BHT PUB-92-004-SI-1

SERVICE INSTRUCTION
BELL MODEL UH-1H-II
ROTOR BRAKE

EFFECTIVITY

KIT NUMBER MODEL SERIAL NO.

205-706-034-117/-121 UH-1H-II ALL

2010

27 SEPTEMBER 2010
BHT PUB-92-004-SI-1

PROPRIETARY RIGHTS NOTICE

These data are proprietary to Bell Helicopter Textron Inc. Disclosure,

reproduction, or use of these data for any purpose other than helicopter
operation is forbidden without prior written authorization from Bell Helicopter
Textron Inc.

The user of this manual may make copies of text, illustrations and check lists as
needed to directly assist in accomplishing helicopter maintenance.

Additional copies of this publication may be obtained by contacting:

Commercial Publication Distribution Center
Bell Helicopter Textron Inc.
776 Henrietta Creek Dr.
Suite 100 Bldg 55
Roanoke, Texas 76262

PN 27 SEPTEMBER 2010
 BHT PUB-92-004-SI-1

LIST OF EFFECTIVE PAGES

Insert latest revision pages; dispose of superseded pages.

On a revised page the portion of text and illustration affected by the latest technical revision is indicated by a black
vertical line. Revised pages without a black vertical line are a result of text shift from page to page or nontechnical
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Original ..................27 Sep 10

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Title..................................0
PN....................................0
A/B...................................0

Chapter 1
1-1/1-2 .............................0
1-3 — 1-22.......................0

Chapter 2
2-1/2-2 .............................0
2-3 — 2-22.......................0

Chapter 3
3-1/3-2 .............................0
3-3 — 3-4.........................0
3-5/3-6 .............................0

Chapter 4
4-1/4-2 .............................0
4-3/4-4 .............................0

LIST OF CHAPTERS
Chapter Description Page

1 INSTALLATION PROCEDURES......................................................................... 1-1

2 OPERATION AND MAINTENANCE.................................................................... 2-1
3 PARTS INFORMATION AND KIT INVENTORY ................................................. 3-1
4 AIRWORTHINESS LIMITATIONS/OVERHAUL SCHEDULE ............................. 4-1

27 SEPTEMBER 2010 A/B

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 BHT PUB-92-004-SI-1

CHAPTER 1 — INSTALLATION PROCEDURES

TABLE OF CONTENTS

Paragraph Page
Number Title Number

1-1 General Information .................................................................................... 1-3

1-2 Preparation ................................................................................................. 1-3
1-3 Modification of Cabin Roof (205-530-517-101)........................................... 1-3
1-4 Component Removal .................................................................................. 1-3
1-5 Component Installation ............................................................................... 1-3
1-6 Installation of Hydraulic Coupling Support (205-030-973) .......................... 1-4
1-7 Installation of Rotor Brake Kit (205-706-034-117/-121) .............................. 1-10
1-8 Installation of Master Cylinder (204-076-036-005) ..................................... 1-10
1-9 Quill Assembly Installation (412-040-123-101/-105)................................... 1-10
1-10 Brake Assembly (9450103-1) and Disk (9440791-1) Installation ............... 1-13
1-11 Hydraulic Hose Installation ......................................................................... 1-13
1-12 Hydraulic Tube Installation ......................................................................... 1-13
1-13 Relocate Map Light..................................................................................... 1-18
1-14 Electrical System Installation ...................................................................... 1-18

FIGURES

Figure Page
Number Title Number

1-1 Cabin Roof Modification and Installation .................................................... 1-5

1-2 Master Cylinder Installation ........................................................................ 1-11
1-3 Quill Assembly Installation.......................................................................... 1-12
1-4 Brake Assembly Installation ....................................................................... 1-14
1-5 Hydraulic Hose Installation ......................................................................... 1-16
1-6 Hydraulic Tube Installation ......................................................................... 1-17
1-7 Circuit Breaker and Instrument Panel Installation....................................... 1-19
1-8 Cable Assembly Installation ....................................................................... 1-21
1-9 Coupling Support Installation...................................................................... 1-22

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INSTALLATION PROCEDURES

1-1. GENERAL INFORMATION. 1-3. MODIFICATION OF CABIN ROOF (205-530-

517-101).
MATERIALS REQUIRED 1-4. COMPONENT REMOVAL.
Refer to BHT-ALL-SPM for specifications and source.
1. Gain access to cabin roof.
NUMBER NOMENCLATURE 2. Remove rivets (7, Figure 1-1) from existing
C-204 Epoxy Polyamide Primer stiffener,s (6) and remove stiffener,s and existing
handle from frame.
C-308 Adhesive Sealant
3. Remove rivets (14) and existing clip (13) from
C-309 Solvent frame.

1. Tag all parts, including attaching hardware (unless 4. Remove rivets (16) and existing clip (15) from
otherwise noted), removed to gain access to work frame.
areas. Protect parts from damage until reinstalled.
5. Remove rivets (2) from existing frame (1) and
2. Following any drilling or cutting, remove burrs and rivets (5) from existing frame (4). Remove existing
metal particles and wipe area with solvent, C-309. frames (1 and 4) from helicopter.
Apply a thin coat of epoxy polyamide primer, C-204, to
bare metal. 1-5. COMPONENT INSTALLATION.

3. When installing ground wires, or components 1. Install frame (4, Figure 1-1) with rivets (5). Pick up
requiring ground, clean structure surface to bare metal existing rivet holes.
to provide good electrical bond.
2. Install frame (1) with rivets (2). Pick up existing
4. Do not string tie or clamp cables until all kit wiring rivet holes.
has been routed and connected.
3. Install frame (3) with rivets (2) and (5). Pick up
existing rivet holes.
NOTE
Installation of Rotor Brake Kit 205-706-034- 4. Install stiffener (6) with rivets (7). Pick up existing
117/-121 consists of: Master Cylinder (204- rivet holes. Refer to Figure 1-1, view A-A.
076-036-005), Quill assembly (412-040-
123-101/-105), Brake Assembly (9450103- 5. Install clip (8) at station 53.70 and install rivets (9).
1), Rotor Brake Disk (9440791-1), and Refer to Figure 1-1, view B-B.
associated hydraulic and electrical
systems. 6. Drill hole in clip to match with rotor brake mount
fitting. Refer to Figure 1-1, view B-B.
5. Some parts of this kit may be delivered
preassembled. 7. Install plate (11) to frame with rivets (12). Pick up
existing rivet holes.
6. Open transmission cowling to access roof area.
8. Install clip (13) to frame with rivets (14). Pick up
1-2. PREPARATION. existing rivet holes. Refer to Figure 1-1, view C-C.

1. Disconnect battery. 9. Install clip (15) to frame with rivets (16). Pick up
existing rivet holes. Refer to Figure 1-1, view C-C.
2. Remove sound proofing or custom interior from
both sides of transmission pylon structure to access 10. Refer to Figure 1-1 detail A for shim
work areas. measurements and install shim (17) to frame (4) with
rivets (5).
3. Remove covers, doors and/or panels as required
to access work areas. 11. Gain access and drill 1.84 to 1.88 dia. hole for
plug (18). Refer to Figure 1-1 detail B for hole location.
4. Remove panels from both sides of pylon structure
to access transmission. 12. De-bur the area around the hole.

5. Open transmission cowling to access roof area. 13. Install the plug (18).

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14. Apply sealant around the outside diameter of the 1-6. INSTALLATION OF HYDRAULIC COUPLING
plug (18). SUPPORT (205-030-973).

15. Refer to Figure 1-1 detail C for the hole locations MATERIALS REQUIRED
for the handle (10) installation.
Refer to BHT-ALL-SPM for specifications and source.
16. Remove rivets (2) from frame (1) where the
handle (10) and the radius block (22) are to be NUMBER NOMENCLATURE
installed.
299-947-100 TYP II, CL2 Adhesive Sealant
17. Remove rivets (5) from frame (4) where the
handle (10) and the radius block (22) are to be 1. Gain access and drill 3.55 dia hole centered 2.5
installed. inches in from top and 2 inches inboard from bracket
Figure 1-9, in transmission bulkhead for support
18. Locate position where the two nutplates (19) are installation.
to be installed and drill four 0.190 to 0.196 dia. holes.
2. Drill out existing rivets along top and bottom
19. Install the two nutplates (19) with the rivets (20). stringers.

