BHT-407-MM-2

CHAPTER 12 — SERVICING

TABLE OF CONTENTS

Paragraph Chapter/Section Page

Number Title Number Number

SERVICING

12-1 Servicing — General...................................................................... 12-00-00 5

12-1A Servicing Tolerance ....................................................................... 12-00-00 5
12-2 Access Panels, Drains, and Sight Gauges ............................... 12-00-00 5

FUEL SYSTEM SERVICING

12-3 Fuel System — Servicing............................................................... 12-00-00 11

12-4 Fueling/Defueling — Preparation.................................................. 12-00-00 11
12-5 Fuel System — General Servicing Instructions ........................ 12-00-00 11
12-6 Fuel System — Draining........................................................... 12-00-00 12
12-7 Fuel System — Fueling ............................................................ 12-00-00 12
12-8 Fuel System — Defueling ......................................................... 12-00-00 12
12-9 Fuel Cell — Purging.................................................................. 12-00-00 14

OIL SYSTEM SERVICING

12-10 Oil Level — Check ......................................................................... 12-00-00 15

12-11 Changing Oil Brands or Specifications .......................................... 12-00-00 15
12-12 Engine Oil System ......................................................................... 12-00-00 15
12-13 Engine Oil System — Servicing................................................ 12-00-00 15
12-14 Engine Oil System — Servicing ........................................ 12-00-00 16
12-15 Engine Oil System — Draining ......................................... 12-00-00 16
12-16 Transmission/Freewheel Oil System ............................................. 12-00-00 16
12-17 Transmission Oil System — Servicing...................................... 12-00-00 16
12-18 Transmission Oil System — Servicing.............................. 12-00-00 16
12-19 Transmission Oil System — Draining ....................................... 12-00-00 17
12-20 Transmission Oil System — Draining (With Special
Drain Fitting and Hose Assembly) .................................... 12-00-00 17
12-21 Transmission Oil System — Draining (Without the Special
Drain Fitting and Hose Assembly) .................................... 12-00-00 17
12-22 Transmission Oil Cooler and Oil Lines — Draining........... 12-00-00 19
12-23 Freewheel Oil System.................................................................... 12-00-00 19
12-24 Freewheel Oil System — Draining............................................ 12-00-00 19
12-25 Freewheel Oil System — Draining (With the Special
Drain Fitting and Hose Assembly) .................................... 12-00-00 19
12-26 Freewheel Oil System — Draining (Without the Special
Drain Fitting and Hose Assembly) .................................... 12-00-00 19
12-27 Tail Rotor Gearbox Oil System ...................................................... 12-00-00 20
12-28 Tail Rotor Gearbox Oil System – Servicing .............................. 12-00-00 20
12-29 Tail Rotor Gearbox Oil System — Draining .............................. 12-00-00 20
12-30 Tail Rotor Gearbox Oil System — Draining (With the
Special Drain Fitting and Hose Assembly)........................ 12-00-00 20
12-31 Tail Rotor Gearbox — Draining (Without Special Drain
Fitting and Hose Assembly) .............................................. 12-00-00 22

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TABLE OF CONTENTS (CONT)

Paragraph Chapter/Section Page

Number Title Number Number

HYDRAULIC SYSTEM SERVICING

12-32 Hydraulic System Servicing ........................................................... 12-00-00 23

12-33 Hydraulic Reservoir — Servicing .............................................. 12-00-00 23
12-34 Hydraulic System — Draining................................................... 12-00-00 23
12-34A Hydraulic System Servicing — Rotor Brake System ................ 12-00-00 23
12-34B Rotor Brake System — Servicing ..................................... 12-00-00 24B

GREASE LUBRICATION

12-35 Grease Lubrication — Servicing .................................................... 12-00-00 25

12-36 Pitch Change Link Bearing — Servicing ........................................ 12-00-00 26A
12-37 Pitch Change Link Bearing — Grease...................................... 12-00-00 26A
12-38 Swashplate — Purging ............................................................. 12-00-00 34
12-39 Hydraulic Pump Drive Shaft — Grease .................................... 12-00-00 34
12-40 Oil Cooler Blower Hanger Bearings — Grease ........................ 12-00-00 35
12-41 Tail Rotor Driveshaft Hanger Bearings — Grease.................... 12-00-00 36
12-42 Tail Rotor Drive Splines — Grease........................................... 12-00-00 37
12-43 Tail Rotor Gearbox Pitch Change Mechanism — Grease ........ 12-00-00 38
12-44 Litter Door Seal — Lubrication....................................................... 12-00-00 38

MISCELLANEOUS SERVICING

12-45 Battery — Servicing ....................................................................... 12-00-00 39

12-46 Fire Extinguisher ............................................................................ 12-00-00 39
12-47 Fire Extinguisher — Servicing .................................................. 12-00-00 39
12-48 Ground Handling Wheels — Servicing .......................................... 12-00-00 39
12-49 Ground Handling Wheels Hydraulic Pump Cylinder —
Servicing ................................................................................... 12-00-00 39
12-50 Ground Handling Wheels Hydraulic Pump Cylinder —
Servicing ........................................................................... 12-00-00 39
12-51 Ground Handling Wheel Axles — Servicing ............................. 12-00-00 39
12-52 Ground Handling Wheel Axles — Grease ........................ 12-00-00 40
12-53 Ground Handling Wheel Tires — Servicing ...................... 12-00-00 40
12-54 Windshield and Windows — Cleaning ........................................... 12-00-00 40
12-55 Oil Cooler Blower Impeller — Cleaning ......................................... 12-00-00 42

FIGURES

Figure Page
Number Title Number

12-1 Access Panels, Drains, and Sight Gauges ......................................................... 8

12-2 Transmission Servicing....................................................................................... 18
12-3 Tail Rotor Gearbox Servicing.............................................................................. 21
12-4 Hydraulic Reservoir Servicing............................................................................. 24

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FIGURES (CONT)

Figure Page
Number Title Number

12-4A Rotor Brake System — Servicing ....................................................................... 24A

12-5 Grease Lubrication.............................................................................................. 26
12-6 Ground Handling Wheel Assembly ..................................................................... 41

TABLES

Table Page
Number Title Number

12-1 Fuel and Filters Intervals..................................................................................... 5

12-2 Grease Lubrication Intervals ............................................................................... 6A
12-3 Oil and Lubricants ............................................................................................... 7

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SERVICING

12-1. SERVICING — GENERAL The Bell Helicopter Textron approved tolerance for
Chapter 12 servicing intervals, unless otherwise
This chapter contains the data required to service the stated, is 10% of the specified hourly or calendar time
helicopter. interval, whichever is less. The tolerances are
established for maintenance scheduling convenience
Table 12-1, Table 12-2, and Table 12-3 contain the list only.
of the recommended servicing intervals for fuel, oil,
filter, grease lubrication, and miscellaneous servicing. Servicing intervals required beyond the stated
The intervals given are the maximum permitted tolerances must be approved by Product Support
intervals under normal operation of the helicopter. Do Engineering.
not exceed these intervals unless stated otherwise. It
may be necessary to increase the frequency of these
intervals if the helicopter operates in extreme NOTE
environmental conditions. Refer to the specific
instructions and figures in this chapter for servicing The following is only applicable for those
and lubrication procedures. For data on the operators whose governing aviation
consumable materials, refer to the BHT-ALL-SPM. authority requires to specifically approve
the servicing tolerance.
For specific information on fuels, oils, and fluids, refer
to the applicable BHT-407-FM-X. If approval of the servicing tolerance is required by the
applicable governing aviation authority, this is the
12-1A. SERVICING TOLERANCE responsibility of the owner/operator.

Refer to the Rolls-Royce Engine Operation and

CAUTION Maintenance Manual for servicing tolerances.

12-2. ACCESS PANELS, DRAINS, AND SIGHT

DO NOT APPLY THESE TOLERANCES IF
GAUGES
THE HELICOPTER IS OPERATED IN
EXTREME ENVIRONMENTAL
CONDITIONS REQUIRING AN Figure 12-1 shows the location of all the access
INCREASED FREQUENCY OF panels, drains, and sight gauges required for servicing
SERVICING. OTHERWISE, DAMAGE TO the helicopter. For the location of other panels required
THE PARTS MAY OCCUR. for maintenance access, refer to Chapter 53.

