Manual - 47D1-G-G2 Mo

MODELS
47 D-l, G, & G-2
NOTICE
CHANGES AND REVISION SERVICES TO THIS MANUAL HAVE BEEN DISCONTINUED. SAFETY OF FLIGHT
MESSAGES WILL BE PROVIDED TO ALL OWNERS ON RECORD WITH BELL HELICOPTER COMPANY.
OWNERS AND OPERATORS ARE ADVISED TO KEEP RECORD OF OWNERSHIP AND MAILING ADDRESSES
CURRENT WITH BELL HELICOPTER COMPANY, P.O. BOX 482 FORT WORTH, TEXAS 76101,
ATTN: SERVICE DEPARTMENT.
MAINTENANCE
and OVERHAUL
INSTRUCTIONS
15 AUGUST 1969
REVISION 4- 1 JUNE 1975
Models 47D-1, 47G &47G-2 BELL HELICOPTER COMPANY
MAINTENANCE & OVERHAUL INSTRUCTIONS
LIST OF EFFECTIVE PAGES
Insert latest revision pages: dispose of superseded pages.

NOTE: On a revised page, the portion of the text and illustration affected by the latest revision is
indicated by a vertical line. Revision to wiring diagrams are indicated by shaded areas.
Original ........... 0 .............. 15 August 1969 Revision .......... 2 ............ 25 October 1974
Revision .......... 1 ............... August 1974 Revision .......... 3 ........... 1 November 1974
Revision .......... 4 ................. 1 June 1975
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Cover .......... .............................. 3 1-7 - 1-8 (Part 2) ...................... 3 3-7 - 3-8 .................................. 0
Title ........................................ 3 1-8A/1-8B (Part 2) .................... 3 3-8A - 3-8C ............................. 0
A-B ...................................... 3
CBlank ........................................ 3 1-9/1-10 (Part 2) ....................... 0 3-9 - 3-16 ................................. 0
Introduction ...................... . 0 1-11/1-12 (Part 2) ...................... 0 3-17 - 3-18 3
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1-1 (Part 1) ................................ 3 1-15/1-16 (Part 2) ...................... 0 3-20 ........... ............................. 3
1-2 (Part 1) ................................ 0 1-17 - 1-18 (Part 2) ................... 0 3-20A - 3-20B ......................... 3
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1-12 (Part 1) .............................. 3 1-26A - 1-26B (Part 2) ............. 1 3-26A/3-26B ............................ 3
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1-14 - 1-16 (Part 1) .................. 3 1-29 - 1-30 (Part 2) ................... 0 3-33 - 3-34 ............................. 3
1-16A (Part 1) ............................ 0 1-31/1-32 (Part 2) ...................... 4 3-35/3-36 ................................. 3
1-17 - 1-18 (Part 1) .................. 3 1-1 - 1-8 (Part 3) ..................... 0 4-1 - 4-5 ................................. 0
1-18A - 1-18F (Part 1) ............. 3 1-9/1-10 (Part 3) ...................... 3 4-6 ....................................... 3
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1-45 - 1-48 (Part 1) .................. 3 2-25 - 2-26 (Part 1) .................. 0 4-19 - 4-20 ............................. 0
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1-51 - 1-56 (Part 1) .................. 0 2-3 - 24 (Part 2) ..................... 0 4-21 - 4-24 ............................. 0
1-56A (Part 1) ........................... 0 2-5 - 2-6 (Part 2) ..................... 3 4-24A ....................................... 0
1-57 - 1-58 (Part 1) .................. 0 2-7 - 2-10 (Part 2) ..................... 0 4-25 - 4-32 ............................. 0
1-59/1-60 (Part 1) ...................... 0 2-11 - 2-13 (Part 2) ................... 3 4-33/4-34 ................................. 0
1-60A - 1-60B (Part 1) ............. 1 2-14 - 2-16 (Part 2) .................. 0 5-1 - 5-4 (Part 1) ..................... 0
1-60C/1-60D (Part 1)................. 1 3-1 - 3-2 .................................. 0 5-5 - 5-6 (Part 1) .................... 3
1-61 -1-62 (Part 1) ................. 3 3-3 ............................................ 3 5-7 (Part 1) ............................... 0
1-63 - 1-64 (Part 1) ................. 0 3-4 ............................................ 0 5-8 (Part 1) ................... ......... 3
1-65/1-66 (Part 1) .................... 4 3-5 - 3-6 ................................... 3 5-9 - 5-10 (Part 1) ................... 0
1-1 - 1-6 (Part 2) ...................... 0 3-6A/3-6B ................................. 3 5-10A (Part 1) .......................... 0
A (Rev. 4)
Models 47D-1, 47G & 47G-2
LIST OF EFFECTIVE PAGES (Cont)
Page Revision Page Revision

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5-16A (Part 1) .......................... 0 10-7 - 10-10 ............................. 0
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Rev. 3 B/C
Models 47D-1, 47G & 47G-2 BELL HELICOPTER COMPANY Introduction
MAINTENANCE
& OVERHAUL INSTRUCTIONS
Introduction
This Handbook of Maintenance and Overhaul Instructions is issued to set forth the recommendations and
procedures for maintaining, overhauling, and servicing Model 47D-1, 47G, and 47G-2 Helicopters, manu-
factured by Bell Helicopter Company, P.O. Box 482, Fort Worth 1, Texas.
CAUTION
The information in this manual is provided to help assure

the personal safety of the occupants of the helicopter.
All directions, instructions, procedures, etc. set forth
must be strictly followed.
This information contained herein has been prepared and approved by the Publications and Service Depart-
ments of this company, and it is therefore urgently recommended that these instructions and procedures be
adhered to. In addition to the information contained in this handbook,the Service Department will render
all possible assistance in the solution of any unusual maintenance or operational problems that may be
encountered.
This handbookis divided into Thirteen major sections and an alphabetical index, as follows:
SECTION I - GENERAL INFORMATION
SECTION II - MAIN ROTOR SYSTEM
SECTION III - MAST AND CONTROLS
SECTION IV - TRANSMISSION SYSTEM
SECTION V - POWER PLANT AND RELATED SYSTEMS (FRANKLIN)
SECTION V - POWER PLANT AND RELATED SYSTEMS (LYCOMING)
SECTION VI - TAIL ROTOR SYSTEM
SECTION VII - FLIGHT CONTROLS (STANDARD)
SECTION VII - FLIGHT CONTROLS (HYDRAULIC)
SECTION VIII - INSTRUMENTS
SECTION IX - ELECTRICAL
SECTION X - BODY AND LANDING GEAR
SECTION XI - WIRING DATA
ALPHABETICAL INDEX
It has always been the endeavor of Bell Helicopter Company to build products which will render maximum
satisfaction and dependability with a minimum of maintenance. Therefore by forwarding us duplicate pages
of your helicopter log, our Service Department will be aware of your service and maintenance problems,
and will be able to concentrate their efforts on devising new methods to reduce maintenance cost and time
to a minimum. The handbook will be revised periodically as improvements in the product are made, and
as improved service methods or procedures are developed. Revised and/or added pages will be forwarded
to you as released. These revised pages should be inserted immediately in order to keep your handbook
up-to-date.
If adjustments described in this handbookdo not produce the desired results, contact the Service Depart-
ment of Bell Helicopter Company for further instructions.
Before attempting repairs not described in this manual, contact the Service Department of Bell Helicopter
Company.
i/ii
Models 47D-1, 47G & 47G-2 BELL HELICOPTER COMPANY Section I (Part 1)
MAINTENANCE
Section I
General Information
1-1. MODEL 47D-1, G AND G-2 HELICOPTERS. side of the tail boom extension. Mechanical linkage
to control pedals provides control of blade pitch to
counteract main rotor torque and to change or main-
1-2. DESCRIPTION. The Model 47D-1, 47G, and47G- tain directional headings.
2 helicopters described in this handbookarebasically
the same, as they are all three-place, single engine Fuselage is of truss-type, steel tube construction.
helicopters. Principle features of difference are the Landing gear is skid-type with retractable, removable
use of hydraulic boost in the main rotor system which wheels. Cabin is constructed of transparent plastic
is factory installed on some later Model 47G and the with a removable door on each side. Flight controls
Model 47G-2. (Hydraulic boost may be installed on in the cabin consist of cyclic control stick, collective
Model 47G as a kit installation.) The Models 47D-1 pitch control stick, and tail rotor control pedals. A
and 47G are powered by a Franklin engine and the rotatable grip on the collective pitch control stick
47G-2 by a Lycoming engine. (Some 47G helicopters operates the throttle, through a cam which correlates
are equipped with the Lycoming engine which is a kit engine power with main rotor blade pitch for correct
installation.) Both engines are mounted vertically in rotor RPM within normal range of flight conditions.
the center frame structure, aft of the cabin, and Carburetor heat and mixture controls, electrical
drive the main rotor through a transmission con- switches, and other necessary engine and flight in-
taining two sets of planetary gears with an overall struments are located on a pedestal in the cabin.
reduction ratio of 9:1. The tail rotor, cooling fan,
generator, and rotor tachometer generator are also
driven through the transmission at suitable speeds. CAUTION
The transmission incorporates a centrifugal clutch
and freewheeling unit which permits autorotational
operation of the rotor with an idling or dead engine. Bell Helicopter Company does not authorize
cadmium plating of structural parts in the
The two-blade, semi-rigid main rotor is mounted to field
the mast through a gimbal ring and linked to a weighted
stabilizer bar whose plane of rotation changes less Note
rapidly than that of the rotor, resulting in more
stable rotor action during maneuvers and in gusty USE OF PAINT STRIPPER. The paint
wind conditions, strippers listed below may be used on all
metal surfaces, except on bonded
The tail (or anti-torque) rotor has two blades and material, such as main rotor blades and
is mounted to rotate in a vertical plane on the right tail rotor blades.
Storage Safety
Material Specification Manufacturer Requirements Hazards
(GENERAL REMOVER)
E-Z Strip MIL-R-25134A Pennsalt Chemicals 6 months from Use in well venti-
19-A (USAF) Corporation date of manu- lated area. Avoid
9009 Sovereign Row facture at skin contact.
Dallas 35, Texas 60°-90°F.
(EPOXY REMOVER)
Delchem None Pennsalt Chemicals 4 months from Use in well venti-

2236A Corporation date of manu- lated area. Avoid
9009 Sovereign Row facture at contact with skin
Dallas 35, Texas 60°-90°F. Store or clothing. Wear-
in polyethylene ing of protective
lined containers clothing is recom-
only. mended.
Rev. 3 1-1
Section I (Part 1) BELL HELCOPTER COMPANY Models 47D-1, 47G & 47G-2
& OVERHAULINSTRUCTIONS
MAINTENANCE
1-3. STATION. (Figure 1-1.) Main components are

located within stations as indicated, measured in
inches from Station 0, which is two inches forward of
the mast center line.
Stations of the main and tail rotor are measured from

center line of hub. (Figure 1-2.)
1-4. PRINCIPAL DIMENSIONS.
Height (Ground line to top

of cabin) 6 ft. 7.76 in.
Height (Ground line to center
of stabilizer bar) 8 ft. 2.36 in.
Height (Ground line to center of
main rotor hub) 8 ft. 7.45 in.
Height (Ground line to top of
main rotor retaining nut) 9 ft. 3.61 in.
Width (Center to center of
skids) 7 ft. 6.00 in.
Width (Overall) 9 ft. 5.58 in.
Length (Tip of main rotor blades
to aft side of tail rotor guard) 41 ft. 4.75 in.
Length (Forward side of cabin to
to aft side of tail rotor guard) 30 ft. 5.00 in.
Length (Landing gear) 10 ft. 1.02 in.
1-5. MAIN ROTOR.
Main rotor disc diameter 35 ft. 1.50 in.