20. Apply adhesive to both sides of edging (21) and 3. Position support and drill holes in web area.
install along the frame (3).
4. Remove support and de-bur area.
21. Install the radius blocks (22) with the rivets (23).
5. Apply bead of adhesive sealant to both sides of
22. Install the handle (10) with the screws (24) and support (1, Figure 1-9).
the washers (25).
6. Position support (1) in place and secure with nine
rivets (MS20470AD4). Pick up existing rivet holes.

7. Locate and drill hole for GND wire.

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Figure 1-1. Cabin Roof Modification and Installation (Sheet 1 of 5)

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BHT PUB-92-004-SI-1

Figure 1-1. Cabin Roof Modification and Installation (Sheet 2 of 5)

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Figure 1-1. Cabin Roof Modification and Installation (Sheet 3 of 5)

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Figure 1-1. Cabin Roof Modification and Installation (Sheet 4 of 5)

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Figure 1-1. Cabin Roof Modification and Installation (Sheet 5 of 5)

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1-7. INSTALLATION OF ROTOR BRAKE KIT (205- 2. Clean sealant from area and remove all foreign
706-034-117/-121). matter. Use a plastic scraper with clean cloth
dampened with solvent (C-309).
1-8. INSTALLATION OF MASTER CYLINDER
(204-076-036-005). 3. Lubricate packing (4, Figure 1-3) with lubricating
oil (C-010 or C-011) and install on quill assembly (5).
MATERIALS REQUIRED
4. Apply a light coat of lubricating oil (C-010) to bore
Refer to BHT-ALL-SPM for specifications and source. of transmission accessory quill port and to mating
diameter of quill assembly (5).
NUMBER NOMENCLATURE
C-308 Adhesive Sealant NOTE
C-349 Decal Sealer Heating time will vary, but transmission
case should be heated until accessory quill
port is very warm to the touch. Do not
1. Remove plug (5, Figure 1-2) from roof, right overheat.
forward side, F.S. 51.13 at B.L. 12.16.
5. Apply heat lamp to face of open accessory quill
2. Position master cylinder (4) in place and secure port on transmission case.
using four bolts (1), eight washers (2) and four nuts (3)
utilizing four existing holes in frame.
CAUTION
3. Apply bead of adhesive sealant (C-308) to roof
surface around master cylinder fill port.
THE 412-040-123-101/-105 QUILL
4. Apply decal (6), “DO NOT APPLY ROTOR ASSEMBLY CONTAINS A LOOK ALIKE
BRAKE ABOVE 40% RPM.” Seal decal with (C-349). PART. ENSURE THAT -101/-105 QUILL
HAS 6 HOLES IN FACE OF PINION AS
SHOWN IN VIEW C-C FIGURE 1-3.
5. Install packing (8) and plug (7) in aft outlet port of FAILURE TO COMPLY WILL RESULT IN
cylinder. TRANSMISSION DAMAGE.

6. Install packing (10), ring (11), nut (12) and elbow D U R I N G I N S TA L L A T I O N O F Q U I L L

(9) on inboard port of cylinder, with tube connection ASSEMBLY, IT MAY BE NECESSARY TO
positioned aft. LIGHTLY TAP QUILL INWARD
UNIFORMLY AROUND THE FACE OF
1-9. QUILL ASSEMBLY INSTALLATION (412-040- QUILL FLANGE NEAR ITS OUTER
123-101/-105). EDGES. DO NOT STRIKE END OF QUILL
SHAFT.
MATERIALS REQUIRED DO NOT ALLOW TEETH OF QUILL
PINION TO CLASH WITH TEETH OF
Refer to BHT-ALL-SPM for specifications and source. MATING GEAR WITHIN TRANS-
M I S S I O N . TO O T H D A M A G E W I L L
NUMBER NOMENCLATURE RESULT.

C-010 or C-011 Lubricating Oil 6. Install rotor brake quill assembly (5) slowly into
C-308 Adhesive Sealant transmission quill port while rotating quill shaft by
hand.
C-309 Solvent
7. Install six bolts (1), six washers (2) and six
washers (3). Install AN960-616 washer against head
of bolt and NAS1197-616 washer against face of quill
CAUTION sleeve. Torque bolts to 160 to 190 in-lb (18.08 to 21.47
N-m).

EXERCISE CARE TO PREVENT ENTRY 8. Verify existence of backlash between gears.

OF LOOSE PARTICLES INTO Measurement is not required.
TRANSMISSION.
9. Apply a small bead of adhesive sealant (C-308)
1. Remove cover plate from left side of transmission around the mounting flange of the quill assembly (5)
at F.S. 138.8 and W.L. 76.1. and transmission case.

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Figure 1-2. Master Cylinder Installation

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Figure 1-3. Quill Assembly Installation

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1-10. BRAKE ASSEMBLY (9450103-1) AND DISK inboard and outboard halves of brake assembly
(9440791-1) INSTALLATION. (9450103-1).

1. Remove four screws (1, Figure 1-4) attaching 10. Insert brake oil transfer tube through the
brake assembly microswitches to inboard and (AN6227-5) packing in inboard half of brake assembly
outboard brake assembly halves. Retain hardware. unit until it bottoms out in hole.

2. Remove and discard screw (9) and washer (10) 11. Place brake assembly spacer over protruding oil
from bleeder valves on inboard and outboard halves. transfer tube in inboard half of brake assembly.

3. Install microswitch assemblies (view A) 180 12. Install the outboard half of brake assembly
degrees (switch pointing up) from original (new brake (9450103-1) and, while holding in place, align brake
assembly) position. Use original screws (1) when assembly spacer and install two bolts (11) and two
installing switch assemblies. Secure with lockwire washers (12), removed in step 4.
(18).
13. Torque bolts (11) to 120 to 130 in-lb (13.56 to
14.69 N-m). Secure with lockwire (18).
CAUTION 1-11. HYDRAULIC HOSE INSTALLATION.

EXERCISE CARE TO PREVENT 1. Locate existing 0.5 in. (12.7 mm) hole in support
HYDRAULIC FLUID LEAKAGE ONTO assembly. Install coupling (3, Figure 1-5) in place with
BRAKE LININGS. tube connecting end forward and secure with nut (4).

4. Remove lockwire (18), two bolts (11) and two 2. Connect one end of hose assembly (1) to coupling
washers (12) from brake assembly (9450103-1) and half (2) and connect to installed coupling (3).
separate halves of brake assembly. Retain bolts,
washers, spacer, transfer tube, and two (AN6227-5) 3. Connect opposite end of hose assembly (1) to
packings in a clean area for reuse. elbow (5).

5. Install packing (14, Figure 1-4), ring (15), bolt (16) 1-12. HYDRAULIC TUBE INSTALLATION.
and elbow (17) in port of inboard brake assembly (8),
with hose connecting end of elbow up. MATERIALS REQUIRED

6. Install inboard half of 9450103-1 brake assembly Refer to BHT-ALL-SPM for specifications and source.
(8) onto rotor brake quill assembly (5). Secure with
three bolts (6) and washers (7). Torque bolts to 50 to NUMBER NOMENCLATURE
70 in-lb (5.65 to 7.91 N-m). Secure with lockwire (18).
C-002 Hydraulic Fluid

NOTE 1. Cut a 0.75 in. (19.05 mm) diameter hole in frame

Rotor brake disk is normally a slip fit on at F.S. 92.00.
flanged adapter. It may be necessary to
remove paint from bore of disk. If, after 2. Cut and position grommet (9, Figure 1-6) around
removal of paint from disk bore, disk will not tube assembly (11). Position tube assembly through
install on adapter using hand pressure only, 0.75 in. (19.05 mm) diameter hole and longeron
disk must be replaced. lightening hole on inboard side at B.L. 15.25. Position
grommet in hole.
7. Install rotor brake disk (13) on flanged adapter (4)
of rotor brake quill assembly. Install four bolts (2) and 3. Install forward tube assembly (5) and connect to
washers (3). Torque bolts (2) to 50 to 70 in-lb (5.65 to brake assembly outlet elbow.
7.91 N-m).
4. Install union (10) between tube assemblies (5)
8. Secure bolts with lockwire (18). Route lockwire and (11).
(18) spanning each set of two bolts (2) through
lockwire holes in (205-040-305) nut, retaining flange 5. Install aft tube assembly (12) and connect to
adapter of rotor brake quill to quill shaft. coupling (13) at firewall disconnect.

