five cycles.
convert from hydraulic fluid (C-072)
MIL-PRF-87257 to hydraulic fluid (C-002) f. Operate the HYDR SYS No. 1 and HYDR
MIL-PRF-5606. SYS No. 2 switches between the On and OFF

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BHT-212-MM-2

positions five times in approximately 2-second

NOTE
intervals.
If the hydraulic cart does not have dual
g. Turn the hydraulic cart off. system hoses, do the following on the
hydraulic system No. 1 and then repeat the
procedure on the hydraulic system No. 2.
h. Turn the electrical power off or disconnect
external power from the helicopter.
2. Do the following steps on the hydraulic system
No. 1 and No. 2 and the flight controls:
i. Disconnect the hydraulic cart from the
hydraulic test couplings of the hydraulic system No. 1
a. Connect the hydraulic cart to the hydraulic test
and No. 2.
couplings of the hydraulic system No. 1 and No. 2
under the left sliding door of the helicopter.
3. For the rotor brake do as follows:
b. Turn electrical power on or apply external
a. Remove the applicable doors and panels to power to the helicopter.
get access to the bleed valves of the rotor brake
assembly. c. Turn the hydraulic cart on and apply 1000 PSI
(6895 kPa) of pressure to both hydraulic systems.

NOTE d. Let the hydraulic cart run for 30 minutes.

There is more than one type of rotor brake
assembly. Use the correct instructions. e. Move the collective stick, cyclic stick, and
pedals to operate all the flight control actuators
b. Bleed each bleed valve of the brake assembly through full travel for a minimum of five cycles.
in accordance with the instructions provided in
Chapter 63, then service the master cylinder with f. Operate the HYDR SYS No. 1 and HYDR
hydraulic fluid (C-072) (paragraph 12-17). SYS No. 2 switches between the On and OFF
positions five times in approximately 2-second
c. Repeat step b. intervals.

d. Install the previously removed doors and g. Turn the hydraulic cart off.
panels.
h. Turn the electrical power off or disconnect
external power from the helicopter.
PHASE 2: After 3 flight hours or 2 weeks
following Phase 1.
i. Disconnect the hydraulic cart from the
hydraulic test couplings of the hydraulic system No. 1
1. Prepare the hydraulic cart as follows: and No. 2.

3. For the rotor brake do as follows:

NOTE
If the hydraulic cart does not have dual a. Remove the applicable doors and panels to
system hoses, do the following procedure get access to the bleed valves of the rotor brake
before doing step 2 for the hydraulic assembly.
system No. 1 and before doing step 2 for
the hydraulic system No. 2.
NOTE
a. Fully drain the hydraulic cart. There is more than one type of rotor brake
assembly. Use the correct instructions.
b. Fill the hydraulic cart to 75% of the total
capacity with hydraulic fluid (C-072) and the remaining b. Bleed each bleed valve of the brake assembly
25% with hydraulic fluid (C-002). in accordance with the instructions provided in

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BHT-212-MM-2

Chapter 63, then service the master cylinder with f. Disconnect the return hoses from the
hydraulic fluid (C-072) (paragraph 12-17). hydraulic cart and route them into an appropriate
container to collect the discarded hydraulic fluid.
c. Repeat step b.
g. Turn electrical power on or apply external
d. Install the previously removed doors and power to the helicopter.
panels.

PHASE 3: After 3 flight hours or 2 weeks NOTE

following Phase 2. To avoid wasting fluid, perform all steps
below in tight sequence without leaving the
1. Prepare the hydraulic cart as follows: system pressurized unnecessarily. If stops
are required to prepare the next step, turn
a. Fully drain the hydraulic cart. the hydraulic cart off.

b. Fill the hydraulic cart with hydraulic fluid h. Turn the hydraulic cart on and apply 1000 PSI
(C-072) until it is full. (6895 kPa) of pressure with a flow of 3 gal/min
(11 L/min) only to the hydraulic system No. 1. The
NOTE hydraulic system No. 2 must stay unpressurized.

