BHT-407-MM-1
CHAPTER 1 — GENERAL INFORMATION TABLE OF CONTENTS Paragraph Number
Title
Chapter/Section Number
Pa g e Number
GENERAL INFORMATION 1-1 1-2 1-3 1-4 1-5 1-6 1-7 1-8 1-9 1-10 1-11 1-12 1-13 1-14
General Information — Description of the Helicopter .................... General In Information — Instructions for Co Continued Airworthiness (ICA) .......... ..................... ....................... ......................... .......................... ......................... .............. Instructions for Continued Airworthiness (ICA) — Scope — Maintenance Requirements and Manuals .. ................................. Supplemental Documents......................................................... Customer Feedback ................................................................. General Information — Use of the Manual .................................... Use of the Manual — Document Structure .. ............................... Use of the Manual — Revision Status and List of Effective Pag age es. s...... ....... .... ....... ...... ...... ...... ...... ...... ...... ...... ...... ...... .... ....... .... ....... ...... ....... .... ....... .... ....... ...... ...... ...... ...... ...... Use of the Manual — Warnings, Cautions, and Notes .. ............. Use of the Manual — Materials Required ................................. Use of the Manual — Special Tools .. . ........................................ Use of th the Manual — Symbols .. ................................................. Use of the Manual — Torques .................................................. Use of the Manual — Wear, Damage, and Repair Limits .........
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FIGURES Fi Figure Number 1-1 1-2
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Title Helicopter Description .. .................................... .. ...... .. ...... .. ......................................... Use of of th t he Ma Manual — S ym ymbols ...........................................................................
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GENERAL INFORMATION 1-1.
GENERAL INFORMATION — DESCRIPTION OF THE HELICOPTER
The Model 407 (Figure 1-1) is a single-engine, seven-place light helicopter. Standard configuration provides for one pilot and six passengers. The fuselage consists of three main sections: the forward section, the intermediate section, and the tailboom section. The forward section utilizes aluminum honeycomb and carbon graphite structure and provides the major load carrying elements of the forward cabin. The intermediate section is a semi-monocoque structure that uses bulkheads, longerons, and carbon fiber composite side skins. The tailboom is an aluminum monocoque construction that transmits all stresses through its external skins. The crew compartment or cockpit occupies the forward part of the cabin. The pilot station is on the right side and the copilot/forward passenger station is on the left side. Each crew seat is covered with flame-retardant fabric and is equipped with a lap seat belt and a dual shoulder harness. Each shoulder harness contains an inertia reel that locks in the event of a rapid deceleration. The aft area of the cabin contains a space of 85 cubic feet (2.4 m3) for the carrying of passengers or internal cargo. The cabin can be configured with utility, standard, or corporate interior kits. Basic configuration includes two aft facing and three forward facing seats. All cabin seats are covered with flame-retardant fabric and are equipped with lap seat belts and shoulder harnesses. The shoulder harnesses lock in the event of a rapid deceleration. The baggage compartment is located aft of the passenger compartment and has a capacity of 16 cubic feet (0.45 m3). The compartment can carry up to 250 pounds (113.4 kg) of baggage or other cargo, which can be secured using a tie-down assembly and the tie-down fittings provided.
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An instrument panel is mounted on a central pedestal in front of the crew seats. The panel is tilted upward for maximum visibility from either seat. As applicable to helicopters S/N 53000 through 54299, the flight instruments are located on the right side of the panel, and the systems instruments are positioned in two rows to the left of the flight instruments. The caution and warning panel is mounted just below the glareshield across the top of the instrument panel. As applicable to 407GX helicopters S/N 54300 and subsequent, the Garmin G1000H Integrated Avionics System provides Flight Instrument, Engine Indication and Crew Alerting (EICAS), Audio Panel and Communication, Navigation and Surveillance (CNS), Flight Management, Hazard Avoidance, and other additional features. This information is provided to the pilot through two large-format full-color display units. The pedestal extends from the instrument panel downward and aft to the cabin seat structure. This forms a mounting platform for optional equipment. The overhead console is centered on the cabin ceiling and incorporates most of the electrical systems circuit breakers and switches. The standard fuel system consists of two crash resistant, bladder-type fuel cells. The forward fuel cell is located underneath and between the aft facing passenger seats. The aft fuel cell is located underneath and behind the aft passenger seats. Total fuel system usable capacity is 127.8 U.S. gallons (869.0 lb). When the auxiliary tank is installed in the baggage compartment (BHT-407-FMS-6), an additional 19 U.S. gallons (136 lb) of fuel is available, which provides a total fuel system usable capacity of 146.9 U.S. gallons (998.9 lb). Fuel from the forward cell is transferred to the main cell by two transfer pumps and fuel from the main fuel cell is supplied to the engine through two boost pumps located at the base of the main fuel cell.