9. Install two (AN6227-5) packings, removed in step 6. Install union (10) between tube assemblies (11)
4, into counterbored cavities in split-line faces of and (12).

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Figure 1-4. Brake Assembly Installation (Sheet 1 of 2)

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Figure 1-4. Brake Assembly Installation (Sheet 2 of 2)

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Figure 1-5. Hydraulic Hose Installation

7. Secure forward tube assembly (5) as follows: a. Drill one 0.190/0.196 in. (4.826/4.979 mm)
hole through longeron, 3.50 in. (88.9 mm) forward of
a. Drill one 0.190/0.196 in. (4.826/4.979 mm) F.S. 92.00 at B.L. 15.25, with hole centered 1.50 in.
hole through longeron, 2.50 in. (63.5 mm) aft of F.S. (38.1 mm) above lower surface of longeron.
63.38, 1.50 in. (38.1 mm) outboard of B.L. 15.25.
b. Drill one 0.190/0.196 in. (4.826/4.979 mm)
b. Drill one 0.190/0.196 in. (4.826/4.979 mm) hole through longeron, 11.12 in. (282.45 mm) aft of
hole through longeron, 5.00 in. (127.00 mm) aft of F.S. F.S. 92.00 at B.L. 15.25, with hole centered 1.50 in.
74.25 at B.L. 15.25, with hole centered 1.62 in. (41.15 (38.1 mm) above lower surface of longeron.
mm) above lower surface of longeron.

c. Secure forward end of tubing (5) in place with c. Drill one 0.190/0.196 in. (4.826/4.979 mm)
clamp (6), screw (7) and nut (8). hole through longeron, 1.00 in. (25.4 mm) aft of F.S.
112.80 at B.L. 15.25, with hole centered 2.00 in. (50.8
d. Secure aft end of tubing (5) in place with mm) above lower surface of longeron.
clamp (1), screw (2), spacer (3) and nut (4).
d. Secure tubing (11) in three places with clamp
8. Secure center tube assembly (11) as follows: (1), screw (2), spacer (3) and nut (4).

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Figure 1-6. Hydraulic Tube Installation

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9. Secure aft tube assembly (12) as follows: 2. Remove cover from windshield center post.

a. Drill one 0.190/0.196 in. (4.826/4.979 mm) 3. Remove dust and glare cover of main instrument
hole through cross frame, 5.75 in. (146.05 mm) left of panel. Remove instruments and components as
B.L. 15.25, right side; with hole centered 0.62 in. required to gain access.
(15.75 mm) from aft edge of cross frame.
4. Drill one 0.190/0.196 in. (4.826/4.979 mm)
b. Drill one 0.190/0.196 in. (4.826/4.979 mm) diameter hole in bulkhead using dimensions shown in
hole through cross frame, 8.50 in. (215.90 mm) right of view B-B, Figure 1-8.
B.L. 15.25, left side; with hole centered 1.00 in. (25.4
mm) from aft edge of cross frame. 5. Install rotor brake cable assembly (1, Figure 1-8)
as follows:
c. Secure tubing (12) in two places with clamp
(1), screw (2), spacer (3) and nut (4). a . Tr i m e x i s t i n g l e a d w i r e s ( 3 ) o f b r a k e
microswitch (4) to approximately 6 in. (152.4 mm).
10. Fill master cylinder reservoir with hydraulic fluid
(C-002) and bleed system at brake unit. Check and fill b. Stow lead wires from terminal ‘NO’ of each
reservoir with brake off. Maintain fluid reservoir while switch (4 and 6).
bleeding. Check for leakage. Refer to BHT PUB 92-
004-23 MM.
c. Attach cable assembly (1) to switch (4) with
contact crimps (2) as follows:
1-13. RELOCATE MAP LIGHT.

Relocate map light aft of current location to just Wire Contact

forward of STA 63 Figure 1-1 by picking up existing
rivet in corner and drill an additional rivet hole W126A20 crimps to ‘NC’
forward of that. W121A20N crimps to ‘C’
1-14. ELECTRICAL SYSTEM INSTALLATION.
d. Attach cable assembly (1) to switch (6) with
Special Tools Required contact crimps (2) as follows:

NUMBER NOMENCLATURE Wire Contact

MS15570-20 Crimping Tool W125A20 crimps to ‘NC’
W122A20N crimps to ‘C’
1. Modify overhead console circuit breaker panel and
instrument panel as follows:

a. Open overhead console (3, Figure 1-7), right NOTE

side.
Contact crimps require extract-insertion tool
MS15570-20. If crimping tool is not
b. Remove plug button (1) located on first row, available to crimp contacts (2), SN60 solder
fourth position inboard. is allowable.
c. Install circuit breaker (2) in place and secure
with jamnut furnished with circuit breaker. e. Route opposite end of wire (W121A20N) and
wire (W122A20N) to local ground using screw (7),
d. Remove cover plate assembly (4) on main washers (8), and nut (9).
i n s t r u m e n t pa n e l ( i f i n s ta l l e d ) o r c u t o u t p e r
deminsions shown in Figure 1-7. f. Route cable assembly (1) with DC trunk
cables up, forward and to overhead console and down
e. Temporarily install rotor brake lamp assembly windshield center post to rotor brake lamp assembly
(5) in opening with terminal marked ‘A’ (right side (5, Figure 1-7) located in instrument panel.
position).
g. Attach terminal of wire (W118A20) to circuit
breaker (2) in right panel of overhead console (3).
NOTE
Separate indicator light from switch by h. Attach opposite end of circuit breaker (2) to
pulling out on nameplate slightly, then 28 volt bus bar.
pushing in. Nameplate will release from
switch. Use a screwdriver and turn slotted i. Route wire (W118A20) forward and down
bolt to actuate holding mechanism of windshield center post to rotor brake lamp assembly
switch. (5) located in instrument panel.

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Figure 1-7. Circuit Breaker and Instrument Panel Installation

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j. Remove rotor brake lamp assembly (5) and k. Route ground wires to common ground
solder the following wires to terminals on indicator and forward side of instrument panel.
switch as follows (Figure 1-8):
l. Check all wires for security and perform
Wire Number From Terminal To Terminal continuity check.
W118D20 A1 Light B1 Light
6. Insert and secure rotor brake lamp assembly (5,
W118C20 B1 Light C1 Light Figure 1-7) in instrument panel.
W118B20 C1 Light D1 Light
7. Install decal (6) on instrument panel adjacent to
W118A20 CB 1 D1 Light rotor brake lamp assembly (5).
W119A20 D2 Light C Test Switch
(S200) 8. Install dust and glare cover on instrument panel.
Install instruments and components removed to gain
W119B20 D2 Light C2 Light access.
W120B20 B2 Light A2 Light
9. Install windshield center post cover.
W120A20 A2 Light C Test Switch
(S200) 10. Secure right side overhead console (3).
W121A20N C ground
11. Adjust both brake assembly microswitches (4
W122A20N C ground and 6, Figure 1-8) so each switch activates when the
respective brake piston moves 0.030 in. (0.76 mm)
W123A20N NO Test Switch ground from normal fully retracted position. Switches shall be
(S200) adjusted after bleeding brake hydraulic system.
W124A20N NO Test Switch ground
(S200) 12. Connect battery.
W125A20 Brake Assy. NC Test Switch
(S180) (S200) 13. Perform operational check (BHT PUB-92-004-10
Operators Manual).
W126A20 Brake Assy. NC Test Switch
(S179) (S200) 14. Replace all cowling, covers, access doors, and
panels removed or loosened to gain access to work
areas.