Area per blade 17.71 sq. ft.
Area both blades 35.42 sq. ft.
Disc area (Area of rotation) 969 sq. ft.
1-6. TAIL ROTOR.
Tail rotor disc diameter 5 ft. 8.125 in.

Area per blade 1.20 sq. ft.
Area both blades 2.40 sq. ft.
Disc area (Area of rotation) 25.31 sq. ft.
1-7. SETTINGS AND RANGES OF MOVEMENT.
1-8. MAIN ROTOR BLADES.
Collective Pitch (Measured at Blade Grip)

Neutral +5 ° 45'
Minimum + 50'
Maximum + 11°
Flapping (any direction) 7° 30'

Preconing angle 2° 30"
1-2
*
MAINTENANCE
BLADE GRIP
47100-3
Figure 1-2. Station Diagram - Main and Tail Rotor
1-9. SWASHPLATE. (Measured with protractor.) Right Pedal Forward -

Wood Blades - 8 1/2 ° to - 9 °
Stick Position Swashplate Angle Right Pedal Forward -
Metal Blades -10 1/2 ° to -11 1/2 °
Neutral - 47D-1 and G Level - Forward Left Pedal Forward -
1 ° - Down - Left Wood Blades +10 1/2 ° to +12 1/2 °
Left Pedal Forward -
Neutral - 47G-2 1/2 ° - Up - Forward Metal Blades +12 1/2 ° to +13 1/2 °
1/2 ° - Down- Left
1-11. SYNCHRONIZEDELEVATOR.
Forward - 47D-1 and G 9° ± 1/2 °
Forward - 47G-2 8 1/2 ° ± 1/2 ° Stick Position Elevator Leading Edge
Aft - 47D-1 and G 9° ± 1/2 ° Neutral Down 15 1/2 ° to 16 1/2 °

°
Aft - 47G-2 9 1/2 ° 1/2 ° Forward Up 13 1/2 ° to 14 1/2
Aft Down 24 ° to 30 °
°
Right - 47D-1 and G 6 1/2 ± 1/2 °
Right - 47G-2 °
6 1/2° ± 1/2 1-12. ENGINE - FRANKLIN.
Left - 47D-1 and G 7 1/2 ° ± 1/2 ° Manufacturer Aircooled Motors, Inc.

Left - 47G-2 7 1/2 ° ± 1/2 °
Model 6V4-200-C32
1-10. TAIL ROTOR BLADES. Number of Cylinders 6
Horsepower 200
Pedal Position Blade Angle Fuel 91/96
Oil
Neutral - Wood Blades + 1 ° to +2° (Temperature above 30°F) Grade 1080 (SAE40)
Neutral - Metal Blades + 1 ° to +2° (Temperature below 40°F) Grade 1065 (SAE 30)
1-3
Section I (Part 1) BELL HELICOPTER COMPANY Models 47D-1, 47G & 47G-2
MAINTENANCE
1-13. ENGINE - LYCOMING. position, during flight or may be removed for weight-
saving.
Manufacturer AVCO Manufacturing Co.
(Lycoming Division) a. To remove wheel assembly, remove lock-pinfrom
outboard end of offset axle and positioning lock-pin
Model VO-435-A1B, A1D or A1E which passes through support bracket and axle. Pull
Number of Cylinders 6 wheel assembly inboard out of support.
Horsepower (derated) 200 at 3100 RPM
Fuel 80/87 Octane b. To install wheel assembly, place washer on offset
Oil axle and insert axle in support from inboard side,
(Temperature above 40°F) Grade 1100 (SAE 50) with short curved tube pointing aft when wheel is in
(Temperature below 40°F) Grade 1065 (SAE 30) retracted position. Install lock-pin through end of off-
set axle at outboard side of support. Align holes and
1-14. TANKCAPACITIES. install large lock-pin through support and axle.
Fuel - 47D-1 29 US Gallons c. To extend wheel, remove large positioning lock-
Fuel - 47G and G-2 41 US Gallons pin and rotate wheel assembly forward until wheel
Oil System - 47D-1 and 47G 3 US Gallons rests on ground. Place lift tube on end of curved
Oil System - 47G-2 3 1/2 US Gallons tube which is now pointing up and slightly aft. Station
Hydraulic Reservoir 1 1/2 US Pints an assistant, if available, at left aft side of tail boom
extension to push down on tail boom. Swing lift tube
1-15. GROUND HANDLING. forward to bring wheel into extended position, align
holes and install lock-pin.
1-16. GROUND HANDLING WHEELS. Two ground
handling wheels and a lift tube are furnished with 1-17. PUSHING OR TOWING. When pushing or towing
helicopter. Wheels may be left installed, in retracted tie-down main rotor and raise helicopter on extended
MAST COVER NUT
Figure 1-3. Hoisting - Jacking and Leveling Diagram

MAINTENANCE
handling wheels. Station a man at left side of tail rotor 1-20. LEVELING. Three leveling lugs are located on
guard to balance and steer helicopter. Push on struc- lower tubes of center frame structure aft of Station
ture or landing gear cross tubes. Do not push or 0, accessible from left side. (See figure 1-3.)
pull on doors, cabin enclosure, elevator, tail rotor,
exposed drive shafts, or aft end of tail rotor guard. a. Jack helicopter clear of ground or floor.
When towing, use suitable rope attached to forward
skid legs or landing gear cross-tube in any safe b. Place spirit level on leveling bar across two
and convenient manner. leveling lugs, and operate jacks to level helicopter
laterally.
1-18. HOISTING. (Figure 1-3.) The mast cover nut
is provided with a hoisting eye to permit hoisting of c. With spirit level aligned on two fore and aft lugs,
entire helicopter. Steady helicopter to prevent swing- level helicopter longitudinally. Recheck lateral level-
ing or turning during hoisting. ing.
1-19. JACKING. Three jack points, consisting of 1-21. MAIN ROTOR TIE-DOWN. (Figure 1-4.) A tie-
short pointed tubes, are welded to underside of the down assembly is furnished as loose equipment and
center frame structure. The two forward jack points is used to secure the main rotor from turning or
are located just aft of forward landing gear cross- flapping. One type is a hingedwoodenblock, the halves
tube saddles. The aft jack point is located just for- of which are shaped and padded to fit the blade tip
ward of lower tail boom attachment point. (See figure contour, furnished with a canvas web strap. A later
1-3.) type is similarly shaped from sheet metal.
47976-97
Figure 1-4. Main Rotor Tie Down

1.5
1-5
a. Open tie-down assembly and install on end of Note

either main rotor blade, with care to avoid damag- When equipped with floats, moor helicop-
ing trailing edge of blade. (Install wooden block with ter with anchors fore and aft, or by tying
strap attachment side up and pass one strap down to a dock or piles.
through slot to secure clamp bolt in place.)
1-23. ACCESS AND INSPECTION PROVISIONS. The
b. Align blade over tail boom, cross straps below uncovered fuselage construction permits access to all
blade and pass straps under upper tail boom struc- parts requiring frequent inspection or service except
tural tubes. Be sure straps are clear of tail rotor where the following means of access are provided.
drive shaft and control cables. Pull blade down until
gimbal ring contacts static stop, and tie straps snug a. Area below cabin floor - remove large access
without strain. Duringwetweather, provide some slack plate from underside of cabin.
to avoid possibility of straps tightening and causing
a "set" in the blade. b. Cabin box beam interior - remove plate from
each side of box beam above cabin floor.
1-22. MOORING.Pass ropes or cables over forward
and aft landing gear cross tubes, andsecure to ground c. Instrument column interior - operate Dzus fas-
stakes or fixed tie-down rings. (See figure 1-5.) Tie teners on panel face, swing panel open on hinge at
down main rotor. (Refer to paragraph 1-21.) lower end.
47976-89
47976- 8 9
Figure 1-5. Helicopter Tie Down

