TECHNICAL BULLETIN

Bell Helicopter No. 212-00-182

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MODEL AFFECTED: 212

SUBJECT: CYCLIC AND COLLECTIVE JACKSHAFTS,

INSPECTION AND MODIFICATION OF.

HELICOPTERS AFFECTED: Model 212 helicopters S/N 30502 through

31311, 32101 through 32152 and S/N 35001
through 35103.

[Model 212 helicopters S/N 35104 and

subsequent will have the intent of this bulletin
accomplished prior to delivery.]

COMPLIANCE: At operator's option but recommended at the

next 3000-hour/5-year inspection.

DESCRIPTION:

Bell Helicopter has been made aware that some cyclic and collective jackshaft
assemblies have experienced internal corrosion. This bulletin outlines the details of a
one-time jackshaft inspection and shows how to reassemble the jackshaft assemblies
to further reduce the possibility of corrosion.

APPROVAL:

The engineering design aspects of this bulletin are FAA/DER approved.

MANPOWER:

Approximately 30 man-hours are required to accomplish this bulletin. Man-hours

are based on hands-on time and may vary with personnel and facilities available.

AN APPROPRIATE ENTRY SHOULD BE MADE IN THE AIRCRAFT LOGBOOK UPON ACCOMPLISHMENT

IF OWNERSHIP OF AIRCRAFT HAS CHANGED PLEASE FORWARD TO NEW OWNER
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MATERIAL:

Consumable Material:
The following material is required to accomplish the bulletin, however this material
is considered consumable (bench stock) material and may not require ordering
depending on the operators consumable material stock levels. This material may
be obtained through your Bell Helicopter Textron Supply Center.

Part Number Nomenclature Qty Reference

MILS81733TY 11-24OZ Sealant 1 (C-392)

MILC81706 CL1AFORM11 Chemical Film Treatment 1 (C-100)
MIL-P-85582,TY1,CL2 Primer(1 Gal, 1 QT) 1 (C-204)
(513X395/91 OX710 or equivalent)
Corrosion Treatment for magnesium parts (see note below), made by mixing:
CHROMIC ACID Chromic Acid 1 LBS (C-116)
CALCIUM SULFATE Calcium Sulfate 1 Gal (C-120)

-NOTE-

Calcium Sulfate will not completely dissolve. See Standard

Practices Manual, paragraph 3-15, step 2 for mixing
procedure.

SPECIAL TOOLS:

T27872-2 Reamer

WEIGHT AND BALANCE:

Not affected.

ELECTRICAL LOAD DATA:

Not affected.

REFERENCES:

BHT 212 Maintenance Manual, Chapter 67

BHT 212 Component Repair and Overhaul Manual, Chapter 67
BHT 212 Illustrated Parts Catalog
BHT-ALL-SPM Standard Practices Manual
BHT-MED-SRM-1 Structural Repair Manual
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PUBLICATIONS AFFECTED:

BHT 212 Maintenance Manual, Chapter 67

BHT 212 Component Repair and Overhaul Manual, Chapter 67

ACCOMPLISHMENT INSTRUCTIONS:

1. Make helicopter ready for maintenance.

2. Remove crew seats, carpets (if installed), control panels from pedestal and
access panels under crew seats & aft of the pedestal to gain access to cyclic
and collective jackshafts.

3. Remove cyclic jackshaft from helicopter. Refer to Maintenance Manual, chapter

67. Tag and identify hardware for reinstallation.

-NOTE-

Refer to figure 1 for the following steps.

4. Separate levers (1) & (5) from tubes (2) & (4). Tag and identify hardware for
reinstallation.

-NOTE-

Levers (1), (3) & (5) may have been manufactured from
aluminum or magnesium. Material should be identified (refer
to Structural Repair Manual, Appendix B-3) and the
appropriate surface treatment applied, when required.
Aluminum is to be treated with chemical film (C-100) and
magnesium with corrosion treatment (C-114), refer to
Standard Practices Manual, Chapter 3. In order to remove
corrosion and to ease the reassembly of the components,
the levers (1), (3) and (5) may be machined down to 1.558 to
1.560 inch (125 RMS finish), treated with the appropriate
surface treatment (C-100 or C-114) and primed (C-204). If
the majority of the parts are found damaged beyond repair, a
complete jackshaft assembly P/N 212-001-003-109A may be
ordered. This assembly is pre-drilled & reamed and includes
levers (1), (3) & (5), tubes (2) & (4) and necessary hardware.