1-20 27 SEPTEMBER 2010

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 BHT PUB-92-004-SI-1

Figure 1-8. Cable Assembly Installation

27 SEPTEMBER 2010 1-21

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Figure 1-9. Coupling Support Installation

1-22 27 SEPTEMBER 2010

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 BHT PUB-92-004-SI-1

CHAPTER 2 — OPERATION AND MAINTENANCE

TABLE OF CONTENTS

Paragraph Page
Number Title Number

2-1 Operation Procedures ................................................................................ 2-3

2-2 Maintenance Procedures............................................................................ 2-3
2-3 Weight and Balance ................................................................................... 2-3
2-4 Rotor Brake System ................................................................................... 2-3
2-5 Troubleshooting — Rotor Brake System .................................................... 2-4
2-6 Servicing — Rotor Brake ............................................................................ 2-4
2-7 Maintenance — Rotor Brake Assembly...................................................... 2-5
2-8 Maintenance — Master Cylinder ................................................................ 2-7
2-9 Maintenance — Quill Assembly.................................................................. 2-8
2-10 Overhaul — Rotor Brake Assembly............................................................ 2-8
2-11 Overhaul — Rotor Brake Master Cylinder .................................................. 2-10
2-12 Overhaul — Rotor Brake Quill Assembly.................................................... 2-14
2-13 Special Inspection — Master Cylinder........................................................ 2-17

FIGURES

Figure Page
Number Title Number

2-1 Rotor Brake Assembly ................................................................................ 2-6

2-2 Rotor Brake Master Cylinder ...................................................................... 2-11
2-3 Rotor Brake Master Cylinder Limits ............................................................ 2-12
2-4 Rotor Brake Quill ........................................................................................ 2-15
2-5 Rotor Brake Quill Damage Limits ............................................................... 2-16
2-6 Rotor Brake Quill Sleeve Rework Limits..................................................... 2-18
2-7 Rotor Brake Quill Retainer Rework Limits .................................................. 2-21

TABLES

Table Page
Number Title Number

2-1 Troubleshooting — Rotor Brake System .................................................... 2-4

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OPERATION AND MAINTENANCE

2-1. OPERATION PROCEDURES. 2. For maintenance procedures applicable to cabin

roof refer to BHT PUB-92-004-23 and BHT PUB-MED-
SRM.
Refer to BHT PUB-92-004-10 Operators Manual.

2-2. MAINTENANCE PROCEDURES. 2-3. WEIGHT AND BALANCE.

1. For maintenance procedures applicable to rotor Compliance with this Service Instruction affects the
brake pads and brake assembly, refer to LORAL weight and balance of the helicopter as shown in the
Manual Q70-2 available from: following chart. Adjust ballast as necessary to return
empty CG to within limits.
Loral Aircraft Braking System
Aircraft Braking Systems Group 2-4. ROTOR BRAKE SYSTEM.
Dept. 640B, Data Control
1210 Massillon Road NOTE
Akron, Ohio, 44315
This chapter contains necessary routine
1. Maintenance procedures applicable to the rotor inspection, maintenance procedures,
brake master cylinder, quill assembly, brake disk, and overhaul procedures and limits for
associated tubing and wiring are contained in this individual components.
Chapter.

LONGITUDINAL *LATERAL

HELICOPTER KIT NUMBER WEIGHT ARM MOMENT ARM MOMENT

lb (N) in. (mm) in-lb (N-m) in. (mm) in-lb (N-m)

UH-1H-II 205-706-034-117/- +31.0 +116.8 +3621 -2.8 -87

121 (137.9) (2967) (409.1) (-71.12) (-9.8)

* In lateral calculations, - is left, + is right.

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2-5. TROUBLESHOOTING — ROTOR BRAKE

SYSTEM.

Table 2-1. Troubleshooting — Rotor Brake System

INDICATION OF
TROUBLE PROBABLE CAUSE CORRECTIVE ACTION
No braking action Insufficient fluid in system Fill and bleed system
Foreign substance in fluid Purge the system
Primary valve open Replace master cylinder
Relief valve open Replace master cylinder
Excessive brake lining wear Replace lining
Spongy action of control Air in system Fill and bleed system
Loss of braking action Worn seal in master cylinder Replace master cylinder
Worn seal in brake assembly Replace brake assembly
Excessive brake lining wear Replace lining
Leaks at master cylinder Worn or damaged seal in cylinder Replace master cylinder seals
Leaks at brake assembly Worn or damaged seals in brake Replace brake assembly seals
assembly
Indicator light inoperative Burned out bulbs Replace bulbs
Loose electrical connections Tighten connections
Broken or disconnected wire Replace or connect wire
Improper micro-switch adjustment Adjust micro-switches
Light indicates when master cylinder Faulty micro-switch Replace switch
not applied
Lining binding Clean brake cylinder
Wire(s) to master caution panel Repair shorted wire
shorted to ground

2-6. SERVICING — ROTOR BRAKE. 1. Apply rotor brake and leave handle in “PARK”
position.
MATERIALS REQUIRED
Refer to BHT-ALL-SPM for specifications and source. 2. Remove reservoir filler cap of master cylinder,
located on top, right forward area of cabin roof.

NUMBER NOMENCLATURE 3. Correct fluid level of reservoir is 0.50 in. (12.7 mm)
below bottom of filler neck; if fluid level is low,
C-002 Hydraulic Fluid replenish with hydraulic fluid (C-002).

4. Reinstall filler cap. Release rotor brake by placing

handle in the “UP” (OFF) position.

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2-7. MAINTENANCE — ROTOR BRAKE b. Open one bleed valve and slip one end of a
ASSEMBLY. length of rubber hose on the valve extension. Route
the other end of this drain hose to a suitable container
MATERIALS REQUIRED in order to capture brake fluid discharged during the
bleeding operation.
Refer to BHT-ALL-SPM for specifications and source.
c. Slowly pull master cylinder handle “DOWN”
NUMBER NOMENCLATURE and hold in this position. Do not allow the handle to
pass center into “PARK” position.
— Grease, MIL-G-7711
d. Close bleed valve and replenish oil in master
1. Removal of rotor brake: cylinder. Return master cylinder handle to “UP”
(horizontal) position.
a. Open transmission cowling and disconnect
electrical leads from rotor brake micro-switches.
e. Repeat steps b. through d. until fluid, as
discharged, is free of trapped air. No less than one-
b. Disconnect hose at quick disconnect. half pint of fluid should be drained from each valve
before concluding bleeding operation.
c. Cut lockwire and remove bolts attaching
brake cylinder to transmission quill. Remove brake f. Repeat steps b. through e. for other bleed
assembly. valve.

2. Inspection of rotor brake:

g . R e m o v e d r a i n h o s e ( s ) a n d “ C AT C H ”
receptacle. Install reservoir cover.
a. Inspect hose assembly for damage and
indication of deterioration.
h. Close transmission cowl.
b. Inspect cylinder for leakage.
5. Brake lining installation:
c. Inspect brake lining for wear. If lining
thickness is 0.15 in. (3.81 mm) or less, replace both a. Remove brake assembly from transmission.
linings.
b. Cut lockwire and remove the two housing
d. Inspect brake disc for wear and general assembly bolts (19, Figure 2-1) and separate
condition. If worn to 0.422 in. (10.72 mm) or less, housings.
scored, or dished in excess of 0.020 in. (0.508 mm),
then replace disc.
c. Relieve tension on cotter pin (9) and remove
pin, each housing. Remove piston and lining assembly
3. Installation of rotor brake: from each housing.
a. Position brake assembly with brake disc
between brake linings. Secure brake assembly to
transmission with three bolts and washers. Lockwire CAUTION
bolts.

b. Connect hose at quick disconnect on BRAKE ASSEMBLY 9450103 REPLACED

bulkhead. BY 9450103-1, WHICH USES
NONASBESTOS LININGS, 5009209
c. Connect electrical leads to brake micro- ( W H I T E PAI N T O N B A C K ) . D O N O T
switches. INTERMIX WITH OLD LININGS, 9430521
(GREEN ZINC CHROMATE ON BACK).
4. Bleeding rotor brake cylinder:
d. Remove linings (14) and piston seal (5) from
a. Check master cylinder for proper fluid level. each piston. Remo ve r eturn pin se al (8) from
(Refer to Paragraph 2-6.) housings.

