BHT-407-II-37

INSTALLATION INSTRUCTION
FOR
AFT ICS KIT
NOTICE
This Installation Instruction provides the procedures to install
the Aft ICS Kit.

EFFECTIVITY

KIT NUMBER MODEL SERIAL NUMBER

407-706-032-101 407 54300 and Subsequent

COPYRIGHT NOTICE
COPYRIGHT 2012
BELL ® HELICOPTER TEXTRON INC.
AND BELL HELICOPTER TEXTRON
CANADA LTD.
ALL RIGHTS RESERVED

14 MAY 2012
BHT-407-II-37

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 or maintenance is forbidden without prior written authorization from
Bell Helicopter Textron Inc.

DESTINATION CONTROL STATEMENT

These commodities, technology, or software were exported from the United

States in accordance with the Export Administration Regulations (EAR).
Diversion contrary to U.S. law prohibited. The data contained in this manual are
classified as ECCN 7E994.

Additional copies of this publication may be obtained by contacting:

Commercial Publication Distribution Center
Bell Helicopter Textron Inc.
P. O. Box 482
Fort Worth, Texas 76101-0482

PN 14 MAY 2012
 BHT-407-II-37

LOG OF REVISIONS

Insert latest revision pages and dispose of superseded ones.

On a revised page, the text and/or illustration affected by the latest revision is shown by a vertical line. A revised
page with only a vertical line next to the page number indicates that text has shifted or that non-technical
correction(s) were made on that page.

Original ........................... 0......................... 14 MAY 12

LOG OF PAGES

Page No. Rev No. Page No. Rev No.

Title .............................................................................0 1-3 – 1-18 ................................................................... 0

PN...............................................................................0 1-19 – 1-20 ................................................................. 0
A/B ..............................................................................0 2-1/2-2 ........................................................................ 0
i/ii ................................................................................0 2-3/2-4 ........................................................................ 0
Help ............................................................................0 3-1/3-2 ........................................................................ 0
Customer Feedback ...................................................0 3-3 – 3-4 ..................................................................... 0
1-1/1-2 ........................................................................0 3-5/3-6 ........................................................................ 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

14 MAY 2012 A/B

 BHT-407-II-37

APPROVAL AND VERIFICATION

The Engineering aspects of this document are TC approved.

Kit 407-706-032-101 has been verified by first article installation on Model 407, S/N 54302, dated 31 August 2011.

ECCN 7E994 14 MAY 2012 i/ii

 H ELP

E VALUATE

L OGISTICS

P UBLICATIONS

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your telling us about it so that we can change whatever is
incorrect or unclear. Please be as specific as possible.

Your complaint or suggestion will be acknowledged and we

will tell you what we intend to do.

You may use the enclosed Customer Feedback form, as

applicable, to inform us where we have erred.

Your assistance is sincerely appreciated.

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 BHT-407-II-37

CHAPTER 1 — INSTALLATION PROCEDURES

TABLE OF CONTENTS

Paragraph Page
Number Title Number

INSTALLATION PROCEDURES

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

1-2 Preparation ......................................................................................................... 1-3
1-3 Aft ICS Kit — Structural Modification .................................................................. 1-4
1-4 Aft ICS Kit — Electrical Installation ..................................................................... 1-9
1-5 Restoration.......................................................................................................... 1-19

FIGURES

Figure Page
Number Title Number

1-1 Aft ICS Kit — Modification................................................................................... 1-5

1-2 Aft ICS Kit — Electrical Installation ..................................................................... 1-10
1-3 Aft ICS Kit — Wiring Diagram ............................................................................. 1-15

ECCN 7E994 14 MAY 2012 1-1/1-2

FOR BEST VALUE, BUY GENUINE BELL PARTS
 BHT-407-II-37

INSTALLATION PROCEDURES

1-1. GENERAL INFORMATION 10. For modification or repairs to glass or carbon fiber
reinforced composites, refer to the BHT-ALL-SRM,
1. This Installation Instruction provides the Chapter 4.
procedures to install the five-place Aft ICS Kit.
11. Refer to the BHT-ELEC-SPM for the electrical
2. It is the responsibility of the installer to verify that installation procedures.
newly installed equipment/systems do not interfere
with, or are susceptible to, the normal operation of 12. It is recommended that an experienced electrical/
other equipment installed in the helicopter. Refer to avionics person performs all steps pertaining to
General Information Letter (IL) GEN-07-113 for connector disassembly/reassembly. If not specified in
additional information. these installation procedures, refer to the
BHT-ELEC-SPM for electrical wiring practices.
3. All openings and ports in components, hoses,
and/or tubes disconnected or removed to facilitate the 13. Perform a continuity check on all wiring newly
modification must be capped, plugged, or otherwise installed or disturbed during this modification.
sealed to prevent contamination during the
modification. 14. Unless otherwise noted, all hose and wire bundle
clamps should be installed to provide optimum
4. Tag all parts, including attaching hardware clearance with structure, component, flight controls,
(unless otherwise noted) removed to gain access to and other hoses and wire bundles.
work area. Protect parts from damage until reinstalled.
15. Install decals (BHT-ALL-SPM, Chapter 8).
5. Retain all parts and attaching hardware for
reassembly, unless otherwise noted. 1-2. PREPARATION

6. Prior to installing any previously removed items 1. Electrically ground the helicopter for safe
(including hardware, hoses, fluid lines/tubes, maintenance.
components, electrical wiring, etc.), do a visual
inspection for wear, mechanical damage, and
2. Disconnect the battery and external power from
corrosion damage. Repair or replace items, as
the helicopter (BHT-407-MM-10, Chapter 96).
required, prior to installation on the helicopter.