5. Inspect levers P/N 204-001-332-001/-005 (1) and 204-001-356-001 (5) as per

figure 2. Repair or replace parts that are found damaged or corroded beyond
limits. Refer to C R & O Manual.
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6. Inspect lever P/N 212-001-321-001 (3) as per C R & O Manual. Repair or

replace parts that are found damaged or corroded beyond limits.

7. Inspect tubes P/N 204-001-326-011 (2) & (4) per figure 3. Repair or replace
parts that are found damaged or corroded beyond limits. Refer to C R & O
Manual.

8. Reassemble lever (1) and tube (2) using Maintenance Manual, chapter 67 and
the following instructions:

a. Insert lever into tube and wet-install the bushing and bolts using sealant (C-
392).
b. Torque nuts to 50 to 70 in-lbs.
c. Completely coat both ends of bolts including washers and bushings with
sealant (C-392).
d. Seal joint between tube and lever using sealant (C-392).

9. Reassemble lever (4) and tube (5) using steps 8a thru d.

10. Reinstall cyclic jackshaft in helicopter using steps 8a thru d and referring to
Maintenance Manual, chapter 67.

11. Remove collective jackshaft from helicopter. Refer to Maintenance Manual,

chapter 67. Tag and identify hardware for reinstallation.

-NOTE-

Levers (1), (3) & (5) may have been manufactured from
aluminum or magnesium. Material should be identified (refer
to Structural Repair Manual, Appendix B-3) and the
appropriate surface treatment applied, when required.
Aluminum is to be treated with chemical film (C-100) and
magnesium with corrosion treatment (C-114), refer to
Standard Practices Manual, Chapter 3. In order to remove
corrosion and to ease the reassembly of the components,
the levers (1), (3) and (5) may be machined down to 1.558 to
1.560 inch (125 RMS finish), treated with the appropriate
surface treatment (C-100 or C-114) and primed (C-204).
Refer to figure 4 for the following steps.

12. Inspect collective jackshaft levers P/N 212-001-105-001 (1) & 212-001-124-001
(5) as per Component Repair and Overhaul, chapter 67. Repair or replace parts
that are found damaged or corroded beyond limits.

13. (SIN 30502 through 31311, 32101 through 32152 & 35001 through 35048)
Inspect collective jackshaft lever P/N 204-001-185-005 (3) as per Component
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Repair and Overhaul, chapter 67. Repair or replace parts that are found
damaged or corroded beyond limits.

14. (S/N 35049 through 35103) Inspect collective jackshaft lever P/N 212-001-248-
001 (3) as per figure 5. Repair or replace parts that are found damaged or
corroded beyond limits.

15. Inspect collective jackshaft tubes (2) & (4) as per figure 3. Repair or replace
parts that are found damaged or corroded beyond limits. Refer to C R & O
Manual.

16. Reinstall collective jackshaft using Maintenance Manual, chapter 67 and the
following instructions:

a. Insert elbow or lever into tube and wet install the bushing and bolts using
sealant (C-392).
b. Torque nuts to 50 to 70 in-lbs.
c. Completely coat both ends of bolts including washers and bushings with
sealant (C-392).
d. Seal joint between tube and lever using sealant (C-392).