1-6
& OVERHAUL INSTRUCTIONS -
MAINTENANCE
d. Front of engine - unsnap sides of fabric cooling aft side of cabin seat-back structure. Fill reservoir
shroud from baffles around engine. to full mark on filler cap drip stick with petroleum
base hydraulic oil, MIL-H-5606.Purge systemduring
e. Battery, relay and junction box - remove covers engine run-up (or with hydraulic test unit connected
as necessary. and operating) by operating cyclic control stick in a
circular motion at least ten times, with manual con-
1-24. SERVICING. trol valve in "BOOST ON" position (push knob down).
Recheck fluid level in reservoir after purging.
1-25. FUEL - MODEL 47D-1. The gravity-flow fuel
system on this model utilizes a single fuel tank which 1-30
has a total capacity of 29 US (24.166 Imp.) gallons. 1-31. STARTING ENGINE.
The tank is mounted in a support which is attached
a. If start is being made in a strong or gusty wind,
to the structure aft of the engine. A drain valve in
the bottom of the tank permits draining moisture
it is recommended that helicopter be headed into
wind. Check that main rotor tie-down is removed
from the sump or draining the system. and both rotor paths are clear. Check all flight con-
trols for freedom of movement. Place collective
pitch control stick full down, pedals neutral and
flow fuel system is supplied by two interconnected
cyclic control stick neutral or slightly forward. Ad-
tanks having a total capacity of 41 US gallons and just friction to aid in keeping sticks in position.
mounted above the engine compartment at each side
of the transmission. Fill system through either or
WARN IN G
both filler openings in forward upper ends of tanks.
When filling through one tank, allow time for equali-
zation by flow through cross-over line before final Retract ground handling wheels of skid
check of fuel level. Drain valves and lines are pro- landing gear before starting. Anchor or
vided at aft end of each tank and on fuel strainer. moor float equipped helicopter fore and
aft to prevent helicopter turning from
torque before tail rotor reaches effective
CAUTION RPM.
b. Mixture control full "Rich". Helicopters equip-
ped with compensating carburetors are automatically
Before filling tanks, ground fuel supply adjusted.
nozzle to ground jack on cabin structure.
c. Carburetor heat control - "Cold".
1-27. OIL - FRANKLIN ENGINE. The oil system d. Models 47D-1 and 47G push fuel shut-off control
incorporates an engine sump which acts as a supply knob in - "ON". Models 47G-2 push fuel shut-off
tank. The sump is at the lower aft side of the engine, control knob full aft - "ON".
and is serviced from the left side of the engine com- e. Check generator switch - "ON" (if existing). Use
partment. The oil system has a total capacity of 3 US external power with battery switch "OFF", ("ON" if
(2.5 Imp.) gallons, of which 2 US (1.7 Imp.) gallons external power is not available, this is an emergency
are retained in the sump. A dip stick attached to the rocedure)
filler cap serves to denote the oil level. Service the
sump with aircraft engine lubricating oil. (Refer to f. Check fuel quantity gage, if helicopter has two
paragraph 1-12.) tanks move selector switch to each tank position.
1-28. OIL - LYCOMING ENGINE. Theoil supplytank g. Prime engine by opening and closing throttle.
is located aft of the engine and accessible from left (One to three times, for cold engine. No prime hot
side of helicopter. Tank capacity is 8 US (6.6 Imp.) engine.) If primer is installed, prime engine by
quarts, and filler cap is provided with a dip stick for holding priming switch "ON" for one to three seconds
measuring oil level. Capacity of entire oil system is for cold engine. (Do not prime hot engine.) Leave
14 US (11.7 Imp.) quarts, including trapped and re- throttle partly open while turning engine over one or
sidual oil. Tank can be drained by opening valve be- two revolutions with ignition switch "OFF".
low tank sump, or by removing cap from tee fitting
below tank. Drain system through tee in lower line Note
between cooler and tank. Drain engine sump by re-
moving sprag mount swivel plate and spindle to per- If a hand primer pump is installed and
mit removalof drain plug through hole in sump adapter. cold weather starting difficulty occurs,
On A1D engines a drain plug is provided at the rear check primer pump for proper operation.
of the engine sump. Turn engine over with ignition "OFF"
during priming, and increase priming
1-29. HYDRAULICSYSTEMSERVICING. Thehydrau- pumps strokes as necessary to insure
lic control boost system reservoir is located on left getting fuel into induction system.
1-7
MAINTENANCE
h. Turn ignition switch to "R" (right magneto has assembly after the engine has started, turn ignition
impulse coupling). Helicopters equipped with Retard switch to "R" and handcrank switch to "ON" position.
Breaker Magneto and Induction Vibrator refer to Engine should run on retarded breaker of right mag-
paragraph 1-32. neto. If engine stops recheck wiring.
i. Energize starter by depressing starter pedal or CAUTION
by pressing "Engine Start" switch. (For hand cranking
refer to paragraph 1-33.)
The handcrank switch must not be switched
j. When engine starts, turn ignition switchto "Both" to the "Handcrank" position while heli-
and adjust throttle to idle engine at 1500 to 1700 RPM copter is in flight.
until oil pressure reaches 65 PSI. Proceed withwarm f. The handcrank switch is provided so that engine
up and ground test. may be started with the handcrank on a retarded
spark.
CAUTION Note
To start engine with handcrank, position
If oil pressure gage fails to indicate within magneto switch to "Both" and handcrank
a few seconds, shut off engine and investi- switch to "ON", when engine starts re-
gate for cause of trouble. turn handcrank switch to "OFF".
k. In the event of fire, continue starting attempt 1-33. HAND CRANKING - LYCOMING ENGINE. The
so as to drain fire into the engine. If fire becomes engine is provided with an adapter for use of a hand
critical, use extinguisher. crank in starting, as optional or emergency pro-
Note cedure. Adapter is located on left side of engine
accessory section, covered by a removable cap.
If engine fails to start due to over-priming Support is mounted by clamps on vertical structural
open throttle wide and place mixture con- tube at left side of center frame, with center of hole
trol in "Cut-Off". Turn ignition switch 5.7 inches above center of longeron. Crank is stowed
"OFF" and turn engine over several rev- in three spring clips on left aft center frame tubes.
Solutions to clear the flooded condition. Shaft of crank has an enlarged section provided with
1-32. RETARD BREAKER MAGNETO AND IN- ratchet-tooth grooves, for engagement with two sets
DUCTION VIBRATOR SYSTEM. Helicopters equip- of spring-loaded dogs on support to prevent kick-
ped with this installation will facilitate engine starting back. For added safety, drive end of crankis attached
in cold weather: to shaft through a friction clutch. Notch in top of
support may be used as wrench to keep clutch nut
a. The retard breaker is so arranged that its con- adjusted so that drive end slips when 75 to 100 foot-
tacts open at a predetermined number of degrees pounds torque is applied.
after the main breaker contacts open, providing
retarded ignition for starting.
b. With ignition switch on "Both" magnetos, the
vibrator is energized only when the starting motor
is operative and provides ignition in the form of a
shower of hot sparks instead of a single spark ob- Never attempt to hand crank a hot engine,
tained from an impulse coupling magneto. unless engine is allowed to cool for five
minutes.
c. Start the engine with magneto switch turned to
"Both" and the handcrank turned to "OFF". a. Remove cap from drive adapter on engine. Insert
d. The moment the engine fires, the starter button crank through support, engaging pin with adapter and
must be released to render the starter vibrator and ratchet grooves with support dogs.
retard breaker inoperative. The engine ignition will
then be controlled by the normal breakers in both b. With ignition switch "OFF", pull engine through
magnetos and the engine will increase speed and several times to be sure it turns freely and that
complete start. magneto impulse coupling is clicking.
Note c. Prime engine by turning throttle control grip once
If intermittent firing is allowed to continue, to full open, to full closed, then opened slightly.
abnormal loads are imposed on the trans-
mission especially the freewheeling d. Position crank so engine will fire on upstroke of
springs and plates. crank.
e. To check operation of retard breaker magneto e. Set ignition switch to "R" magneto. When retard
for proper functioning of vibrator and retard breaker breaker is installed set switch to "Both".
18
MAINTENANCE
f. Pull engine through compression on up-stroke of 1-35. GROUNDTEST - FRANKLIN ENGINE.

crank. (It is not necessary to "spin" crank, as im-
pulse coupling fires plug after piston passes top a. Accomplish ignition system check at 3100 RPM in
center.) minimum pitch, after cylinder head temperature has
reached desired range. A maximum drop-off of 200
g. If engine fails to start after several attempts, RPM, with no engine roughness, is permissible when
repeat step c. to prime engine. If engine floods, allow checking on either magneto.
to stand a few minutes.
b. Operate at 2700 RPM and 15 inches HG, and slow-
ly move the mixture control toward "IDLE CUT-OFF".
h. After start, turn ignition switch to "BOTH", and Observe the engine tachometer for an increase of
adjust throttle, approximately 50 RPM and return mixture control to
"RICH".
i. Remove crank. Replace cap over drive adapter.
Stow crank in spring clips. Note
The purpose of above check is to deter-
1-34. WARM-UP - FRANKLIN ENGINE. mine whether the full rich position is rich
enough to avoid deterioration and over-
heating when engine is at operating mani-
CAUTION
: fold pressure.
c. Increase power to obtain 3100 RPM with the main
Avoid continuous rotor RPM in a range be- rotor pitch lever in full low. Close throttle and check
tween 200 and 230 RPM because of stabili- engine idle speed for 1700 RPM before the rotor
zer bar resonance characteristics. Apply decelerates to load the engine.
sufficient control stick into the wind to
maintain the rotor in a nearly horizontal d. Close throttle and momentarily turn ignition switch
plane. "OFF". Ascertain that engine ceases firing andimme-
diately turn ignition switch to "BOTH".
a. Run engine between 1700 to 1800 RPM until oil
pressure reaches 40 PSI. Observe for clutch engage-
ment, as indicated by synchronization of engine and WARNING
rotor tachometer needles.
Perform this check as rapidly as possible
to prevent a severe backfire when switch
is turned to "BOTH". If engine continues
Engine and main rotor tachometer needles to run with ignition switch "OFF", stop
shall be synchronized at all speeds greater the engine by moving mixture control to
than 1700 engine RPM with the collective "CUT-OFF", and check magneto ground
control stick in full down position. Rapid circuits.
application of collective stick or throttle
below 2800 RPM may cause centrifugal e. Check engine temperatures and oil pressure at
clutch slippage. The clutch will be con- 15 inches HG.
sidered satisfactory if there is no slippage
when hovering at maximum gross weight f. Operate at 3100 RPM in full low pitch, and check
with 3000RPM. Clutch slippage under these control response by moving control stick fore andaft,
conditions shall be reason for clutch dis- and left and right. Observe main rotor tip path re-
assembly and inspection. (Refer to Section sponse. Apply light left and right pedal, and note re-
IV.) sponse.
b. Continue to increase throttle until engine reaches 1-36. WARM-UP AND GROUNDTEST - LYCOMING
approximately 2200 RPM. (This is to prevent slipping ENGINE.
and excessive wear on the clutch.) Maintain this RPM
until oil temperature reaches desired range. Note
Note Engine and main rotor tachometer needles
shall be synchronized at all speeds greater
On extremely cold start, hold engine RPM than 1700 RPM with the collective control
to 1700 until oil temperature reads 30°C., stick in the full down position. Rapid ap-
then proceed as outlined in preceding plication of collective stick or throttle
step b. below 2900 RPM may cause centrifugal
1-9
MAINTENANCE
clutch slippage. The clutch will be con- a. Drain fuel and oil.
sidered satisfactory if there is no slip-
page when hovering at maximum gross b. Remove equipment items which are not to be in-
weight with 3000 engine RPM. Clutch slip- cluded in basic weight. A check list of removable
page under these conditions shall be rea- equipment should be made, to remain with weight
son for clutch disassembly and inspection, data showing clearly whether or not each item was
(Refer to Section IV.) included in weight.
b. Increase throttle to 2200 to 2300 RPM, hold this c. Select a level, wind-free area, preferable inside
speed until engine oil temperature reaches 40°C a closed building. Check adjustment of scales. Check
(104°F) minimum. that main rotor is not tied down.
CAUTION d. Place a jack, on scales, under each of three jack-

points. Raise helicopter off floor, and level longi-
tudinally and laterally.
Avoid continuous rotor RPM in range be-
tween 200 - 230 RPM because of stabili- e. Record each scale reading. Deductweightofjacks,
zer bar resonance characteristics. and any blocks used, to obtain net weight.
c. Operating at 3100 RPM with collective pitch stick

full down, check engine operation on each magneto. Note
A drop-off of 200 RPM is permissible provided no
engine roughness occurs. only if data
Following step is necessary
d. Check throttle idling adjustment by closingthrottle is not available from "asdelivered"weight
and observing tachometer. (Refer to Section V.) record n Flight Manual, or if center
frame has been replaced.
e. Shut down engine according to procedure on Pilot's
Check List. f. Using plumb-lines and steel tape, carefully meas-
ure horizontal distance between forward and aft jack-
1-37. WEIGHT AND BALANCE. points, and between one jack-point and Station O
(located by notch in lug on lower right longeron of
1-38. GENERAL. Accurate recordsofthebasicempty center-frame) Measurements must be on a level
helicopter weight and center of gravity location are plane and parallel to helicopter center line.
necessary for calculation of safe loadings for flight.
This data is furnished in the Flight Manual, showing 1-40. DETERMINING CENTER OF GRAVITY. The
results of a carefully supervised weighing before center of gravity (CG) of the helicopter is the balanc-
delivery. Equipment included inbasic weight,standard ing point, stated in terms of distance forward or aft
loadings, and limitations are also stated. of Station O. The operating CG (loaded and serviced
for flight) must be within specified limits, Stations
When making any alterations, removing or installing minus 3.0 to plus 4.0. (See figure 1-6.) However,
equipment, record the weight and balance change on the empty weight CG will normally be further aft,
form (ACA-337) prescribed by Civil Aeronautics depending on weight. (See figure 1-7.) Note that in
Administration. Refer to Civil Aeronautics Manual weight and balance calculations, all measurements
18 for explanation of principles and procedures. (arms) aft of Station O are positive (+), and arms
(Operators outside territorial United States refer forward of Station O are negative (-).
to instructions of licensing authority.) The following
paragraphs briefly outline procedures as applied to a. Multiply net weight at aft jack-point by the arm
the helicopter. (horizontal distance from Station O) of that jack-
point. Result will be the aft moment, expressed as
1-39. WEIGHING.While it is practical and permis- positive (+) quantity in inch-pounds.
sible to compute the effect of alterations, the heli-
copter should be reweighed whenever accuracy of
recorded weight and balance data becomes question- b. Add net weights recorded at forward jack-points.
able. Error of considerable amount may accumulate Multiply by arm (-) of jack-points to obtain forward
from use of approximate weights andlocation measure- moment (-).
ments, and from minor changes whichare considered
as having "negligible" weight effect. There is also c. Determine total moment (difference between for-
a well-known tendency for an aircraft to increase ward and aft moments, keeping sign of the greater).
weight in service, due to such factors as accumulated Divide by total net weight to obtain CG arm (location
dirt, grease, and paint, and effect of climatic condi- in inches forward or aft of Station O, according to
tions. sign).
1-10
MAINTENANCE
47976-136
Figure 1-6. Determining Center of Gravity
d. Using chart (figure 1-7), determine whether CG BATTERYAJUSTMENT EMPTY