Table 12-1. Fuel and Filters Intervals

INTERVALS (HOURS) COMPONENT TYPE OF FUEL CAPACITY

N/A Fuel Cells Turbine Fuel (C-003) 129.7 gallons (492.0 L)

300 Hours Airframe Fuel Filter 1 N/A N/A

Refer to Rolls-Royce Engine (CEFA) Fuel N/A N/A

Engine Operation and Filter 1
Maintenance Manual

Refer to Rolls-Royce Engine Fuel Filter N/A N/A

Engine Operation and (FMU) 2
Maintenance Manual

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Table 12-1. Fuel and Filters Intervals

INTERVALS (HOURS) COMPONENT TYPE OF FUEL CAPACITY

NOTES:

1 For helicopters S/N 53000 through 54566 and 54568 through 54800.

2 For helicopters S/N 54567 and 54805 and subsequent

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Table 12-2. Grease Lubrication Intervals

INTERVALS (HOURS/
COMPONENT TYPE OF GREASE
MONTHS) 1

25 Hours 4 406-040-339-ALL Grease (C-001), Mobil 28 Only 5 12

Tail Rotor Driveshaft Hanger Bearings

300 Hours 4 8 407-340-339-107 Grease (C-001), Mobil 28 Only 6 12

Tail Rotor Driveshaft and Oil Cooler
Blower Hanger Bearings

50 Hours/3 Swashplate Bearings (2 Places) Grease (C-001)

Months 2 3 4

50 Hours/3 Pitch Change Link Bearing (4 Places) Grease (C-001) or grease (C-172) 13
Months 2 3 4

100 Hours 4 10 Tail Rotor Driveshaft Splines Grease (C-525) or grease (C-561)
(2 Places)

300 Hours/12 Months 4 Hydraulic Pump Drive Grease (C-525) or grease (C-561)

300 Hours/3 Months 4 Tail Rotor Pitch Change Mechanism Grease (C-001)
(2 Places)

600 Hours/12 Months 9 Expandable Blade Bolts (2 Places) Grease (C-561)

6 Months 4 Ground Handling Wheel (2 Places) Grease (C-001)

25 Hours or as Litter Door Seal Lubricant (C-018)

required 4 7 11

NOTES:

1 Do the servicing at the interval that comes first.

2 If the helicopter is parked outside in a heavy dew environment, purge lubricate all exposed control
bearings every 7 days to make sure there are no air pockets that could trap moisture.

3 After each day of operation in rain or snow, or after washing the helicopter, purge to remove any trapped
moisture and to make sure a lubrication film is applied to any exposed, unprotected surface.

4 Specified interval or whenever a new component is installed.

5 WARNING: THIS BEARING HAS A BROWN ELASTOMER SEAL. MIXING GREASE (C-001) MOBIL 28
WITH LUBRICANT (C-026) OR ANY OTHER GREASE, WILL DAMAGE THE BEARING. THE BEARING
MUST BE SCRAPPED IF GREASES HAVE BEEN MIXED.

6 WARNING: THIS BEARING HAS AN ORANGE ELASTOMER SEAL. MIXING GREASE (C-001) MOBIL
28 WITH LUBRICANT (C-026) OR ANY OTHER GREASE, WILL DAMAGE THE BEARING. THE
BEARING MUST BE SCRAPPED IF GREASES HAVE BEEN MIXED.

7 Applicable to S/N 53000 through 53169 Post TB 407-98-11 and S/N 53170 through 54061. It is
recommended that lubricant (C-018) be applied every 25 hours. If required, application of lubricant may
be extended to next inspection interval to accommodate maintenance scheduling.

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Table 12-2. Grease Lubrication Intervals (Cont)

8 As applicable to S/N 53000 through 53518, ASB 407-02-54 “OIL COOLER INLET AIRFLOW —
IMPROVEMENTS TO” shall have been accomplished to coincide with 300 hour oil cooler blower hanger
bearing lubrication interval. Also applicable to S/N 53519 and subsequent.

9 The lubrication procedure is part of the 600-hour/12-month inspection (Chapter 62).

10 Interval may be extended to 150 hours, provided TB 407-02-35, Part IV-B has been accomplished.

11 Helicopters S/N 53000 through 54061 Post TB 407-11-94 and S/N 54062 and subsequent do not require
lubrication and are therefore not affected by this recurrent lubrication interval.

12 Evidence of black grease pushed out from the bearing is cause for rejection. Normal colored grease
(red-purple for Mobil 28) that is pushed out from the bearing seal is not cause for rejection.

13 Grease (C-001) is applicable to 406-310-405-101/-103 Pre TB 407-16-119. Grease (C-172) is applicable

to 406-310-405-101/-103 Post TB 407-16-119 and 406-310-405-105.

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Table 12-3. Oil and Lubricants

INTERVALS (HOURS/
COMPONENT TYPE OF OIL CAPACITY
MONTHS) 1

12 Months Oil/Ground Handling Wheel Hydraulic Fluid 0.07 Pints

Hydraulic Cylinder (C-002) Red (0.033 L)

Refer to Rolls-Royce Oil/Engine Lubricating Oil 2 7.0 Quarts

Engine Operation and (6.62 L)
Maintenance Manual

300 Hours/12 Months Oil/Transmission Lubricating Oil 2 6.0 Quarts

(5.68 L)

300 Hours/12 Months Oil/Tail Rotor Gearbox Lubricating Oil 2 0.33 Quart
(0.31 L)

300 Hours/12 Months 3 Filter Element/Hydraulic N/A N/A

300 Hours/12 Months 4 Filter/Transmission N/A N/A

300 Hours/12 Months Hydraulic Fluid Hydraulic Fluid Red 2 1.68 Quarts
(1.59 L)

NOTES:

1 Do the servicing at the interval that comes first.

2 REFER TO THE APPLICABLE FLIGHT MANUAL (BHT-407-FM-X) FOR THE APPROVED OILS.

3 Refer to Chapter 29 for inspection and cleaning procedures.

4 Refer to Chapter 63 for the removal, inspection, and installation procedures.

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Figure 12-1. Access Panels, Drains, and Sight Gauges (Sheet 1 of 2)

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1 7
8
16
9

6
1. Drain pump access
2. Battery access
3. Engine oil access door
4. Tail rotor gearbox oil servicing
5. Tail rotor gearbox oil drain and chip detector
6. Transmission oil filler port and chip detector
7. Airframe fuel filter
8. Refueling port
9. Drain tube, drain switches
10. Manual drain valves (transmission oil cooler)
11. Ground handling wheels
12. External power receptacle
13. Tail rotor drive shaft
14. Freewheel chip detector
15. Hydraulic reservoir
16. Grounding receptacle

NOTE
1 S/N 53000 through 54566 and 54568 through 54800.

407_MM_12_0002_c01

Figure 12-1. Access Panels, Drains, and Sight Gauges (Sheet 2 of 2)

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FUEL SYSTEM SERVICING

12-3. FUEL SYSTEM — SERVICING 2. Do not wear static producing clothes such as
nylon, rayon or wool. Make sure all personnel around
the helicopter dissipate static electricity potential by
The fuel system is made up of two interconnected fuel
gripping the static ground line with their bare hands.
cells. The system is serviced through a single filler port
installed on the right hand side on the helicopter. An
electrical grounding jack is also installed on the right 3. Do not fuel or defuel the helicopter in areas
hand side of the helicopter near the filler port. An where fumes and gases can accumulate.
electrically operated sump drain valve is installed in
the bottom of each fuel cell. Operation of the sump 4. Do not fuel or defuel the helicopter in a hangar or
drain valves is done through two switches installed on in other closed places. Make sure the helicopter is a
the right hand side of the helicopter below and aft of minimum of 50 feet (15.2 m) away from any building.
the fuel filler port. The airframe fuel filter is installed on
the aft face of the right hand side of the forward 5. Make sure no other aircraft or motorized vehicle
firewall. The fuel filter has a manual drain valve, operates under its own power within 50 feet (15.2 m)
bypass capability, and an impending bypass switch. of the helicopter.
The switch is connected to the caution/warning and
advisory panel in the flight compartment. 6. Position the service unit no closer than 20 feet
(6.1 m) and as far away as the hose will permit. Make
sure all the vent doors are open.
12-4. FUELING/DEFUELING —
PREPARATION
7. Connect the service unit to an approved ground
rod. Utilize the grounding receptacle (16, Figure 12-1)
12-5. FUEL SYSTEM — GENERAL SERVICING and grounding cable to connect the helicopter to the
INSTRUCTIONS service unit or to an approved ground rod.

8. Make sure the service unit hose nozzle is

grounded to the helicopter grounding receptacle (16)
WARNING
before the dust cap is removed from the nozzle or
before the filler cap is removed from the helicopter.