3. Remove the forward facing passenger seats

7. Consumable materials may or may not be
(BHT-407-MM-3, Chapter 25).
supplied with the kit, depending on customer’s
requirements of consumable items at the time the kit
was ordered. To inform maintenance personnel of 4. Remove the aft facing passenger seats
consumables required, a MATERIALS REQUIRED (BHT-407-MM-3, Chapter 25)
statement is provided at the beginning of each
paragraph, as applicable. Refer to the BHT-ALL-SPM 5. Remove the following interior components of the
for information on consumable materials (C-XXX). passenger compartment for the standard or corporate
configuration (BHT-407-MM-3, Chapter 25):
8. Draw layout on sheet metal with a fine-tipped
non-corrosive ink marker or equivalent. To prevent • Hat bin
structural damage, do not use metal scribers or lead
pencils. • Right headliner

9. Following any drilling or cutting, remove burrs • Aft control column panel
and metal particles. Clean and touch up the surfaces
as required (BHT-ALL-SPM). • Center headliner

ECCN 7E994 14 MAY 2012 1-3

FOR BEST VALUE, BUY GENUINE BELL PARTS
BHT-407-II-37

6. If installed, remove the roof blanket on the right instructions contained in the BHT-ALL-SPM,
side of the passenger compartment interior for the Chapter 7.
utility configuration (BHT-407-MM-3, Chapter 25).
(6) Apply a coat of epoxy polyamide primer
7. If installed, remove the hat bin blanket of the (C-204) on the bare surface of the cabin roof beam (1)
passenger compartment interior for the utility around the cable tie mount (4).
configuration (BHT-407-MM-3, Chapter 25).
b. On the right side, install each of the two
standoffs (5) on the cabin roof beam (1) as follows:
1-3. AFT ICS KIT — STRUCTURAL
MODIFICATION
(1) Mark the location of the two standoffs (5)
on the cabin roof beam (1) using a non-permanent
marker to the dimension shown in View B.
MATERIALS REQUIRED
(2) Install the two standoffs (5) with adhesive
Refer to BHT-ALL-SPM for specifications. (C-331) on the cabin roof beam (1) as per the
instructions contained in the BHT-ALL-SRM,
NUMBER NOMENCLATURE
Chapter 3.
C-204 Epoxy Polyamide
Primer 2. Install the cable tie mount (2) on the aft control
column cover (3) as follows:
C-301 Adhesive

C-331 Adhesive a. Mark the location of the cable tie mount (2)
using a non-permanent marker on the aft control
C-406 Abrasive Cloth column cover (3) to the dimension shown in View A.

C-516 Clean Cloth b. Remove the paint and/or primer from the
bonding surface area (BHT-ALL-SRM, Chapter 3).
1. On the right side, modify the cabin roof beam (1,
Figure 1-1) as follows: c. Lightly sand the far side surface of the cable
tie mount (2) with an abrasive cloth (C-406).

a. Install the cable tie mount (4) on the cabin roof

beam (1) as follows: d. Clean the cable tie mount (2) with a clean
cloth (C-516).

(1) Mark the location of the cable tie mount

e. Bond the cable tie mount (2) on the aft control
(4) on the cabin roof beam (1) to the dimension shown
column cover (3) with adhesive (C-301) per the
in View B.
instructions contained in the BHT-ALL-SPM,
Chapter 7.
(2) Remove the primer from the cabin roof
beam (1) (BHT-ALL-SRM, Chapter 3).
f. Apply a coat of epoxy polyamide primer
(C-204) on the bare surface of the aft control column
(3) Lightly sand the far side surface of the cover (3) around the cable tie mount (2).
cable tie mount (4) with an abrasive cloth (C-406).
3. Modify the aft control column panel (9) as follows:
(4) Clean the cable tie mount (4) with a clean
cloth (C-516). a. At two places, locate and drill one hole 0.625
to 0.635 inch (15.87 to 16.12 mm) through the aft
(5) Bond the cable tie mount (4) on the cabin control column panel (9), at the location shown in
roof beam (1) with adhesive (C-301), per the View D.

1-4 14 MAY 2012 ECCN 7E994

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 BHT-407-II-37

F 5.49 IN.
(139.4 mm)

B AND C
2.44 IN. 1
(61.9 mm)

2
1

VIEW A
LOOKING FORWARD
1 6
4
2.30 IN. 1 7
(58.4 mm) 5
2 8
1

0.94 IN.
(23.8 mm) 2.50 IN.
(63.5 mm)

1.60 IN.
(40.6 mm)
3.20 IN.
(81.2 mm)
VIEW B VIEW C
LOOKING INBOARD ON RIGHT SIDE LOOKING INBOARD ON RIGHT SIDE

NO OBJECT BEYOND THIS POINT 407_II_37_0001a

Figure 1-1. Aft ICS Kit — Modification (Sheet 1 of 3)

ECCN 7E994 14 MAY 2012 1-5

FOR BEST VALUE, BUY GENUINE BELL PARTS
BHT-407-II-37

3.32 IN.
(84.3 mm)
(TYP)
2.34 IN.
(59.4 mm) (TYP)
9
1.94 IN.
(49.3 mm) (TYP)

3.09 IN. 10
1
(78.5 mm)
(TYP)

9.49 IN.
10.23 IN. (241.0 mm)
(259.8 mm)
SEE DETAIL E

11
1

1
VIEW D
LOOKING AFT

0.876 IN.
(22.25 mm)
0.438 IN.
(11.13 mm)

9 12

0.126 TO 0.131 IN.

(3.2 TO 3.3 mm) DIA.

0.625 TO 0.635 IN.

(15.87 TO 16.12 mm)
DETAIL E

NO OBJECT BEYOND THIS POINT 407_II_37_0001b

Figure 1-1. Aft ICS Kit — Modification (Sheet 2 of 3)

1-6 14 MAY 2012 ECCN 7E994

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 BHT-407-II-37

Figure 1-1. Aft ICS Kit — Modification (Sheet 3 of 3)