WEIGHT
(REQUIRED
CG - ASWEIGHED
CG)
is located within required range for total empty BATTERY
WEIGHT
weight. Lines representing weight and CG arm should
intersect within "Required Range" and as close as Example with assumed values:
possible to line designated "Most Acceptable Value".
(Add or remove ballast, 47D-1.) Relocate battery as Empty weight = 1580.0 pounds.
necessary. (Refer to paragraph 1-41.)
As weighed CG = 6.30 inches aft of station O.
1-41. DETERMINING BATTERY LOCATION - 47G Required CG (see chart) = 6.60 inches aft of Sta-
AND 47G-2. The empty helicopter must be properly tion O
balanced, with CG within required range for weight
as shown on chart (figure 1-6), in order to obtain Battery weight = 35.0 pounds
proper balance whenhelicopter is serviced andloaded
for flight. If required empty CG is not maintained,
the loading limitations decal in cabin will not apply. BATTERYADJUSTMENT= 1580 (6.60 - 6.30) 1580 (0.30)
Adjust battery location along support slides to obtain 13.5 - 13.5
= * 13.5 = 13.5 inches aft
required empty weight CG.
d. If balance cannot be obtained by relocatingbattery
a. Battery installation weight (approximate): add ballast at station -62.0, using the following for-
mula.
mula.
1. With AN3154 battery - 35.0 pounds. (REQUIRED
WEIGHT CG - ASWEIGHED
CG)
BALLAST= BALLASTARM - REQUIREDCG
2. With AN3151 battery - 55.0 pounds.
1-42. DETERMINING BALLAST ADJUSTMENT FOR
b. If required CG arm is longer than as weighed MODEL 47D-1. Ballast should be installed in or re-
b. Ifarm,
CG required
move CG arm aft.
battery is longer than as weighed
If required moved from the helicopter to maintainthe as-deliver-
CG arm is the normal
shorter than as weighed CG arm, move battery for- ed
ed CG. With ballast
CG. With properly adjusted,
ballast properly adjusted, the normal
variation in CG which takes place during flight due
to consumption of fuel and oil, will remain within
the specified range i.e., between 2.0 inches forward
c. Use following formula, when battery is weighed of and 2.88 inches aft of station O. The following
in helicopter, to determine necessary change in equation should be used when determining the amount
battery location: of ballast to be installed or removed.
1-11
MAINTENANCE& OVERHAULINSTRUCTIONS
. . ........
CG LOCATION-INCHES AFT OF STATION ZERO 47976-137
Figure 1-7. Required CG Limits

1-12 Rev. 3
MAINTENANCE
ADJUSTMENT= WEIGHT(AS DELIVEREDCG - ASWEIGHEDCG)

BALLASTARM- AS-DELIVERED CG 1-43. LUBRICATION. (Figure 1-8.) Use Lubrication
Chart as guide for recommended lubricants and
Note frequency of application to components of the heli-
copter. General and special notes, in paragraphs be-
If the as-delivered CG is larger than the low, contain additional information to supplement the
as-weighed CG, ballast should be added. chart. (Refer to paragraphs 1-44 and 1-45.)
If the as-delivered CG is smaller than as-
weighed CG, ballast should be removed. a. Lubricants: Letter symbols on chart refer to mili-
tary specifications as shown in Table of Lubricants.
EMPTY WEIGHT: Total true weight as determined in When unable to procure lubricants by specification
paragraph 1-40. numbers, refer to paragraph 1-46 for lists of com-
mercially-designated lubricants conforming to each
AS-DELIVERED CG: Weight empty CG furnished, in specification.
weight and balance data, delivered with the helicopter
from the factory. b. Lubrication Periods: Periods shown on chart
have been set to coincide with scheduled inspections
Note and to meet needs of normal service conditions. More
frequent lubrication may be required under adverse
If the as-delivered CG is not maintained operating conditions.
for the Model 47D-1 helicopter, the fuel
vs cockpit loading decal does not apply. c. MIL-G-25537 (Aero-Shell No. 14) grease hasbeen
approved as an all purpose helicopter grease and is
AS WEIGHED CG: CG as determined in paragraph recommended for complete lubrication of the Bell
1-40. Model 47 helicopter where grease is used as a lubri-
cant. Preparations are in progress to lubricate all
BALLAST ARM: Distance from Station O to the bal- production helicopters with MIL-G-25537 grease.
last location. Distance forward of Station O is minus When a helicopter serial number break has been
(-). Distance aft of Station O is plus (+). established the manual will be revised to reflect
the information. For helicopters delivered prior to
As an example assume the following: lubrication at the factory with MIL-G-25537 grease
the procedure recommended for changing from one
Total true weight = 1900.0 pounds. grease to another is to delay the change over until
there is an opportunity at overhaul to remove the
As-delivered CG = +4.11 inches aft of Station O. old grease by cleaning. The main rotor hub assem-
bly, the tail rotor hub and pitch change mechanism,
As weighed CG = 3.50 inches aft of Station O. swashplate and cooling fan bearing grease must be
changed at overhaul. All other bearings can be
Ballast arm = +210.0 inches aft of station O. purged sufficiently, using a grease gun to remove
the old grease. While purging does not insure com-
BALLAST = 1900.0(4.11- 3.50)
ADJUSTMENT 1900.00
(0.61) plete removal of the old grease the amount remaining
210.0- 4.11 205.89 should be too small to have any significent effect
= +5.6pounds on the properties of the new grease. Gross con-
5.6 pounds of ballast should be added to station tamination of one grease with another is badpractice,
as all greases are not compatible.
+210.0. It must be remembered Has
all greases are not compatible. MIL-G-25537
MIL-G-25537
that a plus (+) hasa temperature range of-65°F to +165°F.
quantity is the amount of ballast to be added and a
minus (-) quantity is the amount of ballast to be
d. Points of Application: Index numbers on chart
removed. are identified by key on facing page. Where similar
lubrication points occur, and arrow with broken
Note lines points to a typical example.
Ballast is sometimes installed on the ped-
estal, 62.0 inches forward of Station O. If e. Methods: Grease gun symbol indicates part has
this had been true in the example above lubricator fittings. Hand symbol is used for parts
the equation would have been the following: without fittings, where bearings require packing
by hand or with suitable adapter for grease gun.
BALLASTADJUSTMENT=1900.0 (4.11 - 3.50) 1900.00 (+0.61)
(-62.0-4.11) -- 66.11 1-44. GENERAL NOTES - LUBRICATION.
-17.5 pounds
a. When using sprayed solvents or compressed air

17.5 pounds of ballast should be removed from sta- to clean engine or aircraft, take suitable precautions
tion -62.0. to avoid forcing dirt, water, or solvents intobearings.
1-13
MAINTENANCE
NOTE
Broken arrows indicate lubrication of

all like parts. SEE DETAIL
SEE DETAIL B
AND NOTE 1 ON
SHEET 2,
SEE DETAIL C
OHA
(ASREQUIRED)
Figure 1-8. Lubrication Chart (Sheet 1 of 2)

1-14 Rev. 3
Note 1 35. Swivel and Link Bearings

36. Link and Scissor Lever Bolts
a. Remove lockwire from boot on mast con- 37. Scissor Lever Bearings
trol and slide boot up on the mast.
Note 2
b. Apply lubricant MIL-G-25537 from the top,
to spline on mast and spline in collective Do not over pack tail rotor drive shaft
sleeve. Move the collective sleeve up and couplings. Remove excess grease from
down on the mast to obtain lubricant to the boots after greasing couplings.
splines.
c. Slide boot down on mast and attach with Note 3
lockwire.
MIL-L-6082 oil, use a minimum of 50 hours
FOR engine break-in, however, DO NOT mix
PARTS NOMENCLATURE KEY with any other oil. MIL-L-22851 oil, use
AFTER engine break-in only, however, DO
1. Flight Control Linkage and Power Cylinder NOT mix with any other oil
2. Flight Control Linkage (Bearings without fittings)
3. Throttle Cam Box TABLE OF LUBRICANTS
4. Adapter Plate Trunnion Pins
5. Cyclic Control Dampers Symbol Specification
6. Handling Wheel Bearings
7. Hydraulic Reservoir GLT MIL-G-25537
8. Cooling Fan Bearings (Alternate) MIL-C-23827
9. Engine Control Cables OHA MIL-H-5606
10. Engine Oil Tank - See NOTE 3 OEA - See NOTE 3 MIL-L-6082
11. Tail Rotor Drive Shaft Couplings - See NOTE 2 - See NOTE 3 MIL-L-22851
12. Tail Rotor Drive Shaft Bearings - See NOTE 2 OE MIL-L-2104B
13. Universal Joint
14. Extension Shaft Bearings
15. Extension Shaft Splines (See also list of equivalents by com-
16. Tail Rotor Gear Box merical designation.)
DETAIL A: Tail Rotor Hub Area Note
17. Pitch Change Link Bearings All Fabroid liner type rod end bearings
18. Pitch Change Head and Rod Bearing do not require lubrication. Replace when
19. Delta Hinge Bearings play exceeds limits specified in inspec-
20. Blade Grip Bearings tion section.
21. Felt Washers - Blade Grips
Detail B: Main Rotor Hub Area

23. Mast Splines - See NOTE 1
24. Pitch Link Rod-End Bearings 50 Hour
25. Equalizer and Mixing Lever Bearings
26. Damper Link Rod-End Bearings
27. Stabilizer Bar Dampers 100 Hour
28. Stabilizer Bar Pivot Bearings
29. Blade Grip Bearings
30. Pillow Block and Gimbal Bearings At Overhaul
Detail C: Swashplate Area All
All like
like parts
parts
31. Gimbal Ring Needle Bearings Oil Can
32. Swashplate Carrier Bearings Grease Gun
33. Collective Pitch Yoke Bearing
34. Lever Pivot Bearings Hand
47976-138-2F
Figure 1-8. Lubrication Chart (Sheet 2 of 2)