BE VERY CAREFUL WHEN YOU FUEL

9. Make sure the area around the helicopter is clear
OR DEFUEL THE HELICOPTER.
to permit rapid evacuation of the personnel and
AVIATION FUELS ARE EXTREMELY
vehicles in the case of an emergency. If power is
FLAMMABLE. THE FUEL FUMES AND
required to fuel or defuel the helicopter, turn the
G A S E S C A N I G N I T E W I T H S TAT I C
battery switch and required system switches on before
ELECTRICITY, FRICTION SPARKS, HOT
you start the operation. Do not operate any switches
EXHAUST PIPES, LIGHTED
until the operation is completed.
CIGARETTES, ELECTRICAL DEVICES,
OR SIMILAR IGNITION SOURCES. DO
NOT SMOKE AROUND THE NOTE
HELICOPTER.
If power is required to fuel or defuel the
helicopter, turn the battery switch and
MAKE SURE THAT ONLY QUALIFIED required system switches on before you
PERSONNEL ARE IN THE AREA WHEN start the operation. Do not operate any
YOU FUEL OR DEFUEL THE switches until the operation is complete.
HELICOPTER.
10. Make sure all the helicopter power is off.
1. Do not fuel or defuel the helicopter in high wind
conditions or when an electrical storm is within a 3 11. Make sure no personnel are aboard the
mile (4.83 km) radius of the fueling area. helicopter when you fuel or defuel the helicopter.

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BHT-407-MM-2

12-6. FUEL SYSTEM — DRAINING 4. Make sure the fuel in the service unit is the
correct type. Refer to applicable Flight Manual
1. Make sure the FUEL BOOST/XFR LEFT and (BHT-407-FM-X).
FUEL BOOST/XFR RIGHT circuit breaker switches
are off. 5. Position the service unit and secure it with the
hand brake and wheel chocks.
2. Set the BATT switch to the ON position.
6. Make sure the fire extinguisher is operational and
3. Make sure the FUEL VALVE switch is OFF. accessible.

4. On the right side of the aft fuselage push in the 7. Connect the service unit to the ground rod. Utilize
FWD FUEL SUMP and AFT FUEL SUMP drain the grounding receptacle (16, Figure 12-1) and a
switches and drain the forward and aft fuel cells into a grounding cable to connect the helicopter to the
clean dry container. Inspect for water or other service unit or to the ground rod.
contamination.

8. Connect the hose nozzle ground to the helicopter

12-7. FUEL SYSTEM — FUELING grounding receptacle (16) and remove the dust cap on
the fueling hose.

SPECIAL TOOLS REQUIRED

9. Open the filler cap and service the helicopter fuel
cells with the required quantity of turbine fuel (C-003).
NUMBER NOMENCLATURE
10. Replace the filler cap on the helicopter and install
Commercial Carbon Dioxide Fire the dust cap on the fueling hose.
Extinguisher,
50 pounds (23 kg), with
Extension Assembly 11. Remove the hose nozzle ground connection from
the helicopter.

12. Remove the helicopter ground from the service

MATERIALS REQUIRED
unit. Remove the service unit ground from the ground
rod.
Refer to BHT-ALL-SPM for specifications.

NUMBER NOMENCLATURE 12-8. FUEL SYSTEM — DEFUELING

C-003 Turbine Fuel

1. Prepare the helicopter for fueling (paragraph

CAUTION
12-5).
IF THE CONDITION OF THE FUEL
NOTE REMOVED FROM THE HELICOPTER IS
QUESTIONABLE, TEST THE FUEL TO
If power is required, turn the battery and MAKE SURE IT IS CLEAN BEFORE IT IS
required switches on before the start of the USED AGAIN IN ANOTHER
fueling operation. Do not operate any HELICOPTER. IF YOU USE
switches until the operation is completed. C O N TA M I N AT E D F U E L , I T C O U L D
CAUSE AN ENGINE FAILURE.
2. Make sure the helicopter electrical power is off.
1. Prepare the helicopter for defueling (paragraph
3. Make sure the vent line is free of obstruction. 12-5).

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2. Notify the fire department of the defueling 11. Apply aircraft electrical power and set the FUEL
location and of the times you plan to start and stop the BOOST/XFR LEFT and FUEL BOOST/XFR RIGHT
operation. circuit breaker switches to ON. Make sure all the fuel
in the forward fuel cell is transferred to the aft fuel cell.
3. Make sure no personnel are inside the helicopter Position switches to OFF and remove aircraft electrical
during the defueling operation. power.

NOTE 12. Defuel the helicopter.

If power is required, turn the battery and

required system switches on before the
start of the defueling operation. Do not CAUTION
operate any switches until the operation is
complete.
IF THE CONDITION OF THE FUEL
4. Make sure the helicopter electrical power is off.
REMOVED FROM THE HELICOPTER IS
QUESTIONABLE, TEST THE FUEL TO
5. Make sure the fire extinguisher is operational and MAKE SURE IT IS CLEAN BEFORE IT IS
accessible. USED AGAIN IN ANOTHER
HELICOPTER. IF YOU USE
6. Make sure the vent line is free of obstruction. C O N TA M I N AT E D F U E L , I T C O U L D
CAUSE AN ENGINE FAILURE.
7. Position the service unit and secure it with the
hand brake and wheel chocks. 13. Make sure all the fuel has been removed from the
main fuel cell.
8. Connect the service unit to the ground rod. Utilize
the grounding receptacle (16, Figure 12-1) and a
grounding cable to connect the helicopter to the 14. Remove the defueling hose from the helicopter.
service unit or to the ground rod.
15. Install the filler cap.
9. Open the filler cap.
16. Remove the defueling hose ground connection
10. Install the defueling hose in the aft fuel cell.
from the helicopter.

17. Remove the helicopter ground from the service

CAUTION unit. Remove the service unit ground from the ground
rod.
DO NOT LET THE BOOST PUMPS RUN
DRY FOR EXT E NDED P ERIODS OF 18. If the helicopter is to be stored for a long period of
TIME. time, purge the fuel system (paragraph 12-9).

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12-9. FUEL CELL — PURGING

WARNING

SPECIAL TOOLS REQUIRED U S E O N LY D R Y F I LT E R E D A I R ,

NITROGEN (GAS) (C-315) OR CARBON
DIOXIDE GAS.
NUMBER NOMENCLATURE
4. Blow low pressure dry filtered air into the fuel
Commercial Explosimeter
cells for a period of eight hours. Then blow low
(Combustible Gas
pressure nitrogen (gas) (C-315) or carbon dioxide gas
Indicator Calibrated for
into the fuel cells for a few minutes.
Fuel Vapors)
5. Remove the hose from the fuel filler and let the
helicopter stand for one hour.
MATERIALS REQUIRED

Refer to BHT-ALL-SPM for specifications. WARNING

NUMBER NOMENCLATURE

Commercial Carbon Dioxide Gas MAKE SURE THAT THE EXPLOSIMETER

READS LESS THAN 20%. IF THE
C-009 Lubricating Oil EXPLOSIMETER READS MORE THAN
2 0 % , R E P E AT S T E P 3 T H R O U G H
C-315 Nitrogen (Gas) STEP 5. UNTIL YOU OBTAIN A READING
OF LESS THAN 20%.
C-426 Masking Tape
6. Check the interior of the fuel cells with an
explosimeter and make sure the reading is within the
The fuel system is purged to remove explosive fumes allowable limits.
and gases from the fuel system before you store the
helicopter in a hangar. When the helicopter is ready to 7. Spray the interior of the fuel cells with lubricating
be returned to service after it has been purged, fuel oil (C-009).
the helicopter.

1. Defuel the helicopter (paragraph 12-8). NOTE

Do not block the vent lines.
2. Open all the sump drains and drain lines. 8. Close the drains and install the filler cap.

3. Install an air hose inside the fuel cell through the 9. Install a tag that reads "FUEL SYSTEM
fuel filler. Seal the opening with masking tape (C-426). PURGED".

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OIL SYSTEM SERVICING

12-10. OIL LEVEL — CHECK

NOTE
Only perform the following steps as they
The sight gauges in the transmission, the engine oil
pertain to the specific component(s)
tank, and the tail rotor gearbox permit personnel to affected.
make sure the oil level in these components is within
the permitted limits. Refer to Figure 12-1 for the 1. Refer to the Rolls-Royce Engine Operation and
location of the sight gauges. Maintenance Manual or specific engine
requirements.
Stained or discolored sight gauges could give a false
a. Drain the engine oil system (paragraph
indication of oil/fluid quantity. Clean or replace stained
12-15), flush the engine oil system (Chapter 79), and
or discolored sight gauges.
service the engine oil system with clean oil (paragraph
12-13).
12-11. CHANGING OIL BRANDS OR
SPECIFICATIONS 2. Drain the transmission oil system (paragraph
12-19), flush the transmission oil lines and hoses
(Chapter 63), replace the transmission oil filter
(Chapter 63), drain the freewheel (paragraph 12-24),
CAUTION and service the transmission oil system with clean oil
(paragraph 12-17).