ECCN 7E994 14 MAY 2012 1-7

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BHT-407-II-37

NOTE NOTE
Use the jack receptacle as a template to If the bracket is not installed as per step (4),
locate the holes. you will not be able to install the electrical
connector correctly.
b. At two places, spot drill the location of two
holes 0.126 to 0.131 (3.20 to 3.32 mm) with a No. 45 (4) Install the bracket (11) on the aft control
drill on the aft side of the aft control column panel (9), column panel (9) with adhesive (C-301) per the
as shown in View D. instructions contained in the BHT-ALL-SPM,
Chapter 7. Align the existing hole in the bracket with
c. At two places, spot drill two holes 0.126 to the previously drawn lines and make sure the existing
0.131 inch (3.20 to 3.32 mm) in diameter with a No. 30 hole in the bracket is positioned as shown in View D.
drill through the aft control column panel (9), as shown
in Detail E. 4. Modify the hat bin (12) as follows:

d. Install the cable tie mount (10) on the aft a. At three places, locate and drill one hole 0.625
control column panel (9) as follows: to 0.635 inch (15.87 to 16.12 mm) through the hat bin
(12), to the dimension shown in View F.
(1) Mark the location of the cable tie mount
(10) using a non-permanent marker on the aft control
column panel (9) to the dimension shown in View D. NOTE
Use the jack receptacle as a template to
(2) Lightly sand the far side surface of the locate the holes.
cable tie mount (10) and the aft control column panel
(9) with an abrasive cloth (C-406). b. At three places, spot drill the location of the
two holes 0.126 to 0.131 (3.20 to 3.32 mm) with a
(3) Clean the cable tie mount (10) and the aft No. 45 drill on the far side of the hat bin (12) to the
control column panel (9) with a clean cloth (C-516) dimension shown in View F.
moistened with clean water.
c. At three places, drill two holes 0.126 to
(4) Bond the cable tie mount (10) on the aft 0.131 inch (3.20 to 3.32 mm) in diameter with a No. 30
control column panel (9) with adhesive (C-301) per the drill through the hat bin (12), as shown in View F.
instructions contained in the BHT-ALL-SPM,
Chapter 7. d. Install each of the four cable tie mounts (13)
on the hat bin (12) as follows:
e. Install each of the two brackets (11) on the aft
control column panel (9) as follows: (1) Mark the location of the cable tie mount
(13) using a non-permanent marker to the dimension
(1) Mark the location of the hole in the shown in View F.
bracket (11) using a non-permanent marker to the
dimension shown in View D. (2) Lightly sand the far side surface of the
cable tie mount (13) and the hat bin (12) with an
(2) Lightly sand the plastic surface of the abrasive cloth (C-406).
bracket (11) and the aft control column panel (9) with
an abrasive cloth (C-406). (3) Clean the cable tie mount (13) and the
hat bin (12) with a clean cloth (C-516).
(3) Clean the bracket (11) and the aft control
column panel (9) with a clean cloth (C-516). (4) Bond the cable tie mount (13) on the hat
bin (12) with adhesive (C-301) per the instructions
contained in the BHT-ALL-SPM, Chapter 7.

e. Install each of the three brackets (14) on the

hat bin (12) as follows:

1-8 14 MAY 2012 ECCN 7E994

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 BHT-407-II-37

(1) Mark the location of the bracket (14) 3. Install the jack receptacle (2340S1J1) (20) on the
using a non-permanent marker to the dimension right and far side of the aft control column panel (19)
shown in View F. using two screws (6) and washers (7). Tighten the
screws.
(2) Lightly sand the plastic surface on the
bracket (14) and the hat bin (12) with an abrasive cloth 4. Install the connector (2340P1) (11) on the rail (9).
(C-406).
5. Install the decals (2 and 10) on the far side of the
(3) Clean the bracket (14) and the hat bin aft control column panel (19), such that identification
(12) with a clean cloth (C-516) moistened with clean can be made after equipment is installed.
water.

6. Seal the edges of the decals (2 and 10) using

NOTE edge sealer (C-349).
If the bracket is not installed as per step (4),
you will not be able to install the electrical 7. Locate the preassembled jack receptacle
connector correctly. (2340S2J1) (5) and connector (2340P2) (16) in the
cable assembly (W831) (27).
(4) Install the bracket (14) on the hat bin (12)
with adhesive (C-301) per the instructions contained in 8. Install the jack receptacle (2340S2J1) (5) on the
the BHT-ALL-SPM, Chapter 7. Align the outboard left and far side of the aft control column panel (19)
edge of the bracket with the previously drawn lines. using two screws (6) and washers (7). Tighten the
Make sure the existing hole in the bracket is screws.
positioned as shown in View G.

9. Install the connector (2340P2) (16) on the rail (9).

5. Install the rail (6) on the two standoffs (5) with the
washers (7) and the screws (8) as shown in View C.
Tighten the screws. 10. Install the decals (3 and 17) on the far side of the
aft control column panel (19), such that identification
can be made after equipment is installed.
1-4. AFT ICS KIT — ELECTRICAL
INSTALLATION
11. Seal the edges of the decals (3 and 17) using
edge sealer (C-349).

MATERIALS REQUIRED
12. Secure the cable assembly (W831) (27) to the
Refer to BHT-ALL-SPM for specifications. cable tie mount (4) on the far side and center of the aft
control column panel (19) with tie wrap (C-592).
NUMBER NOMENCLATURE
13. Install the two decals (8) on the near side of the
C-292 Tie Wrap
aft control column panel (19) below the jack
C-349 Edge Sealer receptacles (2340S2J1 and 2340S1J1) (5 and 20).

C-592 Tie Wrap 14. Seal the edges of the two decals (8) using edge
sealer (C-349).
1. Locate the cable assembly (W831) (27,
Figure 1-2, View A). 15. Locate the preassembled receptacles (2340J1
and 2340J2) (12 and 15) in the cable assembly (48).
2. Locate the preassembled jack receptacle
(2340S1J1) (20) and connector (2340P1) (11) in the 16. Install the expandable braided sleeving (49) over
cable assembly (W831) (27). the cable assembly (48).