If the hydraulic cart does not have dual i. Move the collective stick, cyclic stick, and
system hoses, do the following on the pedals to operate all the flight control actuators
hydraulic system No. 1 and then repeat the through full travel for a minimum of five cycles.
procedure on the hydraulic system No. 2.

2. Do the following steps on the hydraulic system j. Operate the HYDR SYS No. 1 and HYDR
No. 1 and No. 2 and the flight controls: SYS No. 2 switches between the On and OFF
positions five times in approximately 2-second
intervals.
a. Remove the forward pylon fairing to get
access to the hydraulic reservoirs.
k. Let the hydraulic cart run for 1 minute.
b. Disconnect the hose from the suction outlet
fitting of the hydraulic system No. 1 and No. 2 l. Turn the hydraulic cart off.
reservoirs and drain the hydraulic fluid in a suitable
container. m. Turn the hydraulic cart on and apply 1000 PSI
(6895 kPa) of pressure with a flow of 3 gal/min
c. Connect the hose to the suction outlet fitting of (11 L/min) only to the hydraulic system No. 2. The
the hydraulic system No. 1 and No. 2 reservoirs. hydraulic system No. 1 must stay unpressurized.
Tighten the hose.
n. Move the collective stick, cyclic stick, and
d. Fill the hydraulic system No. 1 and No. 2 pedals to operate all the flight control actuators
reservoirs with hydraulic fluid (C-072) up to the correct through full travel for a minimum of five cycles.
level.
o. Operate the HYDR SYS No. 1 and HYDR
NOTE SYS No. 2 switches between the On and OFF
positions five times in approximately 2-second
If the hydraulic cart does not have dual intervals.
system hoses, do the following on the
hydraulic system No. 1 and then repeat the
p. Let the hydraulic cart run for 1 minute.
procedure on the hydraulic system No. 2.

e. Connect the hydraulic cart to the hydraulic test q. Turn the hydraulic cart off.
couplings of the hydraulic system No. 1 and No. 2
under the left sliding door of the helicopter. r. Connect the return hoses to the hydraulic cart.

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BHT-212-MM-2

s. Turn the hydraulic cart on and apply 1000 PSI

NOTE
(6895 kPa) of pressure with a flow of 5 gal/min
(19 L/min) to both hydraulic systems. There is more than one type of rotor brake
assembly. Use the correct instructions.
t. Let the hydraulic cart run for 5 minutes. b. Bleed each bleed valve of the brake assembly
in accordance with the instructions provided in
u. Turn the hydraulic cart off. Chapter 63, then service the master cylinder with
hydraulic fluid (C-072) (paragraph 12-17).
v. Turn the electrical power off or disconnect
c. Repeat step b.
external power from the helicopter.
4. Install the previously removed doors and panels.
w. If required, add hydraulic fluid (C-072) in the
reservoirs of the hydraulic system No. 1 and No. 2 up 12-18. BATTERY
to the correct level.
The nickel cadmium battery is located in the helicopter
x. Replace the four hydraulic filter assemblies nose compartment. Refer to the BHT-ELEC-SPM and
(Chapter 29). the battery manufacturer’s service manual for
servicing and maintenance.
y. Disconnect the hydraulic cart from the
12-19. FIRE EXTINGUISHERS
hydraulic test couplings of the hydraulic system No. 1
and No. 2.
12-20. ENGINE FIRE EXTINGUISHER BOTTLES

z. Install the previously removed doors and Check gauges of engine compartment fire
panels. extinguisher bottles through the inspection door in the
sides of the engine cowling. If the gauge is below
3. For the rotor brake do as follows: acceptable limit, refer to Chapter 26.

12-21. PORTABLE FIRE EXTINGUISHERS

a. Remove the applicable doors and panels to
get access to the bleed valves of the rotor brake Check gauges of portable fire extinguishers in cabin
assembly. (Chapter 26).