Rev. 3 1-15
MAINTENANCE
1-45. SPECIAL NOTES - LUBRICATION. Following Tail Rotor Drive Shaft Couplings (item 11): When
notes apply to specific components of the helicopter. lubricating floating splined couplings, remove any
(See Lubrication Chart, Figure 1-8.) excess grease from flexible cover to prevent unbal-
ance in rotation. Check that forward shaft can move
Flight Control Linkage (items 1 and 2): Applies to fore and aft in coupling after lubrication, particularly
all bearings of all flight control systems except where in cold weather.
chart shows other treatment. Lubricate bearings with Extension Shaft Splines (item 15): During assembly,
grease fittings at 50 hours; all bearings at overhaul coat internal shaft splines with MIL-G-25537grease
teardown (or earlier if necessary). or white lead base anti-seize compound to prevent
corrosion.
Throttle Cam Box (item 3): Grease cam and roller
by removing cover, or through front opening with
box removed. At overhaul, coat Teleflex control Tail Rotor Gear Box (item 16): Use SAE 10 oil or
cable with MIL-G-25537 (MIL-G-3278 alternate) 10W-30, MIL-L-2104B, oil. Change at first 25 hours,
grease before reinstalling in conduit. thereafter at 100 hours. Check daily at level drain cock
(or sight glass).
Engine Control Cables (item 9): Oil linkage and
terminal sleeves of mixture, carburetor heat, and Tail Rotor Pitch Change Links (item 17): Check
fuel shut-off control cables as indicated. To insure daily for roughness or binding, lubricate as required.
free operation of the throttle control on 47G-2 heli-
copters the teleflex cable should be removed from Tail Rotor Delta Hinge Bearings (item 19): Purge
the casing and both the cable and casing thoroughly bearings at lubrication periods. Wipe off excess
cleaned. When reinstalling cable, smear cable and grease.
fill casing with either of the following lubricants.
Mast Splines (item 23): When installing assemblies on
Dow Corning No. 5 compound temperature Range mast, lightly coat all mast splines (except driving spline
-100°F to +300°F. in transmission) with MIL-G-25537 grease.
Dow Corning No. 33 grease temperature range -100°F Main Rotor Gimbal Bearings (item 30): Purge gim-
to +35°F. bal ring and pillow block bearings at lubrication
periods. Wipe off excess grease.
MIL-G-7421A grease (Texaco low temperature No.
1888) Temperature range -100°F to +250°F. 1-46. LIST OF LUBRICANTS. The following list is
furnished for conveniencein procurement of acceptable
Engine Oil Tank (item 10): Above 40°F (4.4°C) aver- lubricants by commercial designation. This is not
age air temperature, use SAE 50 (Grade 1100). Below intended as a complete list of all available lubricants,
40°F, use SAE 30 (Grade 1065). Drain and refill tank and unlisted oils and greases manufactured toequiva-
after first 25 hours on new or overhauled engine, lent specifications may be used. Main office address
thereafter at each 50 hours. is shown only with first listing of each manufacturer.
LIST OF LUBRICANTS
The following list is furnished for convenience in procurement of acceptable lubricants by commercial
designation. This is not intended as a complete list of all available lubricants, and unlisted oils and grease
manufactured to equivalent specifications may be used. Main office address is shown only with first list-
ing of each manufacturer.
MIL-G-25537
MIL-G-25537 (ALTERNATE MIL-C-23827)

GREASE: HELICOPTER OSCILLATING BEARING, AIRCRAFT
MANUFACTURER'S MANUFACTURER'S
DESIGNATION NAME AND ADDRESS
Aero Shell Grease 14 Shell Oil Company

50 W. 50th Street
New York, N.Y.
1-16 Rev. 3
MAINTENANCE
MANU FAC TURER' S MANU FAC TURER'S

TG-4831 Texaco, Inc.

135 East 42nd Street
New York, N.Y. 10017
Calol 3934 Standard Oil Company of California

225 Bush Street
San Francisco, California 94120
Royco 37 Royal Lubricants Company

River Road
Hanover, New Jersey
MIL-C-23827
Low Temperature Grease EP Texaco, Inc.

135 E. 42nd Street
New York, N. Y. 10017
1-16A
MAINTENANCE
Aero Shell Grease 7 Shell Oil Company

50 W. 50th Street
New York, N. Y. 10020
RPM Aviation Grease 5 Standard Oil Company of California

225 Bush Street
5114 EP Grease Humble Oil and Refining Company
P.O. Box 2180
Houston, Texas
MIL-L-2104B
LUBRICATING OIL - HEAVY DUTY
TL-7094 Texaco, Inc.

TL-7097 P.O. Box 509
Beacon, New York 1250
3545, 3563, 3570 HD-B Motor Oil Humble Oil Company
3629 HD-B Motor Oil P.O. Box 2180
EC-3617 Houston, Texas 77001
Gulf Lube Motor Oil X.H.D. 10W, 50 Gulf Oil Corp.
Gulf Lube Motor Oil X.H.D. 10, 30, 50 Gulf Building
Pittsburg, Pa. 15230
PED 3342, 3344, 3596 Standard Oil Company of California
225 Bush Street
Shellmil B Oil 10, 30, 50 Shell Oil Company
Shellmil B Oil 10,50 50 W. 50th Street
XSL-8393 New York, N.Y. 10020
Shell XSL 8289
Shellmil B Oil 10 Code 5471
Rev. 3 1-17
MAINTENANCE
MIL-H-5606
HYDRAULIC FLUID - PETROLEUM BASE
3126 Hydraulic Oil Humble Oil and Refining Company

Houston 1, Texas
XSL 7828 Shell Oil Company

50 W. 50th Street
New York 20, N.Y.
TL-5874 Texaco, Inc.

135 E. 42nd Street
Staufer Aero-Hydrail 500 Staufer Chemical Company

380 Madison Ave.
Mobil Aero HFB Mobil Oil Corporation

150 E. 42nd Street
1-47. FLUORESCENT PENETRANT MATERIALS. (See Table 1-1.)
1-18 Rev. 3
Model 47D-1,47G, & 47G2 BELL HELICOPTER COMPANY Section I (Part 1)
MAINTENANCE& OVERHAUL INSTRUCTIONS
Table 1-1. Flourescent Penetrant Inspection Materials (Sheet 1 of 5)
NOTE
The following Post Emulsified Penetrant System materials

are the only materials that are approved by Bell Helicopter
Companyfor performing fluorescent penetrant inspections
that are required in this manual.
SECTION I
The following group lists manufacturer's nomenclature for the approved fluorescent penetrant material
and their respective address.
MATERIALS SOURCE
(Post Emulsified Penetrant Systems)
FPE-505 Fluorescent Penetrant AutomationIndustries Inc.

PE-520 Emulsifier Sperry Products Division
DW-530 Wet Developer Danbury, Connecticut
DD-535 Dry Developer
Dubl-Chek FP-20 Penetrant Belmont Chemicals, Inc.

Dubl-Chek ER-80 Emulsifier Division of Sherwin, Inc.
Dubl-Chek D-90 Developer (Dry) 5007 E. Washington Blvd.
Dubl-Chek D-110 Developer (Wet) Los Angeles, Calif., 90022
FP-93 Penetrant Met-L-Check Company

E-56 Emulsifier P.O. Box 5427
D-72 Developer (Dry) Englewood, Calif., 90310
D-78 Developer (Wet)
P-148A Penetrant URESCO Inc.

E-153 Emulsifier 12412 Benedict Avenue
D-492C Wet Developer Downey, Calif.
D-493A Dry Developer
Fluoro Finder FL-2 Penetrant Testing Systems, Inc.

Fluoro Finder Emulsifier FE-5 2826 Mt. Carmel Avenue
Fluoro Finder FD-5 Wet Developer Glenside, Pennsylvania, 19038
Fluoro Finder FD-H Dry Developer
Rev. 3 1-18A
Section I (Part 1) BELL HELICOPTER COMPANY Model 47D-1,47G, & 47G-2
SECTION I (Cont)
MATERIALS SOURCE
(Post Emulsified Penetrant Systems)
Fluro-Chek P-21 Penetrant Turco Products Division

Fluro-Chek E Emulsifier Purex Corp., Ltd.
Fluro-Chek WD Developer (Wet) 24600 S. Main Street
Fluro-Chek DD Developer (Dry) Wilmington, Calif., 90744
PLANTS:
Wilmington, Calif.
Rockdale, Illinois
Joliet, Illinois
Houston, Texas
Philadelphia, Pennsylvania
ZL-2A Zyglo Penetrant Magnaflux Corporation

AE-3 Zyglo Emulsifier 7300 W. Lawrence Avenue
ZP-4 Zyglo Developer (Dry) Chicago, Illinois, 60656
ZP-5 Zyglo Developer (Wet)
ARDROX 985-Pl Penetrant ARDROX Ltd.

Niagara-on-the- Lake
Ontario, Canada
ARDROX985-P3 Penetrant ARDROX Ltd.

ARDROX 9PR4 Emulsifier Brentford, England
ARDROX 9D3 Developer Middlesex, England
Britemor 550 Penetrant Burmiah-Castrol Co.

Quicmor 450 Cleaner Alma Works, Hyde
Britemor BPD2 Dry Developer Cheshire SK14 4NX
England
1-18B Rev. 3
Model 47D-1,47G, & 47G-2 BELL HELICOPTER COMPANY Section I (Part 1)
MAINTENANCE & OVERHAUL INSTRUCTIONS-
SECTION II
The following group lists international agents, with address, that handle the approved Magnaflux
Corporations fluorescent penetrant material.
Argentina Mexico
Coasin, S. A. Salzgitter de Mexico, S.A.

Virrey Del Pino 4071 Av. Insurgentes Sur 1673, 3er piso
Buenos Aires, Argentina Postal M-7078
Attention: Mr. Maidanik Mexico 1, D. F.
Attention: Abel Cruz
Brazil
Peru
Bandeira de Mello, S.A.
Rua Mexico 11, Grupo 1502 Luis Davila
P.O. Box 1208 Antonio Miro Quesada No. 586
Rio de Janeiro, Brazil Magdalena Del Mar
Lima, Peru
Attention: Luis Davila
Chile
Imp. Tec. Vignola S.A.I.C. Puerto Rico

Plaza Justicia, Peral 25
Casilla 93-V Gas Products Corporation
Valparaiso, Chile Ponce de Leon 306
Attention: Mario Vignola Riesle Hato Rey, Puerto Rico 00918
Attention: Milton Cardena
Colombia
Venezuela
Jose Henao Velez & Cia.
Cra. 4A No. 8-63 Raymond Smith
Aptos, Aereos 1818 Edificio "Las Americas"
Call, Colombia Calle Real de Sabana Grande
Attention: Ing. Luis Florez Mera Caracas, Venezuela
Miliciades Sanchez
Aptd. Aereo 4675
Bogota, Colombia
Ecuador
Quim-Ing-Co., Cia. Ltda.
Pinto No. 259
P.O. Box 3611
Quito, Ecuador
Attention: Diego F. Teran D
Rev. 3 1-18C
Section I (Part 1) BELL HELICOPTER COMPANY Model 47D-1, 47G, & 47G-2
MAINTENANCE & OVERHAUL INSTRUCTIONS -
SECTION III
The following group lists international associated companies, manufacturing licensees and agents, with
address, that handle the approved Ardrox Ltd. fluorescent penetrant material.
ASSOCIATED COMPANIES:
Australasia South Africa

Ardrox Australia Pty, Ltd. Ardrox Chemicals Pty. Ltd.
P.O. Box 78 P.O. Box 38075
Lidcombe, New South Wales Booysens, Transvaal
Canada Spain & Portugal
Ardrox Ltd. Brent Iberica, S. A.