ECCN 7E994 14 MAY 2012 1-9

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BHT-407-II-37

E
A

2 1 2

3 1 2 W101
48 3

27 3 50
1 4
51 B
49 3
6 7 5 20 6 7

4
1 8

8 1
19
9
18 10 1 2

11
1 2 17
W101 50
16
1
12
15

24 1 2 14 13 1 2
23 VIEW A
LOOKING FORWARD
4 22

49

48 25 1
21
50 FWD

VIEW B
LOOKING INBOARD ON RIGHT SIDE
NO OBJECT BEYOND THIS POINT 407_II_37_0002a

Figure 1-2. Aft ICS Kit — Electrical Installation (Sheet 1 of 3)

1-10 14 MAY 2012 ECCN 7E994

BUY BELL PARTS, BUY BELL VALUE
 BHT-407-II-37

LBL BL RBL
8.00 0.00 8.00

30 6 7 28 W101
29 48
6 7 26

WL
62.44 6 7 31

34 4
1 33 32
30 1 1
30

VIEW C
LOOKING FORWARD

1 36 39
37 38 9

40 1

1 35

29

46 41
44 42

43 1

45 1

VIEW D
LOOKING DOWN
(HARNESS NOT SHOWN FOR CLARITY)

NO OBJECT BEYOND THIS POINT 407_II_37_0002b

Figure 1-2. Aft ICS Kit — Electrical Installation (Sheet 2 of 3)

ECCN 7E994 14 MAY 2012 1-11

FOR BEST VALUE, BUY GENUINE BELL PARTS
BHT-407-II-37

RBL BL LBL
14.00 W101 0.00 14.00 47 (5 PLACES)
28 26
31

WL
60.70

8 1 29
(3 PLACES)
VIEW E
LOOKING AFT

1. Cabin roof beam (Ref) 27. Cable assembly (W831) (407-079-621-105)

2. Decal (31-065-2340S1J1) 28. Jack receptacle (2340S5J1) (Ref)
3. Decal (31-065-2340S2J1) 29. Hat bin panel (Ref)
4. Cable tie mount (Ref) 30. Cable assembly (W830) (407-079-621-103)
5. Jack receptacle (2340S2J1) (Ref) 31. Jack receptacle (2340S4J1) (Ref)
6. Screw (MS35214-13) 10 Reqd 32. Decal (31-065-2340S4J1)
7. Washer (NAS620A4L) 10 Reqd 33. Decal (31-065-2340S5J1)
8. Decal (31-006-504) 5 Reqd 34. Decal (31-065-2340S3J1)
9. Rail (Ref) 35. Decal (31-065-2340P3)
10. Decal (31-065-2340P1) 36. Decal (31-065-2340P5)
11. Connector (2340P1) (Ref) 37. Connector (2340P5) (Ref)
12. Receptacle (2340J1) (Ref) 38. Receptacle (2340J5) (Ref)
13. Decal (31-065-2340J1) 39. Decal (31-065-2340J5)
14. Decal (31-065-2340J2) 40. Decal (31-065-2340J4)
15. Receptacle (2340J2) (Ref) 41. Receptacle (2340J4) (Ref)
16. Connector (2340P2) (Ref) 42. Connector (2340P4) (Ref)
17. Decal (31-065-2340P2) 43. Decal (31-065-2340P4)
18. Center post assembly (Ref) 44. Receptacle (2340J3) (Ref)
19. Aft control column panel (Ref) 45. Decal (31-065-2340J3)
20. Jack receptacle (2340S1J1) 46. Connector (2340P3) (Ref)
21. Terminal module (2301TB1-K) (M81714/60-22-02) 47. Headset (H10-13H) 5 Reqd
22. Terminal module (2301TB1-L) (M81714/60-22-02) 48. Cable assembly (407-079-621-101)
23. Terminal module (2301TB1-M) (M81714/60-22-10) 49. Expandable braided sleeving (130-053-2-0-30)
24. Terminal module rail (2301TB1) (Ref) 50. Insulation sleeving (130-045-4-0-3) 2 Reqd
25. Decal (31-065-2301TB1) 51. Aft control column cover (Ref)
26. Jack receptacle (2340S3J1) (Ref)
NOTES
SEALANT (C-349) 1 Seal the edges of the decals using edge sealer (C-349).
2 Install the decals on the far side.
3 Same parts as shown in View B.
NO OBJECT BEYOND THIS POINT 407_II_37_0002c

Figure 1-2. Aft ICS Kit — Electrical Installation (Sheet 3 of 3)

1-12 14 MAY 2012 ECCN 7E994

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 BHT-407-II-37

17. Install one insulation sleeving (50) at each end of 28. Seal the edges of the decals (34, View C and 35,
the expandable braided sleeving (49) and shrink the View D) using edge sealer (C-349).
insulation sleeving.
29. Locate the preassembled jack receptacle
18. Connect the receptacle (2340J1) (12) to the (2340S5J1) (28) and connector (2340P5) (37, View D)
connector (2340P1) (11) on the rail (9). in the cable assembly (W830) (30, View C).

19. Connect the receptacle (2340J2) (15) to the 30. Install the jack receptacle (2340S5J1) (28) on the
connector (2340P2) (16) on the rail (9). center of the hat bin panel (29) using two screws (6)
and washers (7). Tighten the screws.
20. Install the decals (13 and 14) on the far side of
the aft control column panel (19), such that 31. Install the connector (2340P5) (37) on the rail (9).
identification can be made after equipment is installed.
32. Install the decals (33, View C and 36, View D) on
21. Seal the edges of the two decals (13 and 14) the hat bin panel (29), such that identification can be
using edge sealer (C-349). made after equipment is installed.

NOTE 33. Seal the edges of the decals (33, View C and 36,
View D) using edge sealer (C-349).
Ensure routing of cable assembly (48) is
satisfactory and that adequate length 34. Locate the preassembled jack receptacle
remains for termination of wires. (2340S4J1) (31) and connector (2340P4) (42, View D)
in the cable assembly (W830) (30, View C).
22. Route the cable assembly (48) from the
receptacles (2340J1 and 2340J2) (12 and 15) to the
terminal module rail (2301TB1) (24, View B) as 35. Install the jack receptacle (2340S4J1) (31,
follows: View C) on the right side of the hat bin panel (29)
using two screws (6) and washers (7). Tighten the
screws.
a. Secure the cable assembly (48, View A) to the
cable tie mount (4) on the aft control column cover (51)
with tie wrap (C-592). 36. Route the cable assembly (W830) (30) from the
jack receptacles (2340S3J1, 2340S5J1, and
b. Secure the cable assembly (48) to the cable 2340S4J1) (26, 28, and 31) to the location of the
tie mounts (4, View A) on the right side center post connectors (2340P3, 2340P5, and 2340P4) (46, 37,
assembly (18) and on the cabin roof beam (1) with tie and 42, View D).
wrap (C-592) (View B).
37. Install the connector (2340P4) (42) on the rail (9).
23. Locate the cable assembly (W830) (30, View C).
38. Install the decals (32, View C and 43, View D) on
24. Locate the preassembled jack receptacle the hat bin panel (29), such that identification can be
(2340S3J1) (26) and connector (2340P3) (46, View D) made after equipment is installed.
in the cable assembly (W830) (30, View C).
39. Seal the edges of the decals (32, View C and 43,
25. Install the jack receptacle (2340S3J1) (26) on the View D) using edge sealer (C-349).
left side of the hat bin panel (29) using two screws (6)
and washers (7). Tighten the screws. 40. Secure the cable assembly (W830) (30, View C)
to the four cable tie mounts (4) on the hat bin panel
26. Install the connector (2340P3) (46) on the rail (9). (29) with tie wrap (C-592).