NOTE NOTE
Ensure that rubber hose used in following Linings are secured to pistons by a snap
step b. is clean. type button.

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Figure 2-1. Rotor Brake Assembly

2-6 27 SEPTEMBER 2010

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 BHT PUB-92-004-SI-1

e. Lubricate housing assembly cylinder walls, f. Loosen switch mounting screw and jamnut on
and seal grooves with a light coat of MIL-G-7711 adjusting screw, and adjust switches as necessary so
grease. that the light illuminates when both pistons have
moved 0.030 in. (0.762 mm) from the “brake off”
f. Install new return pin seal (8) in each housing. position. Tighten screw and jamnut after adjustment.

g. Lubricate contacting surfaces of each piston 2-8. MAINTENANCE — MASTER CYLINDER.

seal groove with a light coat of MIL-G-7711 grease
and install new seal (5) on piston. MATERIALS REQUIRED
h. Lubricate snap button fasteners on brake Refer to BHT-ALL-SPM for specifications and source.
linings with a light coat of MIL-G-7711 grease and
snap brake lining (14) onto piston.
NUMBER NOMENCLATURE
i . I n s e r t p i s t o n a s s e m b l i e s in t o h o u s i n g
— Sealer, EC1126, 3M
assemblies (2 and 6).

j. Install brake return spring (11), spring 1. Removal of master cylinder:

retaining washer (10) and install cotter pin (9) on each
assembly.
a. Remove sealing compound from around top
of master cylinder reservoir above roof.
k. Install crossover tube seal (3) and crossover
tube (4) in housing assembly (2).
b. Loosen hydraulic tubing from end of master
l. Position housings (2 and 6) together and cylinder and allow fluid to run into receptacle.
install housing assembly washer and bolts (19).
Torque bolts evenly to 120 in-lb (13.56 N-m) and c. Disconnect tubing from master cylinder, and
lockwire. plug openings to prevent entry of foreign materials.

m. Install brake assembly on transmission as d. Remove four bolts attaching master cylinder
directed in Paragraph 2-7, step 3. to roof structure and remove master cylinder.
n. Bleed rotor brake system as directed in
2. Inspection of master cylinder. Check master
Paragraph 2-7, step 4.
cylinder for leaks due to worn seal or other
malfunction. Refer to Paragraph 2-5 for
o. Close transmission cowling. troubleshooting. Refer to Paragraph 2-13 for special
inspection.
6. Micro-switch actuator adjustment.

a. Adjust the actuators of micro-switches on the 3. Repair and Replacement.

brake assembly as follows (Figure 2-1):
a. Replace or repair master cylinder if leaking or
otherwise unserviceable.
NOTE
Both micro-switches control one warning 4. Installation of master cylinder:
light, therefore, either or both switches may
be improperly adjusted if light does not a. Place master cylinder in install position at
illuminate at the 0.030 in. (0.762 mm) travel right of overhead console in cabin roof and attach to
position. structure with four bolts, nuts and eight washers.
b. Position micro-switches and actuators in their
approximate locations so that, with brake off and b. Attach hydraulic tubing to forward end of
MASTER CAUTION circuit breaker on, the warning master cylinder.
light is off.
c. Restore soundproofing to original position
c. Note the position of the micro-switch actuator over and around master cylinder, adjacent to overhead
and brake assembly piston with respect to a nearby console.
fixed point in the line of brake assembly piston travel.
d. Carefully apply pressure by pulling downward d. Apply 3M sealer, EC1126, around th e
on the master cylinder handle until the brake assembly exposed filler and master cylinder above the cabin roof
pistons move 0.030 in. (0.762 mm) from their location. to provide weather seal.

e. If the actuators are properly adjusted, the e. Fill reservoir of master cylinder to proper level
warning light should be on when brake assembly 0.50 in. (1.27 mm) below filler-neck. (Refer to
pistons have moved 0.030 in. (0.762 mm). Paragraph 2-6.)

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2-9. MAINTENANCE — QUILL ASSEMBLY. 1. Disassembly of rotor brake.

NOTE a. Cut lockwire from micro-switch bracket

assembly attaching screws (18, Figure 2-1) and
Quill assembly requires overhaul at 2500 remove attaching screws. Lift the two micro-switches
hour intervals. (17) from housing assembly. Cut lockwire and remove
housing assembly bolts (19) and washers and
SPECIAL TOOLS REQUIRED separate housing assemblies (2 and 6); then remove
crossover tube (4) and crossover tube seal (3).
NUMBER NOMENCLATURE
b. Remove cotter pin (9) from brake return pin
T100929 Jack Screw Set (12) and remove spring retaining washer (10) and
brake return spring (11).
1. Removal of quill assembly.
c. Grasp brake lining (14) and pull brake lining,
a . R e m o v e b r a k e a s s e m b l y. ( R e f e r t o piston (7), brake return pin (12), retaining ring (13) and
Paragraph 2-7.) piston seal (5) as an assembly from housing.

b. Remove bolts and washers securing quill to d. Remove brake lining from piston. Lining is
transmission. secured to piston by snap button.
c. Remove quill using T100929 jack screw set.
e. Remove retaining ring (13); then separate
2. Inspection and repair of quill assembly. (Refer to piston (7) from brake return pin (12).
Paragraph 2-12.)
f. Remove piston seal (5) from piston.
3. Installation of quill assembly:

a. Install new packing on quill. g. Remove return pin seal (8) from housing
assembly.
b. Position quill in transmission and secure with
six bolts and washers. Lockwire bolts. h. Remove bleeder valve assembly (16) from
housing assembly (6).
2-10. OVERHAUL — ROTOR BRAKE ASSEMBLY.
i. Repeat steps b. through h. for disassembly of
NOTE other part of housing assembly (2).

The Loral Systems Group has a repair,

o v e r h a u l a n d pa r ts m a n u a l ( Q 7 0 - 2 ) 2. Cleaning Rotor Brake Assembly.
available on request by writing — Loral
Aircraft Braking System, Aircraft Braking a. Clean all metal parts with cleaning solvent (C-
Systems Group, Department 640B, Data 304), and air dry.
Control, 1210 Massillon Road, Akron, Ohio,
44315.
3. Repair and Parts Replacement — Rotor Brake
MATERIALS REQUIRED Assembly: (See Figure 2-1.)

Refer to BHT-ALL-SPM for specification and source. a. Check housings (2 and 6) for cracks or
damage and replace as necessary.
NUMBER NOMENCLATURE
— Grease, MIL-G-7711 b. Check all threads for condition and
cleanliness.
— Packing (2), AN6227B29
— Packing (2), AN6227B6 c. Check all metal parts for wear or damage.

— Primer (Zinc Chromate) d. Replace brake linings (14).

MIL-P-8585A
— Sandpaper, Fine, 350 Grit e. Replace crossover tube seal (3), piston seal
(5), and return pin seal (8) in each assembly.
— Aluminum Lacquer
f. Polish minor scratches in cylinder walls with
— Solvent fine (wet or dry) 350 grit sandpaper.