P.O. Box 390 Carretera de Loeches Km. 1.300
Niagara-on-the-Lake, Apartado, 53
Ontario Torrejon de Ardoz (Madrid)
MANUFACTURING LICENSEES:
Belgium-Holland-Luxembourg Germany
U.C.B., S. A. Roder-Prazision
Division Specialites Chimiques Egelsbach- Flugplatz
33, Rue d'Anderlecht Kreis Offenbach
Drogenbos, Belgium
India
Denmark, Finland, Norway, Sweden
Oriental Chemical Works (Pty.) Ltd.
ABYtmetoder 1/lB Govinda Addy Road
Osterskarsv, 12 Calcutta 27
Akersberga, Sweden
Eire Italy
Brent Chemicals Ltd. Chimical S.A.S.
117, Cork Street Via G. B. Pergolesi 4
Dublin, 8 Milan (410)
France
Framalite
Departement Ardrox
2 Rue Meissonier
Paris (17e )
1-18D Rev. 3
Models 47D-1, 47G, & 47G-2 BELL HELICOPTER COMPANY Section I (Part 1)
SECTION III (Cont)
AGENTS:
East Africa Pakistan

(Kenya, Tanzania, Uganda)
Twiga Chemical Ind. Ltd. Tradeways Ltd.
P.O. Box 30172
Nairobi, Kenya Defence Officers Housing Society
Karachi -4
Ethiopia Singapore
The Ethio Commerce & Engr. Co. Ltd.
P.O. Box 2324 J. Whyte & Co (Malaya) Sdn. Bhd.
Addis Ababa P.O. Box 4019
6-3/4 m.s. Bukit Timah Road
Bukit Timah Post Office
Jordan
Jordan Singapore, 21
Jordan Chemicals, Ltd.

P.O. Box 499 Switzerland
Amman
Max C. Meister
Lowenstrasse 25
Kuwait & Bahrein 8021 Zurich
Specialties Company W.L.L.

P.O. Box 20376 Syria
Kuwait
Syria Equipment Co., S. A.
P.O. Box 241
Lebanon Damascus,
Syrian Arab Republic
Bardawil & Co.
P.O. Box 967
Rue Tripoli, Beirut
Malaysia
J. Whyte & Co (Malaya) Sdn. Bhd.

P.O. Box 79
Petaling Jaya
Selangor, Malaysia
Rev. 3 1-18E
148. SPECIAL TOOLS.
PART NUMBER NOMENCLATURE PART NUMBER NOMENCLATURE
1. 30-729-456-1-T210 Plug, Swivel BearingAssy. 10. 47-150-103-5-T210 Plug - Collective Pitch

and Disassembly Yoke Bearing Assembly
and Disassembly
2. 47-120-104-5-T212 Plug, Rotor Hub Adapter
11. 47-150-103-6-T210 Plug - Swashplate Bearing
3. 47-140-012-1-T210 Plug -Stabilizer Bar Frame Assembly and Disassem-
Bearing Assembly & Dis- bly
assembly
12. 47-600-001-1-T204 Compressor - Engine Valve
4. 47-150-001-T210 Stand - Main Rotor Mast Spring
5. 47-150-003-5-T211 Holding Fixture - Swash- 13. 47-600-001-1-T205 Lifter - Engine Rocker Arm
plate Yoke
14. 47-600-001-1-T212 Stand - Engine and Acces-
6. 47-150-019-1-T215 Wrench - Spanner Collec- sory Build-up
tive Pitch Sleeve Lock- 15. 47-620-001-1-T291 Plug - PlanetaryGear Pin-
nut ion Assembly and Disas-
sembly
7. 47-150-023-1-T215 Wrench - Spanner Collec-
tive Pitch Yoke Lock-nut 16. 47-620-200-1-T290 Gauge - Transmission, Fan
Pinion
8. 47-150-028-1-T210 Plug - Control Plate Link
Bearing Assembly and 17. 47-620-200-3-T210 Holding Fixture - Fan and
Disassembly Tail Rotor Sleeve
9. 47-150-036-2-T210 Plug - Collective Pitch 18. 47-620-200-12-T210 Plug - ClutchSpiderBear-

Lower Bearing Assembly ing Assembly and Disas-
and Disassembly sembly
1-18F Rev. 3
MAINTENANCE
& OVERHAUL INSTRUCTIONS-
SPECIAL TOOLS
19. 47-620-284-1-T210 Wrench - Socket Fan and 38. T100221 Fixture - Mast Holding
Tail Rotor Drive Lock-
nut 39. T100222 Block Assembly - Rotor
Tachometer Drive
20. 47-620-286-1-T210 Wrench - Socket Genera-
tor Drive Lock-nut 40. T100224 Plug - Transmission Cap
21. 47-620-286-1-T211 Wrench - Spanner, Gener-
ator Drive Lock-nut 41. Deleted
22. 47-620-287-1-T220 Wrench - Socket, Rotor

Tachometer Drive Lock- 42. T100227 Wrench - Tail Rotor Drive
nut
43. T100230 Wrench - Clutch Drum
23. 47-620-297-1-T200 Plug - Tachometer Drive Lock-nut
Needle Bearing 44. T100233 Pin - Lower Spider Pinion
24. 47-641-003-3-T212 Plug - Tail Rotor Hub 45. T100234 Pin - Upper Spider Pinion
Bearing
46. T100286 Plug - Tail Rotor Drive
25. 47-794-034 Tie Down Fixture - Main Shaft Alignment
Rotor Blade
47. T100287 Disc - Tail Rotor Drive
26. 47-976-002-1-T202 Aligning Support - Main Alignment
Rotor Blades (2 reqd)
48. T100288 Dummy Bearing - Tail
27. 47-976-002-1-T203 Stand - Main Rotor Align- Rotor Drive Shaft Align-
ing and Balancing ment
28. TC-27872-6 Reamer - Taper, Tall 49. T100289 Centering Plug-TailRotor
Rotor Shaft and Rubber Drive Shaft Alignment
Pedal 50. T100302 Plug - Oil Seal Inserting
29. T100056 Wrench - Spanner, Hub Tail Rotor Gear Box
Grip Adapter Nut
Grip Adapter Nut 51. T100303 Holder - Tail Rotor Gear
30. T100061 Float Inflation Kit Box Drive Shaft
Hoisting Ring - Engine and 52. T100306 Wrench - Spanner, Tail

Rotor Gear Box
Transmission Rotor Gear Box
32. T100090 Holding Fixture, rans 53. T100307 Support - Tail Rotor Gear
mission Lower Sun Gear Box Bearing
54. T100308 Support - Tail Rotor Gear
33. T100132 Fixture - Engine Timing Box Shaft
Gear Drive
55. T100309 Sleeve - Tail Rotor Gear
34. T100169 Pin - Unversal Joint Cen- Box Bearing
tering (2 reqd)
56. T100310 Plug - Transmission Ac-
35. T100217 Bolt - Spray Pump Drive cessory Drive Gear
Clutch Torque Adjusting
57. T100311 Wrench - Transmission
36. T100219 Fixture - Collective Pitch Lower Case Nut
Rigging
58. T100312 Wrench - Transmission
37. T100220 Sling - Rotor Hoist.ng Lock-nut
1-19
Section I (Part 1) BELL HELICOPTER
COMPANY Models 47D-1, 47G & 47G-2
MAINTENANCE
SPECIAL TOOLS
59. T100313 Extractor - Engine Push Rod 80. T100891 Puller - Transmission Fan
Cover and Tail Rotor Drive
60. T100314 Plug - Tail Rotor Gear Box 81. T100892 Plug - Transmission Lower
Oil Seal Insert Case Bearing
61. T100323 Holder - Transmission Gen- 82. T100909 Tail Boom Alignment Tool
erator Drive
83. T100925 Plug -Lower Sun Gear Bearing
62. T100360 Support - Tail Rotor Drive
Shaft 84. T101227 Wrench - Tail Rotor Blade
Sleeve Nut
63. T100361 Wrench - Magneto Thimble
85. T101232 Fixture Control Stick Center-
64. T100363 Sleeve - Tail Rotor Exten- ing
sion Tube
86. T101233 Pin - Valve Centering
65. T100364 Sleeve - Transmission Lower
Case 87. T101239 Plug - Tail Rotor Gear Box
Bearing
66. T100373 Jig - Tail Rotor Rigging
88. T101242 Leveling Bar - Main Rotor
67. T100389 Driving Tool Stud Hub
68. T10393 Plug - Main Rotor Hub Grip 89. T101245 Wrench - Tail Rotor Gear
Bearing Installing Box Spanner
69. T100394 Plug - Main Rotor Hub Grip 90. T101246 Bending Tool - Trim Tab
Bearing Removing
91. T101247 Wrench - Tail Rotor Drive
70. T100407 Wrench - Main Rotor Hub Shaft Coupling
Yoke Nut
92. T101381 Wrench - Main Rotor Mast Nut
71. T100414 Puller Assembly - Trans-
mission
mission Gear
Gear Tail
Tail Rotor
Rotor 93. T101391 Jig - Dynamic Stop Cable
Drive Rigging
72. T100419 Plug and Sleeve - Transmis-
sion Fan Drive 94. T100223 Sleeve - Tail Rotor Gear Box
73. T100420 Plug - Fan and Tail Rotor 95. T100316 Plug Gage - Tail Rotor Gear
Bearing Installation Box
74. T100426 Guide - Tail Rotor Gear Box 96. T100747 Aligning Bar - Main Rotor
51 x 430 Seal Grips
75. T100436 Plate Swashplate Leveling 97. T101218 Plug - Needle Bearing As-
sembly
76. T100878 Balance Fixture - Tail Rotor
and Blades 98. T101234 Fixture - Swashplate Rigging
77. T100879 Strap Assembly- Clutch Drum
Holding 99. T101235 Fixture - Collective Rigging
78. T100880 Wrench - Mast Bearing Re- 100. T101255 Plug - Needle Bearing
taining Nut (47-130-116-1)
101. T101385 Plug - Bearing Stabilizer Bar
79. T100881 Fixture - Transmission Ac-
cessory Drive Gear Holding 102. T101425 Jig - Tail Rotor Rigging
1-20
Models 47D-1, 47G & 47G-2 BELL HELICOPER COMPANY Section I (Part 1)
MAINTENANCE
30-729-455-1-T210 47-140-012-1-T210
47-120-104-5- T212
47-150-003-6-T211
47-150-001-T210
47-150-028-1-T210
47-150-023- 1-T215
47-150-019-1-T215
47-150-036-2-T210 47-150-103-5-T210 47-150-103-6-T210

47739-11-1
Figure 1-9. Special Tools (Sheet 1 of 8)

1-21
MAINTENANCE
47-620-001-1-T291
47-620-200-1- T290
47-620-200-3- T210 47-620-200-12-T210
47-620-286- 1-T210
47-620-284-1- T210 47-620-286-1-T211
47-620-287- 1-T220
47739-11-2

1-22
Models 47D-1, 47G & 47G-2 BELL
HELICOPTER COMPANY Section I (Part 1)
MAINTENANCE
47-620-297-1-T200 47-641-003-3-T212
* 47-976-002-1-T202
47-976-002- 1-T203
TC-27872-6
T100056
T100061
T 100089
T100090
47730-11-3

1-23
MAINTENANCE
T100169
T100217
T100219
T10022002
Deleted
47739-11-4D

1-24
MAINTENANCE S OVERHAUL INSTRUCTIONS
T 100286
T100286T100 T100288
T100287
T100302 T100303
T100308 T100309
T100311
T100310
47739-11-5

1-25
MAINTENANCE
T100313
T100312 T100314
T100323
T100360
T100361
T100364
100363
T100373 T100393 T100394

T100389 47739-11-6D

1-26
MAINTENANCE
T100407
T100414 T100419
T100420
T100426 T100436
T100878 \
(T100880
T100879
T100891 T100892
47739-11-7

1-27
T 100909 T101227
T101232
NOTE:
in accordance with
47739-11-8 existing instructions.