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BHT-212-MM-2

LUBRICATION

12-22. LUBRICATION MAY BE REMIXED THOROUGHLY WITH

THE THICKENING AGENT TO RESTORE
THE ORIGINAL LOAD CARRYING
The lubrication chart (Figure 12-3) consists of a
diagram of the helicopter with detail views. The chart CAPABILITIES. IF THERE IS A LOSS OF
shows all parts requiring periodic lubrication applied by LUBRICATING OIL FROM THE
grease gun, oil can, or by hand. This excludes the THICKENING AGENT, DISCARD THE
engine, transmission, combining gearbox, and tail ENTIRE CONTENTS OF THE GREASE
rotor gearboxes, which are lubricated by oil in DISPENSING EQUIPMENT AND
accordance with servicing instructions. REPLACE WITH A SUITABLE SUPPLY
OF APPROVED LUBRICANT (IL
The lubrication chart uses symbols and abbreviations GEN-03-93).
to indicate the required lubricant, method of
application, and time interval for lubrication of each
part listed. A key on the chart defines the meanings of
symbols and abbreviations.
CAUTION

The intervals specified are the maximum permitted DO NOT USE HIGH CAPACITY/HIGH
under normal operation. Do not exceed theses VE LO CIT Y G REA SE G UNS O N THE
intervals. It may be necessary to increase the CO MP O N E NTS . T HE U S E O F HI G H
frequency of these intervals if the helicopter operates CAPACITY/HIGH VELOCITY GREASE
in extreme environmental conditions. GUNS CAN RESULT IN DAMAGE.

1. After each day of operation in rain, snow, or after If it becomes necessary to change the brand of
washing helicopter, all exposed control bearings grease, remove the old grease by purging until only
should be purge lubricated to remove trapped new grease is present, except as otherwise specified.
moisture and ensure a lubricant film is applied to
susceptible surfaces.
NOTE
2. Parking helicopters outside in a heavy dew Prior to and following grease lubrication,
environment requires that all exposed control bearings visually examine grease fittings for
be purge lubricated every 7 days to ensure no voids presence of the spring loaded steel ball. If
exist that could trap moisture. the steel ball is not visible, does not spring
back to the closed position, the grease
3. If helicopter is stored for periods in excess of fitting indicates excessive leakage, or it is
45 days without operation or service, purge lubricate difficult to inject grease during lubrication,
all bearings. replace the grease fitting (BHT-ALL-SPM,
Chapter 8). If the grease fitting is removed
due to the spring loaded steel ball not being
visible, insert a small steel probe into the
WARNING back of the grease fitting to confirm the
presence of the steel ball. If it is identified
that the steel ball is not present in the
PRIOR TO LUBRICATION, VERIFY THE grease fitting, further investigation is
CONTENT OF GREASE DISPENSING required to ensure that the steel ball has
EQUIPMENT. IF THERE IS PARTIAL not migrated into the component and
SEPARATION OF THE LUBRICATION OIL caused damage. Discard grease fittings
FROM THE THICKENING AGENT, OIL that have been removed.

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BHT-212-MM-2

12-23. DELETED 1. Lubricant (tube pack) (C-015) 204-040-755-005

shelf life is 4 years from packing date on container.
12-24. LUBRICATION — LUBRICANT
RESTRICTIONS (204-040-755-005)
NOTE
Make sure grease is thoroughly mixed prior
MATERIALS REQUIRED to use.

Refer to BHT-ALL-SPM for specifications. 2. In-stock components which utilize lubricant (tube
pack) (C-015) 204-040-755-005 must be pulled from
NUMBER NOMENCLATURE
stock and relubricated upon expiration of the original
C-015 Lubricant (Tube Pack) 4-year shelf life of the lubricant.
204-040-755-005
3. Once a component lubricated with lubricant (tube
pack) (C-015) 204-040-755-005 goes into service, the
relubrication interval is dictated by the calendar and
WARNING service-time schedule, whether the component is
installed on a helicopter or is subsequently removed
and returned to stock as a spare on the shelf.
LUBRICANT MAY CAUSE EYE AND SKIN
IRRITATION. AVOID CONTACT WITH
12-25. FLEX COUPLING LUBRICATION LOG
EYES, SKIN, AND CLOTHING. WASH
THOROUGHLY AFTER HANDLING.