2-8 27 SEPTEMBER 2010

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 BHT PUB-92-004-SI-1

i. Install crossover tube seal (3) and crossover

tube (4) in housing assembly (2).
CAUTION
j. Position housings (2 and 6) together and
MAXIMUM ALLOWABLE INSIDE install housing assembly washers and bolts (19).
DIAMETER OF CYLINDER IS 2.010 IN. Torque bolts to 120 in-lb (13.56 N-m) and lockwire.
(51.05 MM). SEAL WORKING SURFACE
MUST BE FREE FROM PITS, k. Position micro-switches (17) on housing
IMPERFECTIONS AND CONFORM TO A assemblies (2 and 6), install attaching screws (18) and
FINISH OF 15 RMS. lockwire.

g. Replace brake disc if worn to a thickness of 5. Test Procedure — Rotor Brake Assembly:
0.422 in. (10.72 mm) or less, or if dished in excess of
0.020 in. (0.508 mm). a. Connect brake assembly to hydraulic test
stand.
h. Replace brake return springs that are
damaged or which require less than 37 lb (165 N) to b. Place a block between brake linings to
compress a distance of 0.125 in. (3.175 mm). Repaint simulate brake disc.
brake with two coats of zinc chromate primer,
Sp e c i f i c a t i o n M I L - P - 8 5 8 5 A , a n d t w o c o a ts o f c. Hold a constant pressure on brake assembly,
aluminum lacquer (C-215). do not exceed 250 psi (1724 kPa) and back off bleeder
valve on one side of housing to release air and fluid
until fluid runs clear; then tighten bleeder valve.
CAUTION
d. Repeat step c. for opposite bleeder valve.

THE MATING SURFACES OF HOUSING e. Adjust both brake assembly micro-switches

ASSEMBLIES (2 AND 6) ARE PAINTED such that each switch activates when its respective
WITH ONE COAT OF ZINC CHROMATE brake piston moves 0.030 in. (0.76 mm) from its
P R I M E R O N LY. D O N O T PA I N T normal fully retracted position. Switches must be
HYDRAULIC CAVITIES AND THREADS. adjusted after bleeding brake hydraulic system.

4. Assembly of rotor brake: (See Figure 2-1.) f. Apply 250 psi (1724 kPa) hydraulic pressure
to brake, and hold for two minutes.
a. Lubricate housing assembly cylinder walls,
and seal grooves with a light coat of MIL-G-7711 g . Check brak e for leaks and corr ec t as
grease. necessary.

b. Install bleeder valve assembly (16). h. If no leaks are present, apply and release
pressure ten times.
c. Install new return pin seal (8) in each
housing.
CAUTION
d. Lubricate contacting surfaces of each piston
and piston seal groove with a light coat of MIL-G-7711 SIMULATED BRAKE DISC MUST BE
grease and install new seal (5) on piston. FREE WHEN BRAKE PRESSURE IS
RELEASED. MINIMUM ALLOWABLE
e. Insert return pin into piston and secure with CLEARANCE BETWEEN BRAKE LINING
retaining rings (13). A N D D I S C , W I T H P R E S S U R E O F F,
SHALL BE 0.125 IN. (3.175 mm) ON EACH
f. Lubricate snap button fasteners on brake SIDE.
linings with a light coat of MIL-G-7711 grease and
snap brake lining (14) into piston. i. Allow brake to stand for two minutes with
pressure released, and check for static leaks.
g. Insert piston assem blie s into housing
assemblies (2 and 6). j. Remove hydraulic test stand hoses and cap
openings.
h. Install brake return spring (11), spring
retaining washer (10) and install cotter pin (9) on each k. Prepare assembly for stock or return to
assembly. helicopter.

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2-11. OVERHAUL — ROTOR BRAKE MASTER i. Check pin (30) for wear or damage. Do not
CYLINDER. remove pin unless damaged or signs of excessive
wear are evident.
NOTE
j. Remove all packings and glyd rings except
The components of the master cylinder packings (4) and (22). Packings (4) and (22) need not
cannot be repaired and must be replaced be replaced unless damaged.
with like, serviceable items. No special
tools are required. k. Clean all parts with dry cleaning solvent (C-
304).
MATERIALS REQUIRED
Refer to BHT-ALL-SPM for specification and source. 2. Repair and parts replacement of master cylinder.

NUMBER NOMENCLATURE a. Replace cracked or damaged parts.

— Sandpaper, Fine, 350 Grit
b. Replace all packings and glyd rings. (Refer to
C-002 Hydraulic Fluid Paragraph 1.j.)
C-008 Petrolatum
c. Check all springs for damage.
C-304 Solvent
d. Inspect housing and pistons for wear and
204-1653-1 Repair Kit condition. Refer to Limits Chart, (Figure 2-3). Replace
parts that are not within specified limits.
1. Disassembly of master cylinder:
e. Inspect bolt hole diameters. Refer to Limits
a. Remove filler cap (9, Figure 2-2) and Chart, (Figure 2-3).
completely drain all hydraulic fluid from cylinder.
f. Glyd ring and packing working surfaces must
b. Remove handle assembly pivot bolt (15) and be free from pits, imperfections and conform to a finish
remove handle and piston assembly (11) as a unit. of 16 rms. Minor scratches and pits may be polished
with fine (wet or dry) 350-grit sandpaper.
c. Remove link (14) from handle and piston.
g. Replace all bolts that show signs of wear
d. Position piston assembly in arbor press with
cap (13) up and apply sufficient pressure to relieve 3. Assembly of master cylinder. (See Figure 2-2.)
load on retaining ring (12). Remove retainer and
relieve pressure on cap.

CAUTION
CAUTION
WHEN INSTALLING GLYD RINGS AND
PACKINGS USE EXTREME CARE SO
CAP (13) HAS A FORCE APPLIED BY SURFACES OF RINGS WILL NOT BE
SPRING (10) OF APPROXIMATELY 250 DAMAGED.
LB (1112 N).
a. Install spring (6) and piston (8) in main
e. Apply approximately 35 lb (156 N) pressure housing. Install packing on stop (16). Compress piston
to sleeve (5), remove retaining ring (25) and relieve sufficiently to clear hole for stop. Install and tighten
pressure on sleeve. Remove sleeve (5) and springs stop.
(18 and 20). Check for washers at base of spring (18).

f. Remove retainer (19), spring (21) and NOTE

adjustable poppet valve (23).
Lubricate all parts with hydraulic fluid (C-
g. Apply approximately 5 lb (22 N) pressure to 002), or Petrolatum (C-008).
piston (8) and remove stop (16). Remove piston and b. Install adjustable poppet valve (23), spring
spring (6). (21) and retainer (19) into poppet valve (24). Turn
retainer (19) clockwise until outer surface of retainer is
h. Remove retaining ring (2) and plug (1). flush with end of poppet valve.

2-10 27 SEPTEMBER 2010

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 BHT PUB-92-004-SI-1

Figure 2-2. Rotor Brake Master Cylinder

27 SEPTEMBER 2010 2-11

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Figure 2-3. Rotor Brake Master Cylinder Limits

2-12 27 SEPTEMBER 2010

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 BHT PUB-92-004-SI-1

c. Install springs (18 and 20) in piston (11).

Install poppet assembly (19, 21, 23, and 24) in sleeve
(5). Install poppet and sleeve in piston (11) and CAUTION
compress sleeve sufficiently to install retaining ring
(25). WHEN RETAINER (19) IS
APPROXIMATELY FLUSH WITH
d. Install spring (10) and cap (13) in piston SURFACE OF POPPET VALVE (24), ONE
assembly (11). Apply approximately 250 lb (1112 N) to TURN OF RETAINER CLOCKWISE WILL
top of cap (13) and install retaining ring (12). INCREASE HYDRAULIC PRESSURE 40
PSI (276 KPA). ONE TURN
e. Install link (14) and handle (26) on piston COUNTERCLOCK-WISE WILL
assembly. Install piston assembly in housing and DECREASE PRESSURE 40 PSI (276
install handle pivot bolt (15). KPA). RETAINER CAN BE ADJUSTED,
AS REQUIRED, TO OBTAIN ALLOWABLE
f. Install plug (1) and retaining ring (2). PRESSURE. HOWEVER, AS RETAINER
IS SCREWED DOWN NEAR POPPET (23)
THE ADJUSTMENT SENSITIVITY
g. Install plug (3) and filler cap (9).
INCREASES SIGNIFICANTLY, AND LESS
ROTATION OF RETAINER IS REQUIRED.
h. Install pin (30), spring (29), washer (28) and IF THIS CONDITION EXISTS, IT
spring pin (27) if removed at disassembly. PROBABLY MEANS THAT CYLINDER
HAS NOT BEEN PROPERLY BLED.
4. Adjustment of master cylinder. (See Figure 2-2.)
(4) Retainer (19) should be flush with or
below the surface of the popper valve (24). If the
a. Install 0 to 500 psi (0 to 3447 kPa) pressure retainer is below the surface of the popper valve,
gage in outlet port. measure and record the dimension; select AN960PD8
washer or washers to equal this measurement within
b. Fill cylinder with hydraulic fluid (C-002) and 0.016 in. (0.4064 mm). Install the washer or washers
bleed all air from cylinder and gage. (17) under spring (18).