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22 21 20 19
18
23
17 15
25
14
24
13
11
26
16
12
28 10
27
9 29
8 7
30
6 5
31
M OO B IL TA
32 33
4 3 2 36 1
37
38 43 42
41
40
34
39
F
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14.
35
E IAT D ME ER T IN
RD WA R O
Pitot tube Ventilation ducts Battery Winshield Skylight window Servo actuators Hydraulic system Forward fairing Transmission fairing assembly Main transmission assembly Main rotor hub and blade assembly Engine assembly (250-C47B) Engine cowl Oil cooler and blower assembly
15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28.
Aft fairing Engine oil tank access door Tail rotor driveshaft cover Tail rotor driveshaft assembly Tail rotor gearbox fairing Tail rotor gearbox assembly Vertical fin Anti-collision light Tail rotor hub and blade assembly Tail skid and weight Tailboom Finlet Position light Horizontal stabilizer
29. 30. 31. 32. 33. 34. 35. 36. 37. 38. 39. 40. 41. 42. 43.
Directional servo actuator Oil cooler blower inlet duct Aft skin panel Air inlet cowl assembly Baggage compartment Fuel cells Passenger door Litter door Side body fairing Crew door Skid landing gear Forward fuselage Static port Lower window Landing lights 407_MM_01_0002
Figure 1-1. Helicopter Description
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The power plant is comprised of a FADEC controlled Rolls-Royce, Model 250-C47B turboshaft engine featuring a free power turbine. The 6317 RPM output from the engine power takeoff gear shaft is transferred through the engine-mounted freewheel unit, KAflex main driveshaft, a two-stage gear reduction of 15.29 to 1.0 (6317 to 413 RPM) in the transmission and transferred to the mast assembly and main rotor hub and blade assembly. Rotational output is also transferred from the engine to the tail rotor gearbox at 6317 RPM through the freewheel unit, aft short shaft, oil cooler blower shaft, and segmented driveshafts. Inside the tail rotor gearbox, rotational speed is reduced (2.53 to 1) to 2500 RPM and directed to the tail rotor hub and blade assembly. The transmission assembly is attached to the roof of the helicopter, forward of the engine, by a pylon installation. The pylon installation uses two side beams, four elastomeric corner mounts, and two fore/ aft restraint springs. The main rotor is a four-bladed, soft-in-plane design, 35 feet (10.6 m) in diameter, with a composite hub and individually interchangeable blades. The main rotor hub contains a glass/epoxy composite yoke that acts as a flapping flexure. Elastomeric lead-lag, coning/ flapping bearings and dampers which require no lubrication are utilized. The main rotor blades are a composite design utilizing a glass/epoxy spar, glass/ epoxy skins, and a nomex core afterbody. The blades also incorporate a nickel plated stainless steel leading edge erosion strip and are coated with conductive paint for lightning protection. The blades are also individually interchangeable. The tail rotor is a two-bladed teetering rotor, 5.42 feet (1.65 m) in diameter, that provides directional control. It is mounted on the left side of the tailboom and rotates clockwise when looking inboard from the left side of the helicopter. The tail rotor blades are a composite design utilizing a glass/epoxy spar, glass/ epoxy skins, and a nomex core. The blades also incorporate a nickel plated stainless steel leading edge abrasion strip and are coated with conductive paint for lightning protection. Main rotor and tail rotor flight control systems consisting of cyclic, collective, and anti-torque controls are used to regulate the helicopter attitude, altitude, and direction of flight. The flight controls are hydraulically boosted to reduce pilot effort and to counteract control feedback forces.