MATERIALS REQUIRED
NOTE
Do not exceed lubrication intervals Refer to BHT-ALL-SPM for specifications.
specified on lubrication chart.
NUMBER NOMENCLATURE

C-015 Lubricant (Tube Pack)

CAUTION 204-040-755-005

LUBRICANT IN ORIGINAL TUBES AND The flex coupling lubrication log as shown in
COMPONENTS CONTAINING Table 12-2 shall be maintained any time a component
LUBRICANT (TUBE PACK) (C-015) using lubricant (tube pack) (C-015) 204-040-755-005
204-040-755-005 MUST BE STORED AT is installed on the helicopter. This log shall be
MODERATE AMBIENT TEMPERATURES, maintained listing date lubricant 204-040-755-005 was
PREFERABLY LESS THAN 80°F (26.7°C). applied in component. This lubricant carries an
ELEVATED STORAGE TEMPERATURES operational hour and a calendar life as specified in this
PROMOTE OIL SEPARATION FROM THE chapter. Lubricant shall be replaced at requirement
LUBRICANT. occurring first (hours/months).

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BHT-212-MM-2

Table 12-2. Flex Couplings Lubrication Log (Example Only)

PART DATE AIRFRAME DATE AIRFRAME

NOMENCLATURE
NUMBER LUBRICATED HOURS LUBRICATED HOURS

Main Driveshaft

Transmission Tail Rotor

Drive Output Coupling

Tail Rotor Driveshaft

Hanger (8)

Intermediate Gearbox
Input Quill

Intermediate Gearbox
Output Quill

Tail Rotor Gearbox Input

Quill

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BHT-212-MM-2

25 HOURS

50 HOURS

100 HOURS

300 HOURS
SEE DETAIL D AND E

600 HOURS
MAIN DRIVESHAFT COUPLING
212-040-005, -001 AND -011 4 5
1000 HOURS
212-040-005-003, -007, AND -103 5 6
SIX MONTHS

1 2 3
HANGERS WITH
LUBRICATION
SEE DETAIL C FITTING

SEE DETAIL B

5 7
FLEX COUPLINGS

SEE
DETAIL
A

15 ANTI-TORQUE CONTROL
TUBE BEARINGS
(5 PLACES)

212_MM_12_0002a_c02

Figure 12-3. Lubrication Chart (Sheet 1 of 4)

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BHT-212-MM-2

1 1

1. Axle pivot point

2. Actuating cylinder trunnion
1
3. Wheel bearing
4. Pin assembly 2
9
5. Securing pin
FAR SIDE
6. Collective sleeve bearing
7. Scissor bearing
8. Swashplate bearing
9. Collective lever trunnion
10. Outer control plate trunnion
11. Control plate trunnion
12. Scissors pivot cover plate
13. Collective sleeve spline 1 5 4
1
14. Scissors pivot needle bearing 3
TWO PLACES 1
(P/N 212-010-407 scissors)
15. Crosshead bearing TWO PLACES
16. Antitorque control lever TWO PLACES
17. Pitch change link universal
18. Stabilizer centerframe bearing DETAIL A
19. Mixing lever bearing
20. Trunnion bearing
21. Main rotor grip
22. Main rotor trunnion 13

1 8 14 1 8 14

TWO PLACES 7 1
1 6

TWO PLACES
1 8 12

TWO PLACES
8 1

1 9 13 11

THREE PLACES
9 1 9
13
10 1 9 13
TWO PLACES
DETAIL B
212_MM_12_0002b

Figure 12-3. Lubrication Chart (Sheet 2 of 4)

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BHT-212-MM-2

ONE PLACE
TWO PLACES 21 1 11 EACH SIDE
EACH SIDE
ONE PLACE
EACH SIDE

17 1 8
1 8 19 22 1 11
ONE PLACE
EACH SIDE

1 8 18

TWO PLACES
EACH SIDE

DETAIL C

212-010-701
HUB AND BLADE

1 10 15

D
FW

DETAIL D
212_MM_12_0002c

Figure 12-3. Lubrication Chart (Sheet 3 of 4)

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BHT-212-MM-2

Figure 12-3. Lubrication Chart (Sheet 4 of 4)

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