D O N O T M I X O I L S O F D I FF E R E N T 3. Drain the tail rotor gearbox (paragraph 12-29)

SPECIFICATIONS. IF OILS BECOME and service the tail rotor gearbox with clean oil
MIXED, SYSTEM SHALL BE DRAINED, (paragraph 12-28).
FLUSHED, AND REFILLED WITH
PROPER SPECIFICATION OIL. 4. Operate helicopter for not less than 30 minutes
nor longer than 5 hours.
Use only the oil brands or specifications approved by
the manufacturer of the helicopter or of the engine. 5. Drain the engine, transmission, freewheeling unit,
and tail rotor gearbox. Service the engine,
Refer to the applicable Flight Manual
transmission, and tail rotor gearbox with proper
(BHT-407-FM-X). Record the specification and brand
amount of approved oil. Refer to previous step a,
of oil used in the helicopter logbook. Refer to the step 2, and step 3.
logbook to make sure the oil will not be mixed
incorrectly. 6. During first 100 hours of operation with new oil,
check oil sight glasses closely for indications of foggy
When adding oil to the engine, main transmission, or or hazy appearance. If these indications occur, repeat
tail rotor gearbox, the identical brand and specification step 5 until eliminated.
of oil already in the engine or each gearbox shall be
used. However, in circumstances where emergency 12-12. ENGINE OIL SYSTEM
top-off or inadvertent mixing may occur, it is
acceptable to use oil with a different brand name 12-13. ENGINE OIL SYSTEM — SERVICING
within the same specification. Refer to the applicable
Manufacturer Data Section (BHT-407-MD-X). The engine oil system is serviced by removing the oil
filler cap installed on the engine oil tank. The oil tank is
installed aft of the oil cooler blower and closed by the
If oils of different specifications have been mixed or a aft fairing (Chapter 53). Access to the oil tank is gained
different oil specification is being introduced, do the through an access door on the top of the aft fairing (3,
following: Figure 12-1).

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BHT-407-MM-2

12-14. Engine Oil System — Servicing 12-15. Engine Oil System — Draining

1. Position a container under the helicopter below

NOTE the drain tubes.
If the helicopter engine has been shut down
for more than 15 minutes, scavenge oil 2. Open the access door on top of the aft fairing and
could have drained into the gearbox. Dry remove the oil filler cap.
motor the engine for 30 seconds before you
check the oil level. If you do not do this, a 3. Open the access door on the LH side of the aft
false high engine oil consumption rate fairing, open the manual drain valve, and drain the oil
indication or overfilling of the oil tank could from the engine oil tank.
result.
4. Close the manual drain valve and the manual
Make sure the helicopter is level when drain valve access door.
servicing. If not level, underfill or overfill of
the engine oil system will result.
5. Install the filler cap on the engine oil tank and
close the access door on the aft fairing.
1. Check the quantity of oil in the engine oil tank
within 15 minutes of the engine shut down.
6. Drain the engine gearbox in accordance with the
Rolls-Royce Engine Operation and Maintenance
NOTE Manual.

If the oil pressure fluctuates and oil foams,

12-16. TRANSMISSION/FREEWHEEL OIL
drain the engine oil system (paragraph
SYSTEM
12-15) and replace the oil with new oil.
The transmission oil system consists of the
If you use oil stored in small containers,
transmission and the freewheel unit. The transmission
shake the container to mix the additives
oil system is serviced through the oil filler cap installed
before you pour the oil in the engine oil
on the transmission (paragraph 12-17).
tank.
12-17. TRANSMISSION OIL SYSTEM —
If there is mixing of oil between the engine
SERVICING
and the transmission, the engine gearbox
double lip PTO seals could be leaking.
The transmission is installed on the roof of the
Refer to Chapter 71. Different oils are used
helicopter. The system is serviced by removing the
in the engine and in the transmission. Refer
filler cap installed on the forward right side of the
to paragraph 12-11.
transmission.
2. Open the access door (3, Figure 12-1) on the aft
12-18. Transmission Oil System — Servicing
fairing and remove the oil filler cap from the engine oil
tank.
NOTE
3. Fill the engine oil tank to the correct range on the If the oil pressure fluctuates and oil foams,
sight gauge. Use only approved lubricating oil. Refer drain (paragraph 12-19) and replace the oil
to the applicable BHT-407-FM-X and to the with new lubricating oil.
Rolls-Royce Engine Operation and Maintenance
Manual. If you use oil stored in small containers,
shake the container to mix the additives
before you pour the oil in the transmission.
4. Install the filler cap on the engine oil tank.
If there is mixing of oil between the engine
5. Close the access door (3, Figure 12-1) on the aft and the transmission, the engine gearbox
fairing. double lip PTO seals could be leaking.

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 BHT-407-MM-2

Refer to Chapter 71. Different oils are used 12-20. Transmission Oil System — Draining
in the engine and in the transmission. Refer (With Special Drain Fitting and Hose
to paragraph 12-11. Assembly)

Make sure the helicopter is level when

servicing. If not level, underfill or overfill of SPECIAL TOOLS REQUIRED
the transmission oil system will result.

NUMBER NOMENCLATURE
1. Remove the transmission cowling (Chapter 53).
H4713 Drain Fitting and Hose
Assembly
2. Make sure the oil cooler and drain lines manual
shut-off drain valves (3 and 4, Figure 12-2) located on
the baggage compartment wall are closed. 1. Remove the transmission cowling (Chapter 53).

2. Remove the oil filler cap (2, Figure 12-2) from the
3. Remove the filler cap (2) on the transmission.
transmission.

3. Remove the drain plug (6).

NOTE
It is recommended that the transmission oil 4. Install the drain fitting (7) in the drain port.
level be filled to the lower portion of the OIL
LEVEL marking. 5. Drain the oil from the transmission oil system.

4. Fill the transmission with lubricating oil (refer to 6. Remove the drain fitting (7) from the drain port.
applicable BHT-407-FM-X) to within the OIL LEVEL
marking on the sight gauge (1).
7. Install the drain plug (6).

5. Install the filler cap (2) on the transmission. 8. Install the oil filler cap (2) in the transmission.

9. Install the transmission cowling (Chapter 53).

6. Install the transmission cowling (Chapter 53).

10. Drain the oil cooler and drain lines (paragraph

12-19. TRANSMISSION OIL SYSTEM — 12-22).
DRAINING
12-21. Transmission Oil System — Draining
The transmission oil system can be drained in the (Without the Special Drain Fitting and
three ways that follow: Hose Assembly)

1. Remove the transmission cowling (Chapter 53).

• with the special drain fitting and hose
assembly (only the transmission is drained)
2. Remove the oil filler cap (2, Figure 12-2) from the
(paragraph 12-20)
transmission.

• without the special drain fitting and hose 3. Position a container under the helicopter drain.
assembly (only the transmission is drained)
(paragraph 12-21) 4. Disconnect the freewheel to transmission return
line at the forward firewall.
• by draining the residual oil from the oil cooler
and the oil lines (only the oil cooler and the oil 5. Drain the oil from the transmission oil cooler and
lines are drained) (paragraph 12-22) the oil lines (paragraph 12-22).

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BHT-407-MM-2

Figure 12-2. Transmission Servicing

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 BHT-407-MM-2

6. Connect the freewheel to transmission return line 12-25. Freewheel Oil System — Draining (With
at the forward firewall. the Special Drain Fitting and Hose
Assembly)

7. Install the filler cap (2) on the transmission.

SPECIAL TOOLS REQUIRED
8. Install the transmission cowling (Chapter 53).

NUMBER NOMENCLATURE
12-22. Transmission Oil Cooler and Oil Lines —
Draining H4713 Drain Fitting and Hose
Assembly
1. Position a container under the helicopter drain
tubes. 1. Position a container under the drain tube.

2. Open the two drain valves (3 and 4, Figure 12-2) 2. Open the right hand engine cowlings (Chapter
on the baggage compartment wall. 53).

3. Remove the freewheel chip detector (Chapter

3. Drain the oil from the transmission oil cooler and
63).
oil lines.

4. Install the drain fitting in the port of the freewheel

4. Close the drain valves (3 and 4). chip detector.

12-23. FREEWHEEL OIL SYSTEM 5. Install the hose assembly on the drain fitting.

6. Drain the oil from the freewheel oil system.

The freewheel oil system shares lubrication oil with the
transmission oil system. The freewheel oil system is
serviced through the transmission oil filler cap 7. Remove the hose assembly from the drain fitting.
(paragraph 12-18).
8. Remove the drain fitting from the freewheel chip
12-24. FREEWHEEL OIL SYSTEM — DRAINING detector port.