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The hydraulic system provides boost power for the cyclic, collective, and anti-torque flight controls. The system includes a pump, reservoir, pressure and return filter assemblies, flight control servo actuators, and interconnecting tubing and fittings. The hydraulic pump is mounted on and driven by the transmission. The pump is designed to operate continuously and provides a rated discharge pressure of 1000 -25/+50 PSI. Main rotor cyclic and collective flight controls regulate pitch and roll attitude and thrust. Control inputs from the cyclic and collective control sticks in the cockpit are transmitted by push-pull tubes to hydraulic servo actuators mounted on the top deck. The actuators operate the cyclic and collective levers, which raise, lower, and tilt the swashplate. The swashplate converts fixed control inputs to the rotating controls and allows cyclic and collective pitch inputs to the main rotor. The tail rotor, or anti-torque, flight controls provide pitch adjustment of the tail rotor blades for yaw control. A set of pedals on the cockpit floor, forward of th e pilot seat, are connected to a directional control hydraulic servo actuator, located in the aft fuselage near the tailboom. Push-pull tubes connect the actuator to the fixed pitch change mechanism mounted on the tail rotor gearbox. The tail rotor fixed mechanism is connected to the rotating controls through a rotating push-pull tube. The push-pull tube attaches to a sliding crosshead that moves in and out on splines on the tail rotor mast to provide pitch control. Rotating counterweights minimize the control forces required. The helicopter is equipped with a 28 VDC electrical system. Power for this system is obtained from a nickel-cadmium 24 volt, 17 amp/hour battery or optional 24 volt, 28 amp/hour battery and a 30 volt, 200-amp starter generator. The starter generator has been derated to 180 amps to ensure adequate cooling under all operating conditions up to 18,000 feet Hp. Basic helicopter landing gear is the low skid type. Optional high skid gear or pop-out emergency flotation gear is also available. The landing gear is attached to the bottom of the forward and aft bulkheads. The gear uses a three-point attachment configuration to prevent ground resonance. The skid type landing gear consists of two skids attached to the ends of two arched crosstubes that are secured to the fuselage by means of a three-point attachment configuration. Each skid tube is fitted with a tow fitting, two saddles with sockets for crosstubes, skid shoes along the bottom, a
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rear cap, and two eyebolt fittings for mounting of ground handling gear.
•
Electrical Standard (BHT-ELEC-SPM)
For additional information on the 407 helicopter, refer to specific chapters within this manual and to the BHT-407-MD (Manufacturer’s Data) section of the Flight Manual.
•
Structural Repair Manual (BHT-ALL-SRM and BHT-206-SRM)
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Special Tools Illustrated Parts Breakdown manual (BHT-SPECTOOL-IPB)
•
Corrosion Control Guide (CSSD-PSE-87-001)
•
Rolls-Royce 250-C47B Operation Maintenance Manual (CSP21001) Illustrated Parts Catalog (CSP23001)
1-2.
GENERAL INFORMATION — INSTRUCTIONS FOR CONTINUED AIRWORTHINESS (ICA)
The Model 407 helicopter is certi fied under FARs Parts 27 and 36, Appendix J. Additionally, it is approved under Canadian Airworthiness Manual Chapters 516 (ICAO Chapter 11) and 527, Sections 1093 (b) (1) (ii) and (iii), 1301-1, 1557 (c) (3), 1581 (e), and 1583 (h). The Instructions for Continued Airworthiness (ICA) include the data necessary to assure the continued airworthiness of the rotorcraft, each engine, rotor, and all components that are part of this rotorcraft’s type certification basis. The information in this manual is applicable to 407 helicopters S/N 53000 through 54299 as well as 407GX helicopters S/N 54300 and subsequent that incorporate the Garmin G1000H Glass Cockpit.
1-3.
INSTRUCTIONS FOR CONTINUED AIRWORTHINESS (ICA) — SCOPE — MAINTENANCE REQUIREMENTS AND MANUALS
The following technical manuals are the manuals that comprise the Instructions for Continued Airworthiness (ICA) and which are necessary to maintain the continued airworthiness of the rotorcraft.
and and
1-4.