1-28
MAINTENANCE
T101218
*.^^^(8 I ®
T101234 T101235
T101255
T101425
T101385 47739-1-8A
47739-11-8A
Figure 1-9. Special Tools (Sheet 8A of 8)

1-28 A
MAINTENANCE & OVERHAUL INSTRUCTIONS Maintenance Inspection
MAINTENANCE INSPECTION
GENERAL
This section contains a schedule of maintenance inspections applying to Models 47D-1, 47G and 47G-2 helicopters in
the following sequence:
CAUTION
Make certain to use the inspection schedule for the correct

model helicopter, since they differ in important details.
1. Inspection methods.
2. Daily Inspection - required prior to first flight each day.
3. Periodic Inspections - required at 50, 100, 300, 600 and 1200 hour intervals.
4. Special Inspections - required by unusual events, such as hard landing or sudden stoppage of rotor.
5. Mandatory Retirement Schedule - list of parts which are limited to a definite maximum service life.
Note
In text of this manual wherever the terms magnaflux or zyglo

appear reference should be to magnetic particle or fluorescent
penetrant.
MAGNETIC PARTICLE INSPECTION PROCESS.
This is a process developed for the purpose of detecting flaws in ferrous metal parts, which though perhaps invisible
to the naked eye, could cause structural failure. This process is useful in detecting not only surface cracks, but
sub-surface blow holes, inclusions, etc. Magnaflux is one type of magnetic particle inspection, it, or its equivalent may
be used.
FLUORESCENT PENETRANT INSPECTION PROCESS.
This process was developed for the purpose of detecting flaws in non-ferrous metal parts. This process is useful in
detecting only surface cracks and therefore is, in general, used only for maintenance inspection. To perform a
satisfactory inspection, a post emulsified penetrant system must be used. It must meet or exceed GROUP V
penetrant materials requirements as listed in fluorescent penetrant materials, table 1-1.
MASKING OF BEARINGS FOR FLUORESCENT PENETRANT INSPECTION.
Note
The following procedure is recommended for fluorescent

penetrant inspection of parts having staked bearings.
The exposed bearing surface should be wiped clean with a cloth moistened with cleaning solvent. Apply two coats of
BG lacquer (United Chrominum, Inc., 100 E 42nd Street, New York 17, N.Y.), allowing one hour drying time for each
coat. The lacquer should be sufficiently thick to allow easy removal after inspection. Where possible, it is advisable to
have lacquer overlap on part outside of bearing from 1/8 to 1/4 inch. Take care to avoid scuffing. The lacquer coat
can be peeled easily after inspections.
Rev. 3 1-29
Maintenance Inspection MAINTENANCE & OVERHAUL INSTRUCTIONS
INSPECTION OF FLIGHT CONTROL LINKAGE BOLTS.
All maintenance and inspection operations involving control linkage should be conducted with care to avoid possibility
of damage through improper handling and adjustment. Particular attention should be given to freedom of operation and
clearance of rod-ends at points of connection, throughout range of travel. Binding, bottoming-out, or interference
between parts of linkage can produce abnormal and excessive stresses during operation, which may result in damage or,
in extreme cases, eventual failure of affected parts. The following practices and precautions are recommended:
a. When removing main rotor, disconnect pitch change link-rods at pitch horns, leaving links attached to stabilizer
bar mixing lever. This decreases possibility of damaging link-rods while handling rotor.
b. Secure any disconnected linkage so as to prevent damage by accidental movement.
c. After any adjustment of control linkage, check thoroughly for freedom of operation through entire range of
control movement. On main rotor controls, this check should include positioning rotor at right angles to the helicopter
center line, holding stabilizer bar at extreme travel, and checking for possible interference while moving controls
through full travel in all directions.
Note
Perform checks with hydraulic boost "OFF" then with boost

"ON".
d. Avoid over-torque of bolts connecting linkage.
e. All clost tolerance bolts used as replacements in flight control systems should be inspected by magnetic particle
method. Those procured from Bell Helicopter Company are so inspected.
CLEANING OF PARTS FOR INSPECTION.
Note
It is not necessary to strip cadmium plating for magnetic particle

inspection.
1. Magnetic particle inspection (ferrous metal).
a. Remove top finish coat only. Do not remove yellow primer.
b. Perform inspection.
2. Fluorescent penetrant inspection (non-ferrous material).
a. Strip the finish coat and primer using E-Z strip 19A or equivalent, use a stiff brush.
b. Rinse thoroughly with pressure water spray.
c. Perform inspection.
REFINISHING OF PARTS AFTER INSPECTION.
1. Protective finish for exterior surface of ferrous metal parts.
a. Lightly roughen the existing primer with scotch-brite. Clean parts with aliphatic naphtha or equivalent, dry
with filtered compressed air.
b. Apply a coat of super Koropon primer. Allow to dry a minimum of 30 minutes and a maximum of
four hours.
c. Apply finish coat with acrylic lacquer or equivalent.
1-30 Rev. 3
Model 47D-1,47G, & 47G-2 BELL HELICOPTER COMPANY Section I (Part 1)
2. Protective finish for exterior surfaces of non-ferrous material parts.
a. Clean with aliphatic naphtha or equivalent.
b. Apply a coat of epoxy polymide primer. Allow to dry a minimum of one hour and a maximum of eight
hours.
c. Apply finish coat with acrylic lacquer or equivalent.
MAGNAFLUX INSPECTION - SHAFT - TAIL ROTOR DRIVE - 47-645-202.
Procedure.
Each shaft must be inspected by all of the following steps using the wet continuous method conforming to MIL-I-6868.
The length of any indication shall be determined by the residual method.
1. Magnetize the shaft by placing each end of the shaft between the contact plates and passing 1000 amperes
through the shaft, thus developing circular magnetization around the shaft. Inspect the shaft complete for longitudinal
indication running parallel to the long axis.
2. Magnetize the shaft by placing in a coil, in a direction such that the long axis of the shaft will be approximately
90 degrees to the direction of current flow in the coil, and pass 500 to 700 amperes through the shaft, thus, producing
longitudinal magnetization parallel to the long axis. Inspect the shaft complete.
3. After completing inspection, demagnetize the shaft and check with pocket field indicator or compass.
Acceptance Criteria:
1. Indications of cracks, in either the longitudinal or transverse directions, are cause for rejection regardless of
length or direction.
2. Surface or sub-surface indications of stringers, shuts, non-metallic inclusions, bursts, seams or laps shall be
acceptable provided they are within all the following limits (Figure 1-10).
Rev. 3 1-30A/1-30B
MAINTENANCE Maintenance Inspection
SHAFT (Anti-Torque Drive)

Part No. 47-645-202
47645-39
Figure 1-10. Shaft (Anti-Torque Drive)
a. Indications of deflects parallel to the long axis shall not exceed 1/2 inch in length and not more
than three indications in any one square inch of surface in section "AA".
b. Indications of defects parallel to the long axis shall not exceed 1/4 inch in length and not more
than two such indications in any one square inch of surface area in section "BB".
c. Magnetic indications transverse, or circumferential, to the long axis is cause for rejection
regardless of location or size.
d. Magnetic indications in the threads, in section "BB" are cause for rejection.
3. Indications which are caused by change in section are acceptable regardless of length or direction.
MAGNAFLUX INSPECTION - INDEX PLATE - 47-669-118.
Procedure:
Each part must be inspected by all the following steps using the wet continuous method conforming to
MIL-I-6868. The length of any indication may be determined by the residual method.
1. Magnetize each part by placing between contact heads such that the current passes through part
in the axial direction and pass approximately 700 amperes DC or 500 amperes AC current through the
part. Inspect part complete for indications.
2. Magnetize each part by placing inside a coil such that the current flow in the coil is transverse or
circumferential to the axial direction of the part and pass 700 amperes DC, or 500 amperes AC, current.
Inspect part complete for indications.
3. After completion of inspection, demagnetize the part, and check with pocket field indicator or com-
pass to assure demagnetization.
1. Indications interpreted as cracks are cause for rejection regardless of size or location.
2. Surface or subsurface indications of stringers, shuts, inclusions, bursts, laps or seams will be
acceptable provided they are within all the followinglimits. (Figure 1-11.)
a. Indications, circumferential or transverse to the axial direction (±15degrees) of the part are
cause for rejection.
1-31
AXIAL DIRECTION
Axial Direction
Index Plate Assembly

Part No. 47-661-801-5
Index Plate - 47-669-118

47645-41 47645-36
Figure 1-11. Index Plate Figure 1-12. Index Plate Assembly
b. Indications that are parallel to the axial direction of the part are acceptable privided the length
does not exceed two inches and provided no more than six such indications are present on the entire part.
The total additive length of all indications shall not exceed 12 inches.
3. Indications caused by a change in section thickness are acceptable.