9. Install the freewheel chip detector (Chapter 63).

NOTE
Draining the freewheel oil system will also 10. Close the right engine cowlings (Chapter 53).
drain part of the transmission oil system.
The amount of oil drained may be more 12-26. Freewheel Oil System — Draining
than the amount of oil contained only by the (Without the Special Drain Fitting and
freewheel assembly. Hose Assembly)

The freewheel oil system can be drained in the two 1. Open the right engine cowlings (Chapter 53).
ways that follow:
2. Position a container under the drain tube.
• with a special drain fitting and hose assembly
(paragraph 12-25) 3. Remove the chip detector and the chip detector
housing (Chapter 63).
• without the special drain fitting and hose
assembly (paragraph 12-26). 4. Drain the oil from the freewheel oil system.

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BHT-407-MM-2

5. Install the chip detector housing and the chip 12-29. TAIL ROTOR GEARBOX OIL SYSTEM —
detector (Chapter 63). DRAINING

The tail rotor gearbox oil system can be drained in the

6. Close the right engine cowlings (Chapter 53). two ways that follow:

12-27. TAIL ROTOR GEARBOX OIL SYSTEM • with a special drain fitting and hose assembly,

• without the special drain fitting and hose

The tail rotor gearbox oil system is serviced through assembly.
the oil filler cap (2, Figure 12-3) installed on the tail
rotor gearbox. The tail rotor gearbox is covered by a 12-30. Tail Rotor Gearbox Oil System — Draining
fairing. An access door on the top of the fairing (With the Special Drain Fitting and Hose
provides access to the oil filler cap (2). A second Assembly)
access door is located on the bottom side of the fairing
and provides access to the tail rotor gearbox chip
detector (4), which is removed to drain the tail rotor SPECIAL TOOLS REQUIRED
gearbox. The door also provides cooling for the tail
rotor gearbox through a screen assembly installed on
the panel. NUMBER NOMENCLATURE

H4749 Drain Fitting and Hose

12-28. TAIL ROTOR GEARBOX OIL SYSTEM – Assembly
SERVICING

1. Position a container under the drain tube.

NOTE
Make sure the helicopter is level when 2. Open the access door on the top of the tail rotor
gearbox fairing (Chapter 53).
servicing. If not level, underfill or overfill of
the tail rotor gearbox oil system will result.
3. Remove the oil filler cap (2, Figure 12-3) on the
tail rotor gearbox. This prevents a vacuum.
1. Open the access door on the top of the tail rotor
gearbox fairing (Chapter 53).
4. Open the access door on the bottom of the tail
rotor gearbox fairing (Chapter 53).
2. Remove the tail rotor gearbox oil filler cap (2,
Figure 12-3). 5. Remove the electrical connector (3) from the chip
detector (4).

NOTE 6. Remove the chip detector (4) with the two

Use only approved oil (BHT-407-FM-X). packings (5) from the chip detector port in the tail rotor
gear box. Discard the two packings.
3. Fill the tail rotor gearbox with lubricating oil to the
correct level on the sight gauge (1). Refer to the 7. Install the drain hose assembly on the drain
applicable BHT-407-FM-X for the type of oil. fitting.

8. Install the drain fitting in the chip detector port.

4. Install the oil filler cap (2) on the tail rotor
gearbox.
9. Drain the oil from the tail rotor gearbox.

5. Close the access door on the top of the tail rotor 10. Remove the drain fitting from the chip detector
gearbox fairing (Chapter 53). port.

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 BHT-407-MM-2

Figure 12-3. Tail Rotor Gearbox Servicing

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BHT-407-MM-2

11. Remove the drain hose assembly from the drain 3. Remove the oil filler cap (2, Figure 12-3) on the
fitting. tail rotor gearbox. This prevents a vacuum.

12. Install two new packings (5) on the chip detector 4. Remove the electrical connector (3) from the tail
(4). rotor chip detector (4).

13. Install the chip detector (4) in the chip detector 5. Remove the tail rotor gearbox chip detector (4),
port in the tail rotor gear box. the two packings (5), and the self closing valve from
the tail rotor chip detector port. Discard the two
packings. Refer to Chapter 65.
NOTE
Make sure the electrical connector on the 6. Drain all the oil from the tail rotor gearbox.
tail rotor chip detector is installed with the
connector backshell between the 1 o'clock 7. Install the self closing valve in the port of tail rotor
and the 5 o'clock position. chip detector. Refer to Chapter 65.

14. Install the electrical connector (3) on the chip

8. Install two new packings (5) on the tail rotor chip
detector (4).
detector (4).

15. Install the oil filler cap (2) on the tail rotor
9. Install the chip detector (4).
gearbox.

16. Close the access door on the top of the tail rotor NOTE
gearbox fairing (Chapter 53).
Make sure the electrical connector on the
tail rotor chip detector is installed with the
17. Close the access door on the bottom of the tail connector backshell between the 1 o'clock
rotor gearbox fairing (Chapter 53). and the 5 o'clock positions.

12-31. Tail Rotor Gearbox — Draining (Without 10. Install the electrical connector (3) on the tail rotor
Special Drain Fitting and Hose Assembly) chip detector (4).

1. Position a container under the tail rotor gearbox. 11. Install the oil filler cap (2) on the tail rotor
gearbox.
2. Remove the tail rotor gearbox fairing (Chapter
53). 12. Install tail rotor gearbox fairing (Chapter 53).

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 BHT-407-MM-2

HYDRAULIC SYSTEM SERVICING

12-32. HYDRAULIC SYSTEM SERVICING 6. Install the transmission fairing assembly

(Chapter 53).
The hydraulic system is serviced through the filler
cover (1, Figure 12-4) on the hydraulic reservoir. The 7. Close the forward fairing (Chapter 53).
hydraulic reservoir is installed on the roof of the
helicopter and is covered by the forward fairing. 12-34. HYDRAULIC SYSTEM — DRAINING

12-33. HYDRAULIC RESERVOIR — SERVICING 1. Open the forward fairing assembly (Chapter 53).

2. Remove the transmission fairing assembly

MATERIALS REQUIRED (Chapter 53),

Refer to BHT-ALL-SPM for specifications. 3. Position a container under the hydraulic reservoir.

NUMBER NOMENCLATURE 4. Open the filler cover (1, Figure 12-4) of the
hydraulic reservoir.
C-002 Hydraulic Fluid

C-072 Hydraulic Fluid 5. Remove the drain plug (3) and the packing (4)
from the bottom of the hydraulic reservoir. Discard the
packing.

NOTE 6. Drain the hydraulic fluid from the hydraulic

Make sure the helicopter is leveled when reservoir.
servicing. If not level, underfill or overfill of
the hydraulic system will result. 7. Install new packing (4) on the drain plug (3) and
install the drain plug in the drain port on the bottom of
1. Open the forward fairing assembly (Chapter 53). the hydraulic reservoir.

2. Remove the transmission fairing assembly 8. Service the hydraulic reservoir (paragraph
(Chapter 53). 12-33).

9. Install the transmission fairing assembly

3. Open the filler cover (1, Figure 12-4) on the
(Chapter 53).
hydraulic reservoir.
10. Close the forward fairing (Chapter 53).
NOTE
12-34A. HYDRAULIC SYSTEM SERVICING —
The two hydraulic fluids approved for
ROTOR BRAKE SYSTEM
operation are mixable in any proportion;
however, it is recommended to use (C-072)
Servicing of the optional rotor brake system consists of
for its improved flammability
the following operations:
characteristics.
• Servicing/filling of the rotor brake system to
4. Fill the hydraulic reservoir with hydraulic fluid the correct level through the filler neck of the
(C-002) or hydraulic fluid (C-072) to the correct level master cylinder (2, Figure 12-4A).
on the sight gauge (2).
• Bleeding the rotor brake system through the
5. Close the filler cover (1) on the hydraulic top bleeder valves (4) of the calipers (6 and 7)
reservoir. Install the safety clip on the filler cover. (Chapter 63).

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BHT-407-MM-2

Figure 12-4. Hydraulic Reservoir Servicing

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 BHT-407-MM-2

SEE DETAIL A

DETAIL A

1. Filler cap
2. Master cylinder
3. Handle

NO OBJECT BEYOND THIS POINT 407_MM_12_0015

Figure 12-4A. Rotor Brake System — Servicing

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BHT-407-MM-2

12-34B. Rotor Brake System — Servicing

NOTE
The level of fluid in the master cylinder (2)
MATERIALS REQUIRED is correct when the fluid level reaches the
bottom of the filler neck.
Refer to BHT-ALL-SPM for specifications.