17. Verify rigging per Maintenance Manual, chapter 67.

18. Reinstall panels removed at step 2.

19. Make helicopter ready for flight.

20. Make an entry in helicopter historical records indicating compliance with this
technical bulletin.
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SEE DETAIL A

4
Item P/N Description
1 204-001-332-001 Lever
or -005
2 204-001-326-011 Tube
3 204-001-358-001 Lever
4 204-001-326-011 Tube
5 204-001-356-001 Lever

FIGURE 1
Cyclic Jackshaft
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1.0 IN (25.4 mm)

ARM ASSEMBLY
204-001-356 AND 204-001-332 212-TB-99050-2
DAMAGE LIMITS

DAMAGE LOCATION SYMBOLS:

TYPE OF DAMAGE MAXIMUM DEPTHS AND REPAIR AREAS ALLOWED

MECHANICAL
BEFORE AND AFTER REPAIR 0.020 IN.(0.508 mm) 0.040 IN (1.016 mm)

CORROSION
BEFORE CLEANUP 0.010 IN (0.0254 mm) 0.020 IN (0.508 mm)
AFTER CLEANUP 0.020 IN. (0.508 mm) 0.040 IN. (1.016 mm)

MAXIMUM AREA PER 0.10 SQ.-IN (64.52 SQ.-mm) 0.25 SQ.-IN (161.3 SQ.-mm)
FULL DEPTH REPAIR

NUMBER OF REPAIR AREAS One per area Two per surface 1.0 in. (25.4
mm ) minimum spacing
EDGE CHAMFER 0.030 IN (0.762 mm) BY 45 0.060 IN (1.524 mm) BY 45

CRACKS ALLOWED NONE NONE

NOTES

1. Bearing bore damage not to exceed 0.001 inch (0.025 mm) for 1/4
circumference. Limit
one repair per bore.

2. Tapered hole damage shall not exceed 0.002 inch (0.0508 mm) for 1/4
circumference.
Limit one repair per bore.

Tapered holes (ref) these surfaces (4 places).

FIGURE 2
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Tube assembly
204-001-326-011
204-001-109-001

(Typical Tube assembly shown)

DAMAGE LOCATION SYMBOLS:

TYPE OF DAMAGE MAXIMUM DEPTHS AND REPAIR AREAS ALLOWED

CRACKS ALLOWED NONE

MECHANICAL

CORROSION

MAXIMUM AREA PER

DEPTH REPAIR
FULL DEPTH REPAIR 1.0 sq.-in. (6.45 sq-cm)

NUMBER OF REPAIR AREAS NOT CRITICAL

BORE ELONGATION 0.01 in. (0.25 mm)

NOTES

Mechanical damage to both exterior and interior surfaces of control tube shall
not exceed 10%of tube wall thickness.

Corrosion damageto both exterior and interior surfaces of control tube shall not
exceed 5% of tube wall thickness before cleanup and 10% after cleanup.

Width of repair shall not exceed one third of tube circumference.

FIGURE 3
 FIGURE 4
Collective Jackshaft
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LEVER AND SUPPORT ASSEMBLY

212-001-248

DAMAGE LOCATION SYMBOLS:

TYPE OF DAMAGE MAXIMUM DEPTHS AND REPAIR AREAS ALLOWED

MECHANICAL
BEFORE
BEFOREAND
AND AFTER
AFTER REPAIR
REPAIR 0.020 in (0.508 mm) 0.040 in (1.016 mm)

CORROSION
BEFORE CLEANUP 0.010 in (0.254 mm) 0.020 in (0.508 mm)
AFTER CLEANUP 0.020 in (0.508mm) 0.040 in (1.016 mm)

MAXIMUM AREA PER 0.100 sq. in 0.250 sq. in

FULL DEPTH REPAIR (64.52 sq. mm) (161.3 sq. mm)

NUMBER OF REPAIR AREAS One per area to surface

Five total

EDGE CHAMFER 0.030 in (0.762 mm) 0.060 in (1.524 mm)

by 45 degrees by 45 degrees

NOTES

1. No cracks allowed.

2. Bearing bore damage not to exceed 0.001 inch (0.0254 mm) for 1/4 circumference.

3. Tapered hole damage shall not exceed 0.002 inch (0.0508 mm) for 1/4
circumference. Limit one repair per hole.

Tapered holes (ref) these surfaces (8 places).

FIGURE 5