SUPPLEMENTAL DOCUMENTS
Technical Bulletins (TB) and Alert Service Bulletins (ASB) are published when necessary. These documents supplement the Maintenance Manual (MM) and provide instructions and data to replace or modify components or systems, and perform maintenance practices on the helicopter. When a bulletin affects the way the helicopter is maintained, it is incorporated in the MM at the next available opportunity. Refer to the bulletin record (page BR) for the list of bulletins that have been incorporated in the manual. Temporary Revisions (TR) are published when necessary. TRs supersede the content of the MM on the applicable page range. Refer to the temporary revision record (page TR) for a list of active temporary revisions against the manual. CUSTOMER FEEDBACK
Maintenance Manual (BHT-407-MM)
•
Illustrated Parts (BHT-407-IPB)
•
Component Repair and Overhaul Manual (BHT-407-CR&O)
•
Component Repair and Overhaul Manual – Vendor (BHT-407-CR&O-V)
•
Standard Practices Manual (BHT-ALL-SPM)
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Manual
With the exception of the Rolls-Royce manuals, links to all of these publications are available via the Electronic Commercial Technical Publications Web site at www.bellhelicopter.net.
1-5. •
Practices
Rev. 30
Breakdown
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manual
Bell Helicopter Textron (BHT) strives to provide you, the customer, accurate and straightforward manuals. Sometimes, we may make mistakes. If you find any mistakes, we would appreciate it if you told us. Your observation, suggestion, or complaint will be acknowledged. For your convenience, we have included a Customer Feedback form at the beginning of the Maintenance Manual (MM). You can send it by fax or mail it to us. When you tell us about a mistake that is found in the MM, please be as specific as possible. Your help to
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make sure that this publication is correct is very much appreciated.
1-6.
Chapter 12
Servicing
Chapter 18
Rotor Track and Balance and Vibration Monitoring
GENERAL INFORMATION — USE OF THE MANUAL
VOLUME 3 — EQUIPMENT The instructions provided in the Maintenance Manual (MM) and those modified either by Alert Service Bulletins (ASB) issued by Bell Helicopter Textron (BHT), or by Airworthiness Directives (AD) issued by the local Aviation Authority, shall be strictly followed. 1-7.
USE OF THE MANUAL — DOCUMENT STRUCTURE
The breakdown of the helicopter into systems within the Maintenance Manual (MM) is done under a modified Air Transport Association (ATA) chapter system. NOTE A list of all the chapters contained in this manual is also provided at the beginning of the MM (page i). The MM is divided into 13 volumes and 34 chapters. The volumes group the chapters into general categories as follows:
VOLUME 1 — GENERAL INFORMATION Chapter 1 Chapter 4 Chapter 5
General Information Airworthiness Limitations Schedule Inspections and Component Overhaul Schedule
VOLUME 2 — HANDLING AND SERVICING
Chapter 21
Air Distribution (Ventilation)
Chapter 25
Equipment and Furnishings
Chapter 26
Fire Protection
VOLUME 4 — FUEL/HYDRAULICS Chapter 28
Fuel System
Chapter 29
Hydraulics
VOLUME 5 — AIRFRAME Chapter 30
Ice and Rain Protection
Chapter 32
Landing Gear
Chapter 52
Doors and Windows
Chapter 53
Fuselage
VOLUME 6 — MAIN ROTOR/MAIN ROTOR DRIVE SYSTEM Chapter 62
Main Rotor
Chapter 63
Main Rotor Drive System
VOLUME 7 — TAIL ROTOR/TAIL ROTOR DRIVE SYSTEM Chapter 64
Tail Rotor
Chapter 65
Tail Rotor Drive System
VOLUME 8 — FLIGHT CONTROLS Chapter 67
Flight Controls
Chapter 6
Dimensions and Charts
Chapter 7
Lifting and Jacking
Chapter 8
Weight and Balance
Chapter 71
Power Plant
Chapter 9
Towing
Chapter 75
Engine Air
Chapter 10
Parking, Mooring, and Storage
Chapter 76
Engine Controls
Chapter 11
Placards and Markings
Chapter 79
Engine Oil System
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VOLUME 9 — POWER PLANT
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VOLUME 10 — INSTRUMENTS/ELECTRICAL
CAUTION Chapter 95
Instruments
Chapter 96
Electrical Systems
VOLUME 11 — AVIONICS Chapter 97
Avionics
A M A I N T E N A N C E P R O C E D U R E , PRACTICE, ETC. THAT, IF NOT STRICTLY OBSERVED, COULD RESULT IN DAMAGE TO EQUIPMENT OR TO THE HELICOPTER.