27. Install the decals (34, View C and 35, View D) on 41. Install the three decals (8, View E) on the hat bin
the hat bin panel (29), such that identification can be panel (29) below the jack receptacles (2340S3J1,
made after equipment is installed. 2340S5J1, and 2340S4J1) (26, 28, and 31).

ECCN 7E994 14 MAY 2012 1-13

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BHT-407-II-37

42. Seal the edges of the three decals (8) using edge 51. Install the decal (25) on the adjacent structure
sealer (C-349). such that identification can be made after equipment is
installed.
43. Locate the cable assembly (48, View C) with the
preassembled receptacles (2340J3, 2340J5, and
52. Seal the edges of the decal (25) using edge
2340J4) (44, 38, and 41, View D).
sealer (C-349).

44. Connect the receptacle (2340J3) (44) to the

connector (2340P3) (46) on the rail (9). 53. Locate the following stowed wires in the basic
cable assembly (W101) near the cabin roof beam (1,
45. Connect the receptacle (2340J5) (38) to the View A and View B):
connector (2340P5) (37) on the rail (9).

ICS-27A22 ICS-30A22
46. Connect the receptacle (2340J4) (41) to the
connector (2340P4) (42) on the rail (9). ICS-28A22 ICS-31A22

47. Install the three decals (39, 40, and 45) on the hat ICS-29A22
bin panel (29) and adjacent structure such that
identification can be made after equipment is installed.
54. Route the wires listed in step 53 to the terminal
module rail (2301TB1) (24, View B).
48. Seal the edges of the three decals (39, 40, and
45) using edge sealer (C-349).
NOTE
NOTE In addition to Figure 1-2, reference the
wiring diagram (Figure 1-3) in the following
As applicable, remove and discard existing
tie wraps on all clamps and cable steps to assist with the electrical
assemblies affected by routing of cable installation.
assembly (48). Use replacement tie wrap
(C-292), part number PLT2S-C702, and/or 55. Remove and discard the wire caps (22,
tie-wrap (C-592), part number MS3367, as Figure 1-3) from all the individual wires listed in
required during routing of cable assembly.
step 53.
Do not tighten tie-wraps until the cable
assembly has been routed and the
electrical installation has been completed. 56. Locate the following wires at the terminal module
(2301TB1-M) (23, Figure 1-2, View B):
NOTE
Ensure routing of cable assembly (48) is
ICS-27B22 ICS-30B22
satisfactory and that adequate length
remains for termination of wires. ICS-28B22 ICS-31B22

49. Route the cable assembly (48), with the basic ICS-29B22
cable assembly (W101), from the receptacles
(2340J3, 2340J5, and 2340J4) (44, 38, and 41) to the
terminal module rail (2301TB1) (24, View B). 57. Determine the required length of the wires listed
in step 56 to the terminal module (2301TB1-M) (28,
50. Install the three terminal modules (2301TB1-K, Figure 1-3) and trim the jackets and shields of the
2301TB1-L, and 2301TB1-M) (21, 22, and 23) in the wires to length. Do not trim the individual wires to final
terminal module rail (2301TB1) (24). length at this time.

1-14 14 MAY 2012 ECCN 7E994

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 BHT-407-II-37

AUDIO PANEL (ICS)

LCTN - PEDESTAL 21
2301A1 LCTN - FWD
W101 CABIN ROOF
(GMA 350H) 2301A1P2 2301TB1
PASSENGER 4 MIC AUDIO IN HI 41 ICS-30A22 BLU MP MN ICS-30B22 BLU ICS-30B22 BLU 1
PASSENGER 4 MIC AUDIO IN LO 42 ICS-30A22 WHT MS MR ICS-30B22 WHT ICS-30B22 WHT 2

ICS-26D22 ORN 3
ICS-26D22 WHT 4
ICS-26D22 BLU 5

28

MW MT ICS-31B22 BLU ICS-31B22 BLU 6

MZ MY ICS-31B22 WHT ICS-31B22 WHT 7

ICS-26B22 ORN 8
ICS-26B22 WHT 9
ICS-26B22 BLU 10

PASSENGER 3 MIC AUDIO IN HI 39 ICS-28A22 BLU MF ME ICS-28B22 BLU

PASSENGER 3 MIC AUDIO IN LO 40 ICS-28A22 WHT MH MG ICS-28B22 WHT

PASSENGER 1 MIC AUDIO IN HI 35 ICS-27A22 BLU MB MA ICS-27B22 BLU ICS-28B22 BLU 11

PASSENGER 1 MIC AUDIO IN LO 36 ICS-27A22 WHT MD MC ICS-27B22 WHT ICS-28B22 WHT 12

1 22 23 ICS-26H22 BLU 13
29 ICS-26H22 WHT 14
27 ICS-26H22 ORN 15
PASSENGER 2 MIC AUDIO IN HI 37 ICS-29A22 BLU MK MJ ICS-29B22 BLU ICS-29B22 BLU 16
PASSENGER 2 MIC AUDIO IN LO 38 ICS-29A22 WHT MM ML ICS-29B22 WHT ICS-29B22 WHT 17
19
1 22 23 20