NUMBER NOMENCLATURE NOTE

The two hydraulic fluids approved for
C-002 Hydraulic Fluid
operation are mixable in any proportion;
C-072 Hydraulic Fluid however, it is recommended to use (C-072)
for its improved flammability
characteristics.
1. Open the forward fairing assembly to access the
master cylinder (2, Figure 12-4A) (Chapter 53). 4. Fill the master cylinder (2) with hydraulic fluid
(C-002) or hydraulic fluid (C-072).
2. Loosen and remove the filler cap (1) from the
master cylinder (2). 5. Install the filler cap (1) on the master cylinder (2).
Tighten the filler cap.
3. Make sure the handle (3) is in the stowed
position. 6. Close the forward fairing assembly (Chapter 53).

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 BHT-407-MM-2

GREASE LUBRICATION

12-35. GREASE LUBRICATION — EQUIPMENT. IF THERE IS PARTIAL

SERVICING SEPARATION OF THE LUBRICATION OIL
FROM THE THICKENING AGENT, OIL
Table 12-2 shows the recommended intervals for MAY BE REMIXED THOROUGHLY WITH
grease lubrication. These intervals are the maximum THE THICKENING AGENT TO RESTORE
permitted under normal operation. Do not exceed THE ORIGINAL LOAD CARRYING
these intervals unless otherwise stated. It may be CAPABILITIES. IF THERE IS A LOSS OF
necessary to increase the frequency of servicing when LUBRICATING OIL FROM THE
the operating conditions are more severe. THICKENING AGENT, DISCARD THE
ENTIRE CONTENTS OF THE GREASE
NOTE DISPENSING EQUIPMENT AND
REPLACE WITH A SUITABLE SUPPLY
Do not purge lubricate the oil cooler blower
OF APPROVED LUBRICANT
or tail rotor driveshaft hanger bearings.
(IL GEN-03-93).
Lubricate in accordance with paragraph
12-40 and paragraph 12-41.
If it becomes necessary to change the brand of
If the helicopter is stored longer than 45 days without grease, remove the old grease by purging until only
operating, purge lubricate the bearings before new grease is present, except as otherwise specified.
returning it to service. Purge lubricate means that
fresh grease is injected in the bearing to remove all of
the old grease. Purging does not apply to oil cooler NOTE
blower or tail rotor driveshaft hanger bearings.
Prior to and following grease lubrication,
visually examine grease fittings for
presence of the spring loaded steel ball. If
the steel ball is not visible, does not spring
back to closed position, the grease fitting
indicates excessive leakage, or it is difficult
to inject grease during lubrication, replace
CAUTION the grease fitting (BHT-ALL-SPM,
Chapter 8). If the grease fitting is removed
due to the spring loaded steel ball not being
DO NOT USE HIGH CAPACITY/HIGH
visible, insert a small steel probe into the
VE LO C I T Y G R E AS E G U N S O N T H E
C O M P O N EN T S . T H E U S E O F H I G H back of the grease fitting to confirm the
CAPACITY/HIGH VELOCITY GREASE presence of the steel ball. If it is identified
GUNS CAN RESULT IN DAMAGE. that the steel ball is not present in the
grease fitting, further investigation is
required to ensure that the steel ball has
WARNING not migrated into the component and
caused damage. Discard grease fittings
that have been removed.
PRIOR TO LUBRICATION, VERIFY THE
CONTENT OF GREASE DISPENSING Figure 12-5 shows the grease lubrication areas.

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BHT-407-MM-2

Figure 12-5. Grease Lubrication (Sheet 1 of 8)

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 BHT-407-MM-2

12-36. PITCH CHANGE LINK BEARING —

SERVICING MATERIALS REQUIRED

The following procedure requires that you remove the Refer to BHT-ALL-SPM for specifications.
pitch change link rod to lubricate the bearing. This
permits rotation of the bearing. It is the preferred NUMBER NOMENCLATURE
method. If you choose not to remove the pitch change
link rods to grease the bearing, then grease from all C-001 Grease
four grease points without rotating the bearing.
1. Remove all four pitch change link rods
12-37. PITCH CHANGE LINK BEARING — (Chapter 67).
GREASE

SPECIAL TOOLS REQUIRED

NUMBER NOMENCLATURE

Commercial Grease Gun

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 BHT-407-MM-2

Figure 12-5. Grease Lubrication (Sheet 2 of 8)

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BHT-407-MM-2

Figure 12-5. Grease Lubrication (Sheet 3 of 8)

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 BHT-407-MM-2

Figure 12-5. Grease Lubrication (Sheet 4 of 8)

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BHT-407-MM-2

Figure 12-5. Grease Lubrication (Sheet 5 of 8)

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 BHT-407-MM-2

FWD

22 21 22
1 1

SEE DETAIL H

(100 HOURS) (100 HOURS

S/N 53519 AND SUBSEQUENT SHOWN OR 150 HOURS) 2
DETAIL G

20

DETAIL H
(IF INSTALLED S/N 53000 THROUGH
53442 PRE BHT-407-II-30)

NOTES
1 Refer to Chapter 65 for wear limits and allowable repair.

2 Refer to Table 12-2.

407MM_12_0011_c01

Figure 12-5. Grease Lubrication (Sheet 6 of 8)

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BHT-407-MM-2

Figure 12-5. Grease Lubrication (Sheet 7 of 8)

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 BHT-407-MM-2

Figure 12-5. Grease Lubrication (Sheet 8 of 8)

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BHT-407-MM-2

2. There are four pitch change link rods. There are 12-39. HYDRAULIC PUMP DRIVE SHAFT —
two bearings installed on each pitch change link rod, GREASE
on the top end. Lubricate the two grease fittings on
each bearing (2, Figure 12-5) with grease (C-001). MATERIALS REQUIRED

3. On each pitch change link rod, rotate the Refer to BHT-ALL-SPM for specifications.
bearings (2) 90° and lubricate each grease fitting
again. NUMBER NOMENCLATURE

C-304 Drycleaning Solvent

4. Remove the excess grease with a clean, lint-free
cloth. C-525 Spline Lubricant
Grease
5. Install the four pitch change link rods (MIL-G-81827)
(Chapter 67). Royco 22MS
(Alt. Aeroshell 23C)
12-38. SWASHPLATE — PURGING C-561 Grease

SPECIAL TOOLS REQUIRED NOTE

It is acceptable to remove the hydraulic
pump only to the extent necessary to which
NUMBER NOMENCLATURE
the inspection and lubrication can be
Commercial Grease Gun accomplished.

1. Remove the hydraulic pump (Chapter 29).

MATERIALS REQUIRED 2. For helicopters S/N 53000 through 53408 and

53421 through 53474 Pre TB 407-01-30, complete the
Refer to BHT-ALL-SPM for specifications. following steps:

NUMBER NOMENCLATURE a. Remove the drive shaft (4, Figure 12-5, Detail
C1) from the transmission oil pump housing (6).
C-001 Grease
b. Clean the splines of the driveshaft (4) and
1. Lubricate the swashplate bearings (1, exposed splines of hydraulic pump external driveshaft
Figure 12-5) at the lubricating fittings with grease (8) with drycleaning solvent (C-304). Dry parts and
(C-001). inspect (Chapter 29).

2. Purge lubricate from lubricating fittings. Turn the c. Apply grease (C-525) or grease (C-561) with a
swashplate 90° and purge again. brush to both ends of the driveshaft (4), the exposed
splines of hydraulic pump external driveshaft (8), and
the mating splines of the transmission oil pump.
3. To prevent contamination in the control link
bearings, remove all the excess purged grease from d. Install the driveshaft (4) onto the hydraulic
the inner ring and the outer ring with a clean rag. pump external driveshaft (8) (Chapter 29).