VOLUME 12 — WIRING DIAGRAMS NOTE Chapter 98
Wiring Diagrams
VOLUME 13 — KITS Chapter 99
Kits
A Table of Contents (TOC) is provided at the beginning of every chapter of the MM. Each TOC reflects the breakdown of the chapter (i.e., system) into sections (i.e., sub-systems) and subjects (i.e., components), as applicable, and allows for quick access to the required information within the chapter. Paragraph, figure, and table numbering uses a combination of the chapter number followed by a sequence number, starting at 1 (e.g., Figure 63-7). Page numbering uses a sequence number, starting at 1 at the beginning of each chapter. 1-8.
USE OF THE MANUAL — REVISION STATUS AND LIST OF EFFECTIVE PAGES
The revision status of the manual is provided in the log of revisions at the beginning of the Maintenance Manual (MM) (page A) and on the title page of the manual. The log of pages (starting on page A) provides the revision status of every page in the manual. 1-9.
USE OF THE MANUAL — WARNINGS, CAUTIONS, AND NOTES
WARNING
A M A I N T E N A N C E P R O C E D U R E , PRACTICE, ETC. THAT, IF NOT STRICTLY OBSERVED, COULD RESULT IN PERSONAL INJURY OR DEATH. 1-00-00 Page 8
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A note provides supplemental data about the procedure, practice, condition, etc. for the required maintenance task. Warnings, cautions, and notes are used throughout the manual to emphasize important and critical instructions. They normally appear ahead of the procedure they apply to. Notes used in tables and figures are numbered in sequence, starting at 1. When the number is highlighted with a symbol (e.g., ), the note applies to specific data contained in the table or figure. When the number is not highlighted, the note applies to all of the content. 1-10.
USE OF THE MANUAL — MATERIALS REQUIRED
WARNING
MAKE SURE ALL SAFETY PRECAUTIONS ARE FOLLOWED WHEN HANDLING AND USING CONSUMABLE MATERIALS. FAILURE TO DO SO CAN CAUSE INJURY OR DEATH.
CAUTION HANDLING, STORAGE, AND SAFETY PRECAUTIONS FOR C O N SU M A BL E M A T ER I A LS S H AL L BE IN ACCORDANCE WITH MANUFACTURER’S INSTRUCTIONS, UNLESS OTHERWISE SPECIFIED IN THIS MANUAL. Most of the maintenance procedures require the use of consumable materials. All of the necessary
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consumable materials are listed in a “Materials Required” table at the beginning of every applicable maintenance procedure. The consumable materials are also called out by nomenclature and c-code number in the text (e.g., drycleaning solvent (C-304)). The c-code number is a unique identification code for each material to be referenced in the Standard Practices Manual (BHT-ALL-SPM, Chapter 13). On occasion, the materials that are used in maintenance tasks will change properties, change suppliers, or be discontinued. Also, new or improved materials may become available. If there is ever a difference between the Maintenance Manual and the Standard Practices Manual (BHT-ALL-SPM), the manual that has the latest date of issue or revision shows the preferred material. However, either material may be used for the maintenance task, unless otherwise specified in the procedure. 1-11.
material (C-XXX) that is called out in the applicable text or figure (paragraph 1-10). 1-13.
When a torque value is not shown, the standard torque value for that combination of fasteners shall be used as applicable to fasteners. This will be identified throughout the manual by the term “tighten”. Standard torque values for various combinations of fasteners are found in the Standard Practices Manual (BHT-ALL-SPM, Chapter 2). In cases where torque values are provided, they are highlighted in the applicable figure with a symbol ( T ) followed by the torque value. The text will show a symbol ( T ) only alongside the item affected. This shows that this item has a torque value assigned to it and the reader should refer to the applicable figure for that value.