W101 ICS-26B22 BLU KB KA ICS-26F22 BLU

2301A1P1 ICS-26A22 BLU KF KE ICS-26H22 BLU
ICS-26D22 BLU KK KJ ICS-26K22 BLU ICS-26K22 BLU 18
XCVR 5 AUDIO IN HI 23 ICS-31A22 BLU
XCVR 5 AUDIO IN LO 4 ICS-31A22 WHT 19
ICS-26B22 WHT KD KC ICS-26F22 WHT
ICS-26A22 WHT KH KG ICS-26H22 WHT
ICS-26D22 WHT KM KL ICS-26K22 WHT ICS-26K22 WHT 19

27
PASSENGER HEADSET AUDIO R OUT HI 41 ICS-26A22 BLU
PASSENGER HEADSET AUDIO L OUT HI 40 ICS-26A22 WHT ICS-26B22 ORN LB LA ICS-26F22 ORN
PASSENGER HEADSET AUDIO OUT LO 42 ICS-26A22 ORN ICS-26A22 ORN LF LE ICS-26H22 ORN
ICS-26D22 ORN LK LJ ICS-26K22 ORN ICS-26K22 ORN 20

14
ICS-27B22 BLU 21
1 22 23 24 ICS-27B22 WHT 22
26 25

ICS-26F22 BLU 23
ICS-26F22 WHT 24
ICS-26F22 ORN 25

407-476-621-B 407_II_37_0003a

Figure 1-3. Aft ICS Kit — Wiring Diagram (Sheet 1 of 2)

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 BHT-407-II-37

AFT CABIN HAT RACK

W101 W830 7 W830 6

2340J4 2340P4 2340S4J1

1 ICS-30B22 BLU 1 ICS-30C22 BLU 3 PASSENGER 4 HEADSET 1. Receptacle (2340S1J1) (Ref)

2 ICS-30B22 WHT 2 ICS-30C22 WHT 1
2340S4 2. Receptacle (2340S2J1 (Ref)
3
3. Cable assembly (W831) (Ref)
3 ICS-26D22 ORN 6 ICS-26E22 ORN 4 4. Receptacle (2340S3J1) (Ref)
4 ICS-26D22 WHT 5 ICS-26E22 WHT 2
5. Receptacle (2340S5J1) (Ref)
5 ICS-26D22 BLU 4 ICS-26E22 BLU 5
7 6. Receptacle (2340S4J1) (Ref)
9 8 7. Cable assembly (W830) (Ref)
14 W101 W830 7 W830 5 8. Connector (2340P4) (Ref)
2340J5 2340P5 2340S5J1 9. Receptacle (2340J4) (Ref)
10. Connector (2340P5) (Ref)
6 ICS-31B22 BLU 1 ICS-31C22 BLU 3 PASSENGER 5 HEADSET 11. Receptacle (2340J5) (Ref)
7 ICS-31B22 WHT 2 ICS-31C22 WHT 1
2340S5 12. Connector (2340P3) (Ref)
3
11 10 13. Receptacle (2340J3) (Ref)
8 ICS-26B22 ORN 6 ICS-26C22 ORN 4
14. Cable assembly (W101) (Ref)
9 ICS-26B22 WHT 5 ICS-26C22 WHT 2
10 ICS-26B22 BLU 4 ICS-26C22 BLU 5 15. Connector (2340P2) (Ref)
7 16. Receptacle (2340J2) (Ref)
17. Connector (2340P1) (Ref)
14 W101 W830 7 W830 4 18. Receptacle (2340J1) (Ref)
2340J3 2340P3 2340S3J1
19. Shield termination (S200-3-W1-22-9) 5 Reqd
11 ICS-28B22 BLU 1 ICS-28C22 BLU 3 20. Terminal module (2301TB1-K) (Ref)
12 ICS-28B22 WHT 2 ICS-28C22 WHT 1 21. Identification (130-061-08W3) 3 Reqd
PASSENGER 3 HEADSET
3
2340S3
22. Wire cap (Ref)
13 ICS-26H22 BLU ICS-26J22 BLU
23. Contact (Ref)
4 5
14 ICS-26H22 WHT 5 ICS-26J22 WHT 2 24. Terminal module (2301TB1-L) (Ref)
15 ICS-26H22 ORN 6 ICS-26J22 ORN 4 25. Splice (120-180-1T)
16 ICS-29B22 BLU 7 26. Audio control panel (2301A1) (Ref)
17 ICS-29B22 WHT 12 27. Shield termination (Ref)
13
AFT FACE VERTICAL TUNNEL 28. Terminal module (2301TB1-M) (Ref)
29. Shield termination (S200-3-00) 5 Reqd
W101 W831 W831
2340J2 2340P2 2340S2J1

18 ICS-26K22 BLU ICS-29B22 BLU 1 ICS-29C22 BLU 3 PASSENGER 2 HEADSET

ICS-29B22 WHT 2 ICS-29C22 WHT 1
2340S2
3

ICS-26K22 BLU 4 ICS-26L22 BLU 5

19 ICS-26K22 WHT 5 ICS-26L22 WHT 2
ICS-26K22 ORN 6 ICS-26L22 ORN 4
7

16 15 3
14 2
20 ICS-26K22 ORN 1
W101 W831 3 W831
2340J1 2340P1 2340S1J1

21 ICS-27B22 BLU 1 ICS-27C22 BLU 3 NOTES

22 ICS-27B22 WHT 2 ICS-27C22 WHT 1 PASSENGER 1 HEADSET
3
2340S1 1 Reference contacts (M39029/22-191) (23) supplied with terminal module (20, 24 and 28).
23 ICS-26F22 BLU 4 ICS-26G22 BLU 5
24 ICS-26F22 WHT 5 ICS-26G22 WHT 2 2. denotes new wires.
25 ICS-26F22 ORN 6 ICS-26G22 ORN 4
7 3. denotes existing/stowed wires.
14 18 17
407_II_37_0003b

Figure 1-3. Aft ICS Kit — Wiring Diagram (Sheet 2 of 2)