4. Indications of surface discontinuities in the weld or at the fusion line are cause for rejection.
Subsurface indications in the weld area are acceptable prividing the length or cross section does not ex-
ceed 1/8 inch in length.
MAGNAFLUX INSPECTION - INDEX PLATE - 47-661-801-5.
Procedure:
Each part must be inspected by all the following steps using the wet continuous method conforming to
MIL-I-6868. The length of any indication may be determined by the residual method.
1. Magnetize each part by placing between contact heads such that the current passes through part in
the axial direction and pass approximately 700 amperes DC or 500 amperes AC current through the part.
2. Magnetize each part by placing inside a coil such that the current flow in the coil is transverse or
circumferential to the axial direction of the part and pass 700 amperes DC, or 500 amperes AC, current.
3. After completion of inspection, demagnetize the part and check with pocket field indicator or com-
pass to assure demagnetization.
1. Indicatior interpreted as cracks are cause for rejection regardless of size or location.
1-32
acceptable provided they are within all the following limits. (Figure 1-12.)
a. Indications, circumferential or transverse to the axial direction (±15degrees) of the part are
b. Indications that are parallel to the axial direction of the part are acceptable provided the length
does not exceed two inches and provided no more than three such indications are present on the entire
part. The total additive length of all indications shall not exceed six inches.
3. Indications caused by a change in section thickness are acceptable.
4. Indications of surface discontinuities in the weld or at the fusion line are cause for rejection.
Subsurface indications in the weld area are acceptable providing the length or cross section does not
exceed 1/8 inch in length.
MAGNAFLUXINSPECTION - COUPLING - 47-620-801-3.
Procedure:
Each coupling must be inspected by all of the following steps using the wet continuous method conforming
to MIL-I-6868. The length of any indication shall be determined by the residual method.
1. Magnetize the coupling by passing a copper bar through the center of the coupling and place the
bar between the contact head. Pass 1000 amperes DC, or 750 amperes AC, current through the bar. In-
spect the coupling complete.
2. Magnetize the coupling by placing inside a coil so that the long axis of the part is 90 degrees to
the direction of current flow in the coil, thus developing longitudinal magnetism in the part. Pass 1000
amperes DC, or 750 amperes AC, current. Inspect coupling complete.
3. After completing inspection, demagnetize the part and check with pocket field indicator.
1. Indications of cracks are cause for rejection regardless of length or direction.
2. Surface or subsurface indications of stringers, shuts, non-metallic inclusions, bursts, seams or
laps shall be acceptable provided they are within all the followinglimits. (Figure 1-13.)
a. Indications of circumferential defects that are more than 15 degrees off the direction of the
long axis are cause for rejection regardless of length or direction.
b. Indications in area "AA" and "BB" are cause for rejection regardless of size or direction.
c. Indications in the longitudinal direction (±15 degrees) in all areas except area "AA" and "BB"
are acceptable provided the length of the indication does not exceed 3/8 inch in length and providing no
more than three such indications appear in any one square inch of surface area.
4. Strong magnetic indications where considerable build up is present, indicating the defect has con-
siderable depth and/or cross section, shall be rejectable indications regardless of length, size or direction.
MAGNAFLUX INSPECTION - RING ASSEMBLY (SWASHPLATE GIMBAL) - 47-150-180.
Procedure:
Each ring assembly must be inspected by all of the following steps using the wet continuous method con-
forming to MIL-I-6868. The length of any indication shall be determined by the residual method.
1-33
A A
B B
COUPLING (Engine to Transmission)

Part No. 47-620-801-3
47645-35
Figure 1-13. Coupling (Engine to Transmission)
1. Magnetize the part by passing a copper bar through the approximate center of the adapter and
place the bar between the contact heads. Pass 1100 amperes D.C. current through the bar. Inspect
complete for indications.
Note
The part should be suspended around the copper bar such

that the bar is in the approximate center of the part so
that a uniform magnetic field will be set up within the
part; otherwise, the part must be magnetized four (4)
times, rotating the part 90 degrees around the bar after
each charge of magnetizing current.
2. Place the part in the coil such that the long axis of the part is 90 degrees to the direction of
current flow through the coil. Magnetize the part using 15,000 ampere turns magnetizing force with
D.C. current. Inspect the part 100 percent for indications.
Note
The following general formula shall be used to determine

meter amperage:
Ampere turns - number coil turns (on coil nameplate) =
Amperage (Meter).
For a 5 turn coil, 15,000 ampere turns - 5 coil turns =

3000 Amperes (Meter).
The part should be as close to the coil as possible to

assure an adequate magnetic field buildup within the part.
The part may be rotated and re-shot if necessary.
3. After completion of inspection, demagnetize the part and check with pocket field indicator, or
compass, to assure demagnetization.
134
1. Indications interpreted as cracks are cause for rejection regardless of size or location.
acceptable provided they are within the following limits. (Figure 1-14.)
a. Indications circumferential or transverse to the axial direction (±15degrees) of the part in

critical areas A, B, C, and D (as shown in above sketch) are acceptable provided the length of the indi-
cation does not exceed 1/2 inch in length and provided other limitations herein are not exceeded. Not
more than three such indications allowed in each critical area.
1-34 A
Critical Area
A
Critical
Typical 4
Area
Places
Axial Direction B
Ring Assembly (Swashplate Split Gimbal)

Part No. 47-150-180
47645-34
Figure 1-14. Ring Assembly (Swashplate Split Gimbal)
b. Indications that are parallel to the axial direction of the part (+15 degrees) are cause for re-
jection in critical areas A, B, C, and D if the length of the indication exceeds 1/4 inch in length. Not more
than two such indications less than 1/4 inch are allowed in each critical area.
c. Circumferential or axial direction indications in all other areas of the part are acceptable
provided they do not exceed one inch in length. Not more than two (2) such indications allowed in any one
square inch surface area.
d. Indications of surface discontinuities that break over corners or run into fillets are cause for
rejection.
e. Indications of subsurface discontinuities that break a transverse face shall not exceed 0.031
inch in length or cross section.
3. Indications caused by change in section thickness are acceptable.
4. Strong magnetic indications where considerable build up is present, indicating that the defect has
considerable depthand/or cross section, shallbe cause for rejection regardless of length, size, or direction.
MAGNAFLUX INSPECTION - ADAPTER (MAIN ROTOR BLADE GRIP) - 47-120-183.
Each adapter must be inspected by all of the following steps using the wet continuous method conforming
1. Magnetize the part by passing a copper bar through the approximate center of the adapter and place
the bar between the contact heads. Pass 750 amperes DC, or 500 amperes AC, current through the bar. In-
spect complete for indications.
Note
The part should be suspended around the copper bar such

that the bar is in the approximate center of the part so that
a uniform magnetic field willbe set upwithin the part; other-
wise, the part must be magnetized four (4) times, rotating
the part 90 degrees around the bar after each charge of
magnetizing current.
1-35
2. Magnetize the part by placing inside a coil so that the long axis of the part is approximately 90
degrees to the direction of current flow in the coil and pass 750 amperes DC, or 500 amperes AC, current
through the coil. Inspect the part complete for indications.
Note
The part should be as close to the coil as possible to assure

an adequate magnetic field build up within the part. The part
may be rotated and re-shot if necessary.
3. After completion of inspection, demagnetize the part and check with pocket field indicator, or com-
pass, to assure demagnetization.
1. Indications of cracks are cause for rejection regardless of length, size or direction.
laps shall be acceptable provided they are within all the following limits. (Figure 1-15.)
a. Indications of circumferential defects or indications more than (±15 degrees) off the axial
direction of the part are cause for rejection regardless of size, length or direction.
b. Indications in the axial direction (±15 degrees) not exceeding 3/8 inch are acceptable in all
areas of the part except as restricted by Items c. and d. below, or other limitations herein. Not more than
three such indications allowed in any one square inch of surface area.
c. Indications of surface discontinuities that break over corners or run into fillets are cause for
rejection.
d. Indications of subsurface discontinuities that break a transverse face shall not exceed 0.031
inch in length or cross section.
3. Indications that are caused by a change in section thickness are acceptable.
considerable depth and/or cross section, shallbe cause for rejection regardless of length, size or direction.
47645-42
Figure 1-15. Grip Adapter Nut
MAGNAFLUX INSPECTION - TAIL ROTOR DRIVE - 47-645-205.
Procedure:
Each shaft must be inspected by all of the following steps using the wet continuous method conforming to
MIL-I-6863. The length of any indication shall be determined by the residual method.
1-36
MAINTENANCE
& OVERHAUL INSTRUCTIONS Maintenance Inspection
1. Magnetize the shaft by placing each end between the contact plates and passing approximately
500 - 700 amperes through the shaft, thus developing circular magnetization around the shaft. Inspect the
shaft complete for longitudinal indications running parallel to the long axis.
2. Magnetize the shaft by placing in a coil, in a direction such that the long axis of the shaft will be
approximately 90 degrees to the direction of current flow in the magnetizing coil, and pass 500 amperes
through the shaft. Inspect the shaft complete.
3. After completing inspection, demagnetize the shaft and checkwith pocket field indicator or compass.
1. Indication of cracks, in either the longitudinal or transverse directions, are cause for rejection
regardless of length or direction.

laps shall be acceptable provided they are within all the following limits. (Figure 1-16.)
a. Indications of defects parallel to the long axis (±15 degrees), shall not exceed 1/2 inch in
length and not more than three such indications in any one square inch of surface area in sections "AA"
and "CC" as shown in sketch except as noted in Item d. below.
b. Indications of defects parallel to the long axis (±15 degrees) shall not exceed 3/8 inch in
length and not more than two such indications in any one square inch of surface area in section "BB".
c. Indications more than (±15 degrees) off thelong axis, transverse or circumferential, to the long
axis is cause for rejection if the length of the indication exceeds 1/4 inch in length.
d. Magnetic indications on the inside of the shaft in the spline area of Section "AA" in sketch are
4. Strong magnetic indications where considerable build up is present, indicating the defect has con-
siderable depth and/or cross section shall be rejectable indications regardless of length, size or direction.
SHAFT (Tail Rotor Drive)

Part No. 47-645-205
47645-38
Figure 1-16. Shaft (Tail Rotor Drive)

1-37
MAGNAFLUX PARTICLE INSPECTION - DRAG BRACE CLEVIS - 47-110-373-1 (Figure 1-17)
Procedure:
Each part must be inspected by all of the following steps, using the wet continuous method conforming
1. Magnetize the part by placing each end of the part between contact plates and pass 1000 amperes
DC current through the part. Inspect part complete for indications of defects.
2. Place the part in the coil such that the long axis of the part is 90 degrees to the direction of
current flow through the coil. Magnetize the part using 15,000 ampere turns magnetizing force with DC
current. Inspect the part 100 percent for indications.
Note

meter amperage:
Ampere turns - number coil turns (on coil nameplates)
= Amperage (Meter).
For a 5 turn coil, 15,000 ampere turns - 5 coil turns =

3. After completion of inspection, demagnetize the part and check with pocket field indicator or
compass to assure demagnetization.
Acceptance Criteria.
1. Magnetic indications interpreted as cracks are cause for rejection regardless of size or location
on part.
2. Surface or subsurface indications of stringers, shuts, inclusions, laps, or seams will be acceptable
provided they are within all the followinglimits:
a. Indications of defects parallel to the long axis of the part (plus or minus 15 degrees) are ac-
ceptable provided the length of individual indications does not exceed one inch. Not more than two indi-
cations are allowed in the barrel and each of the two tangs. The total accumulative length of the two in-
clusions in each section, i.e., the barrel and the two tangs, shall not exceed 1 1/2 inches.
47110-88
Figure 1-17. Magnetic Particle Inspection of Drag Brace Clevis

1-38
b. Indications inside of the 0.375 inch diameter bolt hole and within an area 0.187 inch around the
bolt hole (see figure 1-10) are cause for rejection.
3. Indications 1/64 inch or less in length are acceptable and shall not be counted as defects.
4. Indications that are caused by a change in section are acceptable.
considerable depth and/or cross section, shall be cause for rejection regardless of location.
MAGNAFLUX INSPECTION - MAIN ROTOR MAST, 47-130-114. Figure 1-18
Procedure.
Each part shall be inspected by all of the following steps using the wet continuous method conforming to
MIL-I-6868.
1. Magnetize the part by placing it between the contact heads on the magnaflux machine such that the
current flows in the direction of the long axis of the part and pass approximately 2000 amperes DC current
through the part