4. Lift the swashplate boot. Make sure the grease e. Install the hydraulic pump (5) (Chapter 29).
(C-001) has not transferred past the upper seal and
onto the uniball. If the grease has transferred, the 3. For helicopters S/N 53409 through 53420 and
upper seal is damaged or was installed backward. 53475 and subsequent, or S/N 53000 through 53408
Remove the swashplate and investigate. Refer to and 53421 through 53474 Post TB 407-01-30,
Chapter 67. complete the following steps:

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 BHT-407-MM-2

a. Remove the hydraulic pump input shaft (9,

Figure 12-5, Detail C2) (Chapter 29). WARNING
b. Clean the male splines of the input shaft (9)
with drycleaning solvent (C-304). Dry and inspect REFER TO TA B L E 1 2 - 2 FOR
input shaft (9) and interconnect adapter (7) APPLICABLE LUBRICATION INTERVAL.
(Chapter 29). IF YOU GREASE THE BEARING
407- 340-33 9-107 WIT H LUBRICANT
NOTE OTHER THAN (C-001) MOBIL 28 PER
MIL-PRF-81322, THE BEARING MUST BE
Do not apply grease to the splines of the SCRAPPED. THIS BEARING HAS AN
interconnect adapter (7) or the female ORANGE ELASTOMER SEAL.
splines of the input shaft (9). The use of
grease can result in deterioration of the
adapter. NOTE
It is important to make sure that the correct
c. Apply grease (C-525) or grease (C-561) with a amount of grease is injected in the bearings
brush to the male splines of the input shaft (9) and the to eliminate possible over-greasing. A
mating splines of the hydraulic pump (5). bearing that has been over-greased will run
hotter initially and will run hotter for a longer
d. Install the input shaft (9) into the hydraulic period of time compared to a properly
pump (5) (Chapter 29). Install the interconnect adapter greased bearing. This can cause damage
(7) into the input shaft (9) Chapter 29). to the bearing components and deteriorate
the grease lubricating agents.
e. Install the hydraulic pump (5) (Chapter 29).
1. Use a lint-free cloth and wipe away all the dirt and
12-40. OIL COOLER BLOWER HANGER accumulated grease that has expelled from around the
BEARINGS — GREASE bearing seals (15, Figure 12-5) during operation.
Apply a light pressure so that the dirt and used grease
are not forced back into the bearing.
NOTE
Per ASB 407-04-63, all 407 helicopters are 2. Use a lint-free cloth and clean the grease
to have oil cooler blower hanger bearings fitting (12).
407-340-339-107 installed. The following
instructions only apply to bearings
407-340-339-107.
CAUTION

SPECIAL TOOLS REQUIRED

DO NOT USE AN AIR-OPERATED
GREASE GUN.
NUMBER NOMENCLATURE

Commercial Grease Gun

WARNING

MATERIALS REQUIRED PRIOR TO LUBRICATION OF THE

BEARING, VERIFY THE CONTENT OF
Refer to BHT-ALL-SPM for specifications. GREASE DISPENSING EQUIPMENT. IF
THERE IS PARTIAL SEPARATION OF
NUMBER NOMENCLATURE T H E L UB R IC A T I O N O I L F R O M T HE
THICKENING AGENT, OIL MAY BE
C-001 Grease (Mobil 28 only)
REMIXED THOROUGHLY WITH THE

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BHT-407-MM-2

THICKENING AGENT TO RESTORE THE 12-41. TAIL ROTOR DRIVESHAFT HANGER

ORIGINAL LOAD CARRYING BEARINGS — GREASE
CAPABILITIES. IF THERE IS A LOSS OF
LUBRICATING OIL FROM THE
THICKENING AGENT, DISCARD THE SPECIAL TOOLS REQUIRED
ENTIRE CONTENTS OF THE GREASE
DISPENSING EQUIPMENT AND NUMBER NOMENCLATURE
REPLACE WITH A SUITABLE SUPPLY
OF APPROVED LUBRICANT Commercial Grease Gun
(IL GEN-03-93).

3. Make sure that the grease gun you use is MATERIALS REQUIRED
thoroughly cleaned of contaminants and other
greases. Refer to BHT-ALL-SPM for specifications.

NUMBER NOMENCLATURE

C-001 Grease (Mobil 28 Only)

CAUTION

DO NOT ROTATE THE OIL COOLER WARNING

BLOWER SHAFT WHEN GREASING THE
BEARING. DO NOT ADD GREASE
BEYOND WHAT IS DESCRIBED BELOW. REFER TO TABLE 12-2 FOR GREASE
OVER-GREASING IS DETRIMENTAL TO APPLICABLE ON BEARINGS
406-040-339-ALL. IF YOU GREASE THE
BEARING LIFE.
BEARING 406-040-339-ALL WITH
LUBRICANT OTHER THAN (C-001)
4. Use a smooth low-pressure stroke and inject the MOBIL 28 PER MIL-PRF-81322, THE
grease (C-001) Mobile 28 into each grease fitting (12) BEARING MUST BE SCRAPPED. THIS
until the first sign of purging is seen. Cease further BEARING HAS A BROWN ELASTOMER
lubrication at this point. SEAL.

REFER TO TABLE 12-2 FOR LUBRICANT

5. Only after the greasing is completed, rotate the APPLICABLE ON BEARING
shaft through three or four turns. Do not add any 407-340-339-107. IF YOU GREASE THE
additional grease to bearing. BEARING 407-340-339-107 WITH
LUBRICANT OTHER THAN (C-001)
MOBIL 28 PER MIL-PRF-81322, THE
BEARING MUST BE SCRAPPED. THIS
NOTE BEARING HAS AN ORANGE
ELASTOMER SEAL.
The color of the grease is normally
red-purple when it is injected in the bearing,
NOTE
but turns black when the bearing is
damaged. It is important to make sure that the correct
amount of grease is injected in the bearings
to eliminate possible over-greasing. A
6. Use a lint free cloth and clean the excess grease
bearing that has been over-greased will run
that has come out of the bearing seal lips. Apply a light hotter initially and will run hotter for a longer
pressure so that the expelled grease is not forced period of time compared to a properly
back into the bearing. greased bearing. This can cause damage

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 BHT-407-MM-2

to the bearing components and deteriorate BEARING. DO NOT ADD GREASE

the grease lubricating agents. BEYOND WHAT IS DESCRIBED BELOW.
OVER-GREASING IS DETRIMENTAL TO
1. Use a lint-free cloth and wipe away all the dirt and BEARING LIFE.
accumulated grease that has expelled from around the
bearing seal (15, Figure 12-5, Sheet 5, Detail E) 4. Use a smooth low-pressure stroke and inject the
during the operation. Apply a light pressure so that dirt grease into the grease fitting until the first sign of
and expelled grease are not forced back into the purging is seen. Cease further relubrication at this
bearing. point.

2. Use a lint-free cloth and clean the grease

5. Only after the greasing is completed, rotate the
fitting (14).
tail rotor driveshaft three to four turns. Do not add any
additional grease to bearing.

CAUTION
NOTE
DO NOT USE AN AIR-OPERATED The color of the grease is normally
GREASE GUN. red-purple when it is injected in the bearing,
but turns black when the bearing is
damaged.
WARNING
6. Use a lint-free cloth and clean the excess grease
that has come out of the bearing seal (15) lips. Apply
PRIOR TO LUBRICATION OF THE light pressure so that the expelled grease is not forced
BEARING, VERIFY THE CONTENT OF back into the bearing.
GREASE DISPENSING EQUIPMENT. IF
THERE IS PARTIAL SEPARATION OF 12-42. TAIL ROTOR DRIVE SPLINES — GREASE
T H E L UB R I C A T I O N O I L F R O M T H E
THICKENING AGENT, OIL MAY BE
REMIXED THOROUGHLY WITH THE
THICKENING AGENT TO RESTORE THE MATERIALS REQUIRED
ORIGINAL LOAD CARRYING
CAPABILITIES. IF THERE IS A LOSS OF Refer to BHT-ALL-SPM for specifications.
LUBRICATING OIL FROM THE
THICKENING AGENT, DISCARD THE NUMBER NOMENCLATURE
ENTIRE CONTENTS OF THE GREASE
C-525 Grease
DISPENSING EQUIPMENT AND
REPLACE WITH A SUITABLE SUPPLY C-561 Grease
OF APPROVED LUBRICANT
(INFORMATION LETTER (IL) GEN-03-93).
1. Remove the forward short shaft (Chapter 65).
3. Make sure that the grease gun you use is
thoroughly cleaned of contaminants and other
greases. 2. Remove the aft short shaft (Chapter 65).

3. Clean all parts (Chapter 65).

CAUTION
4. Examine the splines of the oil cooler blower shaft
(21, Figure 12-5), the flywheel adapter (20) (if
DO NOT ROTATE THE TAIL ROTOR installed), and the sliding adapters (22) for wear or
DRIVESHAFT WHEN GREASING THE damage (Chapter 65).

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BHT-407-MM-2

NOTE
MATERIALS REQUIRED
The following step applies to shaft
406-040-320 only. Refer to BHT-ALL-SPM for specifications.

5. Examine the dry film lubricant on the splines of NUMBER NOMENCLATURE

the oil cooler blower shaft 406-040-320 (21) for
condition. If necessary, apply dry film lubricant C-001 Grease
(Chapter 65).
C-405 Lockwire
6. Apply grease (C-525) or grease (C-561) as
follows: 1. Remove the lockwire from both ends of the boot
(16, Figure 12-5, Detail F).
a. Use an acid brush and apply a thick layer of
grease (C-525) or grease (C-561) to splines of sliding 2. Loosen the boot (16) from the pitch mechanism
adapter(s) (22), flywheel adapter (20) (if installed), and cap (18) and trunnion (19).
oil cooler blower shaft (21).