1-16 14 MAY 2012 ECCN 7E994

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 BHT-407-II-37

NOTE CONNECT TO
WIRE NO.
2301TB1-M – PIN NO.
Do not shrink the identification (21)
installed in step 58 at this time. ICS-30B22 WHT R

58. Install the applicable identification (21) for the ICS-31A22 BLU W
terminal module (2301TB1-M) (28) over the wires
listed in step 53 and step 56. ICS-31A22 WHT Z

ICS-31B22 BLU T
59. Install one shield termination (29) over the leads
of the shields on each of the wires listed in step 53 and ICS-31B22 WHT Y
step 56, as shown in Figure 1-3.
62. Shrink the identification (21) installed in step 58.
60. Pre-fit the wires listed in step 53 and step 56 to
the terminal module (2301TB1-M) (28). Trim the
63. Locate the stowed wire ICS-26A22 in the basic
individual wires to final length at this time.
cable assembly (W101) near the cabin roof beam (1,
Figure 1-2, View A and View B).
61. Install the contacts (23), supplied with the
terminal module (28), on the wires that follow and
64. Route wire ICS-26A22 to the terminal module rail
insert in the terminal module (2301TB1-M) (28):
(2301TB1) (24, View B).

65. Remove and discard the wire cap (22, Figure 1-3)
CONNECT TO from all the individual wires of ICS-26A22.
WIRE NO.
2301TB1-M – PIN NO.
66. Locate the following wires at the terminal
ICS-27A22 BLU B modules (2301TB1-K and 2301TB1-L) (20 and 24):
ICS-27A22 WHT D

ICS-27B22 BLU A ICS-26B22 ICS-26H22

ICS-27B22 WHT C ICS-26D22 ICS-26K22

ICS-28A22 BLU F ICS-26F22

ICS-28A22 WHT H 67. Determine the required length of the wires listed
in step 66 to the terminal modules (2301TB1-K and
ICS-28B22 BLU E
2301TB1-L) (20 and 24) and trim the jackets and
ICS-28B22 WHT G shields of the wires to length. Do not trim the individual
wires to final length at this time.
ICS-29A22 BLU K
68. Position one shield termination (19) over each of
ICS-29A22 WHT M the shields of wires ICS-26B22 and ICS-26D22, as
shown in Figure 1-3.
ICS-29B22 BLU J

ICS-29B22 WHT L
NOTE
ICS-30A22 BLU P Prepare the leads of the shield terminations
for soldering (BHT-ELEC-SPM, Chapter 4).
ICS-30A22 WHT S
69. Daisy chain the lead of the existing shield
ICS-30B22 BLU N
termination (27) of wire ICS-26A22 to the shield

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BHT-407-II-37

termination (19) of wire ICS-26B22, as shown in 77. Install the contacts (23), supplied with the
Figure 1-3. terminal module (20), on the wires that follow and
insert in the terminal module (2301TB1-K) (20):
70. Daisy chain the lead of the shield termination (19)
of wire ICS-26B22 to the shield termination (19) of
wire ICS-26D22, as shown in Figure 1-3.
CONNECT TO
WIRE NO.
71. Position one shield termination (19) over each of 2301TB1-K – PIN NO.
the shields of wires ICS-26F22, ICS-26H22, and
ICS-26A22 BLU F
ICS-26K22, as shown in Figure 1-3.
ICS-26A22 WHT H
NOTE ICS-26B22 BLU B
Prepare the leads of the shield terminations
ICS-26B22 WHT D
for soldering (BHT-ELEC-SPM, Chapter 4).
ICS-26D22 BLU K
72. Daisy chain the lead of the shield termination (19)
of wire ICS-26F22 to the shield termination (19) of wire ICS-26D22 WHT M
ICS-26H22, as shown in Figure 1-3.
ICS-26F22 BLU A
73. Daisy chain the lead of the shield termination (19)
ICS-26F22 WHT C
of wire ICS-26H22 to the shield termination (19) of
wire ICS-26K22, as shown in Figure 1-3. ICS-26H22 BLU E

74. Join the leads of the shield terminations (19) of ICS-26H22 WHT G
wires ICS-26D22 and ICS-26K22 with a splice (25), as
shown in Figure 1-3. ICS-26K22 BLU J

ICS-26K22 WHT L
NOTE
Do not shrink the identification (21) 78. Shrink the identification (21) installed in step 75.
installed in step 75 at this time.

75. Install the applicable identification (21) for the NOTE

terminal module (2301TB1-K) (20) over the following
Do not shrink the identification (21)
wires:
installed in step 79 at this time.

ICS-26A22 BLU ICS-26F22 BLU 79. Install the applicable identification (21) for the
terminal module (2301TB1-L) (24) over the following
ICS-26A22 WHT ICS-26F22 WHT wires:

ICS-26B22 BLU ICS-26H22 BLU

ICS-26B22 WHT ICS-26H22 WHT ICS-26A22 ORN ICS-26F22 ORN

ICS-26D22 BLU ICS-26K22 BLU ICS-26B22 ORN ICS-26H22 ORN

ICS-26D22 WHT ICS-26K22 WHT ICS-26D22 ORN ICS-26K22 ORN

76. Trim the wires listed in step 75 to final length at 80. Trim the wires listed in step 79 to final length at
this time. this time.

1-18 14 MAY 2012 ECCN 7E994

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 BHT-407-II-37

81. Install the contacts (23), supplied with the • Hat bin
terminal module (24), on the wires that follow and
insert in the terminal module (2301TB1-L) (24): • Right headliner

• Aft control column panel

CONNECT TO
WIRE NO. • Center headliner
2301TB1-L – PIN NO.

ICS-26A22 ORN F 4. Install the aft facing passenger seats

(BHT-407-MM-3, Chapter 25)
ICS-26B22 ORN B

ICS-26D22 ORN K 5. Install the forward facing passenger seats

(BHT-407-MM-3, Chapter 25).
ICS-26F22 ORN A

ICS-26H22 ORN E 6. Connect the battery and/or external power and

close battery access door (BHT-407-MM-10,
ICS-26K22 ORN J Chapter 96).