c. Actuate handle (26) one complete stroke and (5) Install poppet valve (24) in sleeve (5).
check pressure reading. One stroke shall generate a Install sleeve and poppet valve assembly in piston
pressure of 230 to 270 psi (1586 to 1862 kPa). If assembly (11) and install retaining ring (25).
pressure is not within tolerance, record reading,
proceed as follows: (6) Reinstall piston assembly in housing
and install pivot bolt (15). Tighten pivot bolt nut finger
tight with minimum end play.
(1) Drain all fluid from cylinder.
d. Follow steps 4.a. through c. above for
(2) Remove handle pivot bolt (15) and recheck on poppet valve setting.
remove piston and handle as a unit.
e. Remove pressure gage and drain hydraulic
(3) Apply approximately 35 lb (156 N) to fluid.
sleeve (5) and remove retaining ring (25). Remove
sleeve (5) and poppet valve (24). Remove poppet f. Install protective plugs in openings.
valve (24) from sleeve and adjust retainer (19) as
required to obtain required pressure from master g. Prepare assembly for stock or return to
cylinder. helicopter.

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2-12. OVERHAUL — ROTOR BRAKE QUILL magnetic particle inspection (Code M) or fluorescent
ASSEMBLY. penetrant inspection (Code F) methods:

MATERIALS REQUIRED FIGURE 2-4 NOMENCLATURE CODE

Refer to BHT-ALL-SPM for specification and source. INDEX
NO.

NUMBER NOMENCLATURE 3 Nut M

— Adhesive, EA934NA 5 Spacer (Outer) M

C-304 Solvent 5 Spacer (Inner) M

8 Retainer F
SPECIAL TOOLS REQUIRED
13 Sleeve F

NUMBER NOMENCLATURE 19 Pinion M

T101519 Plate Assembly
c. Inspect parts dimensionally (Figure 2-5).
1. Disassembly. d. Inspect shims (6 and 17, Figure 2-4) for
damage and corrosion.
a. Remove nut (3, Figure 2-4) and packing (2)
from flange (1). Discard packing (2).
e. Inspect insert (14) for corrosion or damaged
threads.
b. Remove flange (1) from pinion (19).
4. Repair.
c. Cut lockwire and remove bolts (10) and
washers (11). Remove retainer (8), packing (7), and
shim plate (6). Mark shim plate for reinstallation.
Remove bushing (16) and packings (15). Discard CAUTION
packings (7 and 15).

d. Press seal (9) from retainer (8). Discard seal. DRESS SPLINES AND GEAR TEETH
WITH FINE INDIA STONE IF SURFACE
e. Hold duplex bearings (4) using T101519 plate NICKS, BURRS, OR SCRATCHES ARE
assembly and press pinion (19) from sleeve (13). VISIBLE. DUPLEX BEARINGS (4, FIGURE
2-4) ARE SERIAL NUMBERED AND
f. Remove duplex bearings (4) and spacer set SHALL BE INSTALLED IN MATCHED
(5) from sleeve (13). PAIRS. BOTH BEARINGS OF A PAIR
SHALL BE FROM THE SAME
MANUFACTURER.
NOTE
Do not remove ground shim (17) from BEARING SPACERS (5) ARE FINISH-
sleeve (13) unless damaged. GROUND TOGETHER, ARE SERIAL
NUMBERED AND SHALL BE REPLACED
g. Remove screws (18) and shim plate (17). AS A MATCHED SET.
Identify shim plate for reinstallation.
f. Replace all unserviceable components.
2. Cleaning.
g. If shims (6 and 17) are damaged, return rotor
a. Clean parts with dry cleaning solvent (C-304). brake drive quill to Bell Helicopter Textron CPR for
evaluation and repair.
b. Dry with filtered compressed air.
h. Replace threaded inserts (14) as required
3. Inspection. (BHT-ALL-SPM).

a. Inspect pinion (19, Figure 2-4) for chipped, i. Replace clinch nuts (12) if damaged or loose.
broken or excessively worn teeth.
(1) Use a drift or bolt threaded into nut to
b. Visually inspect parts for excessive wear or drive clinch nut out, being careful not to damage hole
damage (Figure 2-5). Inspect the following parts by in sleeve flange.

2-14 27 SEPTEMBER 2010

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 BHT PUB-92-004-SI-1

Figure 2-4. Rotor Brake Quill

27 SEPTEMBER 2010 2-15

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Figure 2-5. Rotor Brake Quill Damage Limits

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 BHT PUB-92-004-SI-1

(2) Clean sleeve by vapor degreasing to bolts 50 to 70 in-lb (6 to 8 N-m). Lockwire (0.032) bolts
trichloroethane. in pairs.
(3) Clean up surface of sleeve flange to f. Install flange (1) on splined end of pinion (19).
remove any raised burrs. Install packing (2) on nut (3) and install nut (3) on
pinion (19). Torque nut 125 to 150 ft-lb (169 to 203 N-
(4) Treat hole and any reworked areas on m). Lockwire (0.032) nut (3) between bolts holding
sleeve with chemical film material (BHT-ALL-SPM). disc assembly to flange (1).
(5) If clinch nut was tight before removal,
coat new nut with unreduced epoxy polyamide primer 2-13. SPECIAL INSPECTION — MASTER
and drive nut (12) in place. Remove any raised burrs CYLINDER.
on sleeve flange face, and touch up with chemical film
material (BHT-ALL-SPM). MATERIALS REQUIRED
Refer to BHT-ALL-SPM for specification and source.
(6) If clinch nut was loose before removal,
remove cadmium plating from surfaces of clinch nut
contacting the sleeve with abrasive paper. Clean NUMBER NOMENCLATURE
clinch nut (12) and mating surface of sleeve (13) with
cheesecloth dampened with solvent (C-309). Bond C-002 Hydraulic Fluid
clinch nut (12) in sleeve (13) with adhesive
(EA934NA).
NOTE
(7) Clean excess adhesive from threads
and surface of sleeve flange and hole. Clinch nut shall Each 1000 hour interval, or 12 months
be 0.010 in. (0.254 mm) minimum below surface of whichever occurs first.
sleeve flange.
1. Flush rotor brake hydraulic system to eliminate
(8 ) Check that side of sleeve flange water, chips, and other contaminates. Refill system
contacting shim plate is flat and clinch nut does not with hydraulic fluid (C-002).
protrude above surface.
2. Check hydraulic pressure of master cylinder as
5. Repair corrosion and damage to sleeve (13, follows:
Figure 2-4) and retainer (8) (refer to Figures 2-6 and 2-
7). a. Disconnect hose assembly at rotor brake
caliper and connect a 0 to 500 psi (0 to 3425 kPa)
6. Lubrication. pressure gage to hose. Bleed all air from hose at gage
location to ensure accurate maximum pressure
a. Lubricate bearings, gear and mating surfaces reading.
with approved oil.
b. Slowly move (approximately two seconds
b. Use corrosion preventive compound on duration) master cylinder handle through complete
mating threads of dissimilar metals. application cycle, recording maximum pressure
attained on gage.
7. Assembly.
NOTE
a. Install duplex bearings (4, Figure 2-4) and
spacer set (5) in sleeve (13). Required pressure for rotor brake hydraulic
system is 250 ± 20 psi (1724 ± 138 kPa).
Maximum pressure occurs just prior to
NOTE handle engaging park position detent (full
Bearings (4) are assembled back-to-back down).
on each side of spacer set (5). c. If pressure reading on gage is not with
b. Support inner race of duplex bearings (4) specified range 250 ± 20 psi (1724 ± 138 kPa) remove
with plate assembly and press pinion (19) in bearings master cylinder in accordance with Paragraph 2-8 and
(4). adjust in accordance with Paragraph 2-11, step 4. If
master cylinder cannot be adjusted, replace with a
c. Install packings (15) on bushing (16) and serviceable cylinder that has been checked.
install bushing (16) in sleeve (13).
d. After brake system pressure of 250 ± 20 psi
d. Press seal (9) in retainer (8). Install packing (1724 ± 138 kPa) has been established, remove gage
(7) in groove on retainer (8). from hose and install hose to rotor brake caliper.

e. Install retainer (8) and shim (6) on sleeve e. Bleed rotor brake system in accordance with
(13). Install four bolts (10) and washers (11). Torque Paragraph 2-7, step 4.