NOTE CAUTION
Flanges of forward and aft sliding adapters
(22) must be positioned 90° to each other.
Refer to Chapter 65 for assembly DO NOT USE SOLVENTS TO CLEAN THE
instructions. BOOT (16) OR THE EJECTED GREASE.

b. Install sliding adapter(s) (22), and flywheel 3. Remove all of the ejected grease from the seals
adapter (20) (if installed) (Chapter 65). and the boot (16) with a clean brush.

c. Remove unwanted grease (C-525) or grease 4. Lubricate the two grease fittings (17) with grease
(C-561). (C-001) until the new grease comes out from the
seals.
7. Install the forward short shaft (Chapter 65).
5. Remove the ejected grease with a clean brush.
8. Install the aft short shaft (Chapter 65).
6. Install the boot (16) in the groove of the trunnion
12-43. TAIL ROTOR GEARBOX PITCH CHANGE (19) and the cap (18). Safety with lockwire (C-405).
MECHANISM — GREASE
12-44. LITTER DOOR SEAL — LUBRICATION
SPECIAL TOOLS REQUIRED
MATERIALS REQUIRED
NUMBER NOMENCLATURE
Refer to BHT-ALL-SPM for specifications.
Commercial Grease Gun
NUMBER NOMENCLATURE

C-018 Lubricant

NOTE
The lubrication procedure applies to S/N
53000 through 53169 Post TB 407-98-11,
and S/N 53170 and subsequent.

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 BHT-407-MM-2

1. Apply a thin layer of lubricant (C-018) to the • Upper seal (23) with the litter door seal (24) on
faying surfaces of the following: upper door frame

• Litter door seal (24, Figure 12-5, Detail J) with • Lower pad (25, Figure 12-5, Detail K) with the
the passenger door airframe

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 BHT-407-MM-2

MISCELLANEOUS SERVICING

12-45. BATTERY — SERVICING 12-49. GROUND HANDLING WHEELS

HYDRAULIC PUMP CYLINDER —
SERVICING
Access to the battery is through the battery door in the
nose compartment. Service the battery in accordance
with Chapter 96, the Electrical Standard Practice The hydraulic pump cylinder is serviced with hydraulic
Manual (BHT-ELEC-SPM), and the instructions from oil from a filler screw at the center of the hydraulic
the battery manufacturer. pump cylinder.

12-46. FIRE EXTINGUISHER MATERIALS REQUIRED

The portable fire extinguisher is mounted on the front Refer to BHT-ALL-SPM for specifications.
of the center post, between the seats of the pilot and
the copilot. NUMBER NOMENCLATURE

C-002 Hydraulic Fluid

12-47. FIRE EXTINGUISHER — SERVICING

12-50. Ground Handling Wheels Hydraulic Pump

Cylinder — Servicing
CAUTION
1. Remove the screw and fill the hydraulic pump
cylinder with hydraulic fluid (C-002) within 3/8 inch
IF THE FIRE EXTINGUISHER HAS BEEN (9.52 mm) below the filler hole.
FIRED, DO NOT USE IT. RECHARGE THE
FIRE EXTINGUISHER BEFORE YOU 2. Install the filler screw.
RETURN IT TO SERVICE.
3. If air is present in the hydraulic pump cylinder, do
1. Make sure the fire extinguisher is not damaged, the steps that follow:
the nozzle is not obstructed, the pin is secure, and the
seal is not damaged.
a. Set the pump valve to the open position.

2. Make sure the indicator is in the green arc on the b. Hold the pump with the valve down.
gauge. If the indicator is not in the green arc, recharge
or replace the fire extinguisher. c. Operate the handle through approximately 10
cycles to bleed the air from the hydraulic pump
3. Weigh the fire extinguisher. If the weight of the cylinder.
fire extinguisher is less than the acceptable minimum
weight indicated on the fire extinguisher, recharge or d. Close the valve.
replace the fire extinguisher.
e. Remove the filler screw and check the oil
level.
12-48. GROUND HANDLING WHEELS —
SERVICING f. Install the filler screw.

The ground handling wheels are installed on the 12-51. GROUND HANDLING WHEEL AXLES —
fittings on the landing gear skid tubes. Servicing the SERVICING
ground handling wheels includes adjusting the oil level
in the hydraulic pump cylinder, greasing the axles, and Grease the wheel axles and the pivot points in
inspecting the wheels. accordance with Table 12-2.

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BHT-407-MM-2

12-52. Ground Handling Wheel Axles — Grease 2. Examine the tires for the correct inflation
pressure. Refer to the tire/tire manufacturers for
correct pressure.
MATERIALS REQUIRED
12-54. WINDSHIELD AND WINDOWS —
Refer to BHT-ALL-SPM for specifications. CLEANING
NUMBER NOMENCLATURE

C-001 Grease MATERIALS REQUIRED

Refer to BHT-ALL-SPM for specifications.

1. Lubricate the wheel bearing through the grease
fitting with grease (C-001). NUMBER NOMENCLATURE

C-330 Cleaner
2. Remove the wheel (15, Figure 12-6) from the
lever (13). C-355 Detergent

3. Remove the nut (12), the two washers (11), and

the bolt (10) which hold the lever (13) to the shaft (9).
CAUTION
4. Remove the two nuts (7), the four washers (5),
and the two bolts (4) which hold the bellcrank (6) to the DO NOT USE COMPOUNDS
shaft (9). CONTAINING ABRASIVES OR
CHLORINATED HYDROCARBONS.
5. Slide the shaft (9) from the housing (8) and the AVOID EXCESSIVE SCRUBBING OR
bellcrank (6). POLISHING OF PLASTIC PANELS. HEAT
BUILDUP MAY DAMAGE PLASTIC
PANELS.
6. Apply grease (C-001) to the shaft (9), to the
bellcrank (6), and to the two bushings (14) in the
REMOVE RINGS, WATCHES, AND HARD
housing (8).
OBJECTS FROM HANDS AND WRISTS
BEFORE WASHING TRANSPARENT
7. Slide the shaft (9) through the two bushings (14) PANELS.
in the housing (8) and the bellcrank (6).
1. Clean windshield and windows with large
8. Install the two bolts (4), the four washers (5), and quantities of clean water and a solution of detergent
the two nuts (7). (C-355). Gently free all insects or dirt with soft pads or
fingers. Do not use sponges or coarse cloths. Rinse
the area continuously while removing insects or dirt.
9. Slide the lever (13) over the shaft (9).
2. Flush entire area thoroughly with clean water.
10. Install the bolt (10), the two washers (11), and the
nut (12).
3. Allow surfaces to air dry.

11. Install the wheel assembly (15) on the lever (13). 4. Minor scratches may be reduced or removed by
using cleaner (C-330).
12-53. Ground Handling Wheel Tires — Servicing
5. Apply cleaner (C-330) with a clean soft cloth or
1. Examine the condition of the side walls and the tissue in a circular motion until clean. Polish with
treads of the tires. Replace tires as required. another clean, soft, cotton cloth.

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 BHT-407-MM-2

Figure 12-6. Ground Handling Wheel Assembly

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BHT-407-MM-2

12-55. OIL COOLER BLOWER IMPELLER — shaft is disconnected from the forward and
CLEANING the aft short shaft.

c. Use an atomizer and spray the drycleaning

MATERIALS REQUIRED solvent (C-304) at the impeller, between the vanes
while you slowly turn the tail rotor driveshaft by hand.
Refer to BHT-ALL-SPM for specifications. Dirt is normally concentrated on the aft face of the
drive plate and at the junction of the vanes and the aft
NUMBER NOMENCLATURE face of the forward ring.

C-304 Drycleaning Solvent

d. Once you complete this phase of the cleaning,
use the atomizer and spray a mixture of the hot water
1. To clean the oil cooler blower impeller, do the and aircraft cleaning soap at the impeller, to rinse the
steps that follow: solvent.

NOTE e. To complete the cleaning, thoroughly rinse the

impeller with water and dry with compressed air.
Do not allow water intrusion into the oil
cooler blower hanger bearings.
f. Remove the forward and aft hanger bearing
a. Put protective covers on the forward and aft oil protective covers after the cleaning is complete.
cooler blower hanger bearing assemblies.
NOTE
b. Put a container at the oil tank drain to collect
the drycleaning solvent and dirt. Do not over-grease the bearings. Follow
the instructions specified in paragraph
12-40.
NOTE
During the cleaning, do not permit the g. Grease the forward and aft oil cooler blower
impeller to turn freely if the oil cooler blower hanger bearings (paragraph 12-40).

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