82. Shrink the identification (21) installed in step 79. NOTE

A kit software and configuration loading
1-5. RESTORATION
procedure (BHT-407-MM-10, Chapter 95) is
not required in conjunction with the
1. If applicable, install the hat bin blanket of the
installation of this kit.
passenger compartment interior for the utility
configuration (BHT-407-MM-3, Chapter 25).
7. Perform an operational check of the
Intercommunication System (ICS) (BHT-407-MM-11,
2. If applicable, install the roof blanket on the right Chapter 97).
side of the passenger compartment interior for the
utility configuration (BHT-407-MM-3, Chapter 25).
8. Amend the weight and balance records in
3. Install the following interior components of the accordance with Chapter 2.
passenger compartment for the standard or corporate
configuration (BHT-407-MM-3, Chapter 25): 9. Return helicopter to the flight configuration.

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 BHT-407-II-37

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

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 BHT-407-II-37

OPERATION AND MAINTENANCE

2-1. OPERATION PROCEDURES 2-2. MAINTENANCE PROCEDURES

Refer to the BHT-407-MM-11, Chapter 97 and

Refer to the following documents for operating
BHT-407-MM-12, Chapter 98 for maintenance
procedures:
procedures.

• Garmin G1000H Integrated Flight Deck Pilot’s 2-3. WEIGHT AND BALANCE
Guide for the Bell 407GX (190-01255-00).
Compliance with this Installation Instruction affects the
weight and balance of the helicopter as shown in the
• Garmin G1000H Integrated Flight Deck —
following table. Adjust ballast as necessary to return
Cockpit Reference Guide for the Bell 407GX
empty weight Center of Gravity (CG) to within
(190-01254-00).
allowable limits (BHT-407-MM-2, Chapter 8).

The Garmin G1000H Integrated Flight Deck Pilot’s

NOTE
Guide provides detailed system and operational
information while the Garmin G1000H Integrated This is the delta weight effect of this kit.
Flight Deck — Cockpit Reference Guide for the Bell This includes weight and effect of the items
407GX provides higher level quick reference data. removed when this kit is installed.

LONGITUDINAL *LATERAL

HELICOPTER KIT NUMBER WEIGHT ARM MOMENT ARM MOMENT

407 407-706-032-101 8.4 123.2 1035 0.1 1

(3.8) (3129) (119.2) (3) (0.1)
*In lateral calculations, - is left, + is right.

WEIGHT pounds (kilograms)

ARM inches (millimeters)

MOMENT inch•pounds  kg × mm 
 ----------------------
100 
-

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 BHT-407-II-37

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 (407-706-032-101) ......................................................................... 3-3

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 BHT-407-II-37

PARTS INFORMATION AND KIT INVENTORY

3-1. PARTS INFORMATION

NOTE
This chapter lists assemblies, subassemblies, and Common hardware packed with kit may
detail parts for the Aft ICS Kit. vary from that in following parts list. Some
items of this kit may be shipped
Part numbers in parentheses ( ) are alternate or preassembled. All modifications required
superseding part numbers. for field installation of this kit will be
annotated with flagnotes.

3-2. KIT INVENTORY (407-706-032-101)

QUANTITY PART NUMBER NOMENCLATURE

1 407-706-032-101 Aft ICS Kit, Consisting of:

1 407-079-621-101 Cable Assembly 5-Station ICS, Consisting of:

5 ABC06N-22S Connector

2 M81714/60-22-02 Module
1 M81714/60-22-10 Module

15 S200-3-W1-22-9 Shield Termination

5 S200-3-00 Shield Termination

AR 04049H22-02N24 Wire

AR 04049H22-03N24 Wire

1 120-180-1T Splice

8 130-061-08W3 Identification Tubing

1 407-079-621-103 Cable Assembly Aft Headset, Consisting of:

3 ABC03N-22P Connector
6 S200-3-W1-22-9 Shield Termination

3 TJ-120 Jack Receptacle

AR 04049H22-02N24 Wire

AR 04049H22-03N24 Wire

6 130-005-4-2 Insulation Tubing

1 130-061-03W2 Identification Heat Tubing

8 130-061-06W3 Identification

3 30-266-1 Wire Cap

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BHT-407-II-37

QUANTITY PART NUMBER NOMENCLATURE

1 407-706-032-101 (Cont) Aft ICS Kit, Consisting of:

1 407-079-621-105 Cable Assembly Forward Headset, Consisting of:

2 ABC 03N-22P Connector

4 S200-3-W1-22-9 Shield Termination

2 TJ-120 Jack Receptacle

AR 04049H22-02N24 Wire

AR 04049H22-03N24 Wire

4 130-005-4-2 Insulation Tubing

1 130-061-03W2 Identification Heat Tubing

2 130-061-06W3 Identification
2 30-266-1 Wire Cap

2 MS27039-1-04 Screw

10 MS35214-13 Screw

2 NAS620A10L Washer

10 NAS620A4L Washer

7 ABMM-D Cable Tie Mount

1 DCR-1A-04 Rail

5 H10-13H Headset

5 3111-260-0000 Bracket
2 120-229-3E5 Standoff

1 130-053-2-0-30 Expandable Braided Sleeving

2 130-045-4-0-3 Insulation Sleeving

5 31-006-504 Decal

1 31-065-2301TB1 Decal

1 31-065-2340J1 Decal
1 31-065-2340J2 Decal

1 31-065-2340J3 Decal

1 31-065-2340J4 Decal

1 31-065-2340J5 Decal

1 31-065-2340P1 Decal

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 BHT-407-II-37

QUANTITY PART NUMBER NOMENCLATURE

1 407-706-032-101 (Cont) Aft ICS Kit, Consisting of:

1 31-065-2340P2 Decal

1 31-065-2340P3 Decal

1 31-065-2340P4 Decal
1 31-065-2340P5 Decal

1 31-065-2340S1J1 Decal

1 31-065-2340S2J1 Decal

1 31-065-2340S3J1 Decal

1 31-065-2340S4J1 Decal

1 31-065-2340S5J1 Decal

6.0 ounces 299-947-066, Type I Adhesive (C-301)

(177 ml)

3.0 ounces 299-947-125, Type I Adhesive (C-331)

(88 ml)

1 BHT-407-II-37 Installation Instruction

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