USE OF THE MANUAL — SPECIAL TOOLS 1-14.
Some maintenance procedures require the use of Bell Helicopter Textron (BHT) special tools, commercial tools, or workaids. All of the necessary tools are listed in a “Special Tools” table at the beginning of every applicable maintenance procedure. A description and illustration of the BHT special tools are found in the Special Tools Illustrated Parts Breakdown manual (BHT-SPECTOOL-IPB). Supplier information for the commercial tools is provided when tools are too specific and may be difficult to find. Other commercial tool brands with equivalent or similar tools may be used to accomplish the tasks. Dimensions and materials necessary to make the workaids are shown in the applicable figures. 1-12.
USE OF THE MANUAL — TORQUES
USE OF THE MANUAL — SYMBOLS
Some illustrations have symbols to highlight common processes such as the application of sealant, primer, corrosion preventive compound, etc. Other processes include the use of heat, assembly fluid, or unreduced wet primer. Figure 1-2 shows all of the symbols used in this manual. In addition, always use the consumable
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USE OF THE MANUAL — DAMAGE, AND REPAIR LIMITS
WEAR,
CAUTION
THE METRIC EQUIVALENTS TO U.S. STANDARD WEIGHTS AND MEASURES A R E P R O V I D E D I N T H I S M A N U A L . HOWEVER, USE ONLY THE U.S. STANDARD VALUES WHEN YOU TAKE A MEASUREMENT TO ESTABLISH A SPECIFIC DIMENSION OR TO DETERMINE THE SERVICEABILITY OF A COMPONENT. Throughout the Maintenance Manual (MM), wear, damage, and repair limits, including fits and tolerances, are provided in the inspection and repair procedures to determine if the parts are serviceable. It is not intended that all dimensions provided be examined as a prescribed maintenance procedure. However, you must examine the dimensions of parts that show signs of wear or physical damage.
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ASSEMBLY FLUID
ADHESIVE
CORROSION PREVENTIVE COMPOUND
GREASE
GREASE
GREASE
HEAT APPLICATION
LOCKWIRE
NO ORGANIC FINISH
PRESERVATIVE
SEALANT
SYSTEM LUBRICANT
THERMAL FIT BY COOLING
TIE WRAP
TORQUE
WET UNREDUCED PRIMER
429_MM_01_0001_c01+
Figure 1-2. Use of the Manual — Symbols
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Non-Destructive Inspection (NDI) of a part or component of an assembly is required only when the MM or another Bell Helicopter Textron (BHT) approved document specifically instructs the maintainer to do so (e.g., when written steps of an inspection or other procedure call for NDI procedures to be carried out on specific parts). However, NDI is to be accomplished when indications resulting from a visual inspection convey that a crack or other defect may exist and that further inspection is required using NDI procedures (BHT-ALL-SPM, Chapter 6) to ensure the airworthiness of the part or component. As applicable, the BHT-ALL-SPM, BHT-ALL-SRM, and BHT-ELEC-SPM contain all of the common information and procedures required during the inspection and repair of parts.
WARNING
LIMITS OR AS A RESULT OF AN ACCIDENT OR INCI DENT INSPECT ION, AND DEEMED UNAIRWORTHY, SHALL BE PERMANENTLY MARKED AS SCRAP OR PHYSICALLY DESTROYED TO THE EXTENT THAT THERE IS NO POSSIBLE REPAIR OR INSTALLATION OF THE PART ON ANY HELICOPTER OR COMPONENT IN THE FUTURE. Any wear or damage that exceeds the allowable limits or cannot be reworked to a serviceable condition is cause for rejection of the part. If one part of a matched, serialized set is damaged in excess of the allowable limits, both parts must be replaced. The limitations and instructions contained in the MM are for the sole and exclusive purpose of maintaining, repairing, or modifying only parts, components, and systems approved by Bell Helicopter Textron (BHT).
ALL PARTS THAT ARE REMOVED FROM SERVICE DUE TO REACHING THEIR
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