27 SEPTEMBER 2010 2-17

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BHT PUB-92-004-SI-1

Figure 2-6. Rotor Brake Quill Sleeve Rework Limits (Sheet 1 of 3)

2-18 27 SEPTEMBER 2010

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 BHT PUB-92-004-SI-1

Figure 2-6. Rotor Brake Quill Sleeve Rework Limits (Sheet 2)

27 SEPTEMBER 2010 2-19

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BHT PUB-92-004-SI-1

Figure 2-6. Rotor Brake Quill Sleeve Rework Limits (Sheet 3)

2-20 27 SEPTEMBER 2010

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 BHT PUB-92-004-SI-1

Figure 2-7. Rotor Brake Quill Retainer Rework Limits (Sheet 1 of 2)

27 SEPTEMBER 2010 2-21

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BHT PUB-92-004-SI-1

Figure 2-7. Rotor Brake Quill Retainer Rework Limits (Sheet 2)

2-22 27 SEPTEMBER 2010

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 BHT PUB-92-004-SI-1

CHAPTER 3 — PARTS INFORMATION AND KIT INVENTORY

TABLE OF CONTENTS

Paragraph Page
Number Title Number

3-1 Parts Information ........................................................................................ 3-3

3-2 Kit Inventory (205-530-517-101 and 205-706-034-117/-121) ..................... 3-3

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PARTS INFORMATION AND KIT INVENTORY

3-1. PARTS INFORMATION. 3-2. KIT INVENTORY (205-530-517-101 AND 205-

706-034-117/-121).
(Refer to BHT PUB-92-004-23P IPB).
NOTE
Some component parts of this kit may be
shipped preassembled.

Table 3-1. Kit Inventory (205-706-034-117/-121)

QUANTITY PART NUMBER NOMENCLATURE

1 205-530-517-101 Kit, Mod Cabin Roof, Consisting of:

1 . 205-530-517-115 Shim

1 . 204-030-617-137 Frame

1 . 204-030-617-141 Frame

1 . 204-030-617-147 Clip

1 . 204-030-617-149 Clip

1 . 204-030-617-151 Frame

1 . 204-030-617-153 Clip

1 . 204-030-636-009 Plate

1 . 212-030-345-001 Handle Installation

2 . . 20-042-11-16 Radius block

2 . . 212-030-344-011 Clip

1 . . 212-030-345-003 Edging

1 . . 90-040-3 Handle

2 . . MS27039-1-11 Screw

2 . . NAS1149D0316J Washer

2 . . MS21069L3 Nutplate

4 . . MS20426AD3-5 Rivet

4 . . MS20470AD4-5-5 Rivet

56 . MS20470AD4-5 Rivet

1 . 100-046S120A1 Plug Button

1 QT . AMS-S-8802 Sealant

6 oz. . 299-947-100 Type II Class II Adhesive

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Table 3-1. Kit Inventory (205-706-034-117/-121) (Cont)

QUANTITY PART NUMBER NOMENCLATURE

1 205-706-034-117/-121 Kit, Rotor Brake, Consisting of:

1 . 204-076-036-005 Master Cylinder

1 . 204-072-147-001 Decal

1 . 204-076-336-001 Decal

1 . 205-075-368-005 Lamp assembly

1 . 205-075-934-001A Cable assembly

1 . 212-076-169-001 Tube assembly

1 . 212-076-170-001 Tube assembly

1 . 205-076-153-001 Tube assembly

1 . 412-040-123-101/-105 Quill assembly

4 . AN4-7A Bolt

4 . AN4H5A Bolt

1 . AN520-10R8 Screw
(Alt. MS35207-263)

6 . AN6-13A Bolt

2 . AN6289D5 Nut

2 . AN743-12 Bracket

1 . AN814-4D Plug

1 . AN924-5D Nut

7 . AN960-416L Washer

1 . MS27039-1-05 Screw

6 . MS27039-1-14 Screw

6 . AN960-616 Washer

3 . AN960PD10L Washer

8 . AN960PD416 Washer

3 . MS20073-04-11 Bolt

100 in. . AS100028 Lockwire

1 . MS20995F32-48 Lockwire
(Alt. MS20995C32-48)

7 . MS21042L3 Nut

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 BHT PUB-92-004-SI-1

Table 3-1. Kit Inventory (205-706-034-117/-121) (Cont)

QUANTITY PART NUMBER NOMENCLATURE

2 . MS21902D5 Union

2 . MS21908D5 Elbow

7 . MS21919DG5 Clamp

1 . MS25244-5 Circuit breaker

2 . MS28777-5 Ring

1 . MS28778-4 Packing

2 . MS28778-5 Packing

1 . MS29561-248 Packing

1 . MS35489-10 Grommet

1 . MS35489-118 Grommet

1 . M15570-20 Crimping tool

6 . NAS1197-616 Washer

6 . NAS43DD3-40N Spacer

1 . NAS679A3 Nut

4 . NAS679A4 Nut

1 . T666035-5-0120 Hose assembly

(Alt. R9800DD5-12)
(Alt. 124027-5-0120)

1 . 375213-5 Coupling half

1 . 375508-5 Coupling

1 . 9440791-1 Disk

1 . 9450103-1 Brake assembly

4 . 1841-1-5620 Terminal

1 (50 ft.) . AA52081-C Tape

8 oz. . AMS-S-8802 Sealant

2 oz. . 299-947-100 Type II Class II Adhesive

1 . 205-030-973-001 Coupling Support Installation

1 . . 205-030-974-001 Support

3 . . MS20470AD4-4-5 Rivet

1 . BHT PUB-92-004-SI-1 Service instruction

27 SEPTEMBER 2010 3-5/3-6

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 BHT PUB-92-004-SI-1

CHAPTER 4 — AIRWORTHINESS LIMITATIONS AND OVERHAUL SCHEDULE

TABLE OF CONTENTS

Paragraph Page
Number Title Number

4-1 Introduction ................................................................................................. 4-3

4-2 Overhaul Procedures.................................................................................. 4-3

TABLES

Table Page
Number Title Number

4-1 Airworthiness Limitations/Overhaul Schedule ............................................ 4-3

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AIRWORTHINESS LIMITATIONS AND OVERHAUL SCHEDULE

4-1. INTRODUCTION. 4-2. OVERHAUL PROCEDURES.

This schedule lists the overhaul interval that the Main Refer to Table 4-1 for overhaul schedule and Chapter
Rotor Brake Quill Assembly may remain in service 2 of this Service Instruction for overhaul procedures.
until component overhaul is required. The Main Rotor
Brake Assembly has no retirement life time limitation.

Table 4-1. Airworthiness Limitations/Overhaul Schedule

PART NUMBER NOMENCLATURE OVERHAUL INTERVAL

412-040-123-101/-105 Quill Assembly 2500 Hours

27 SEPTEMBER 2010 4-3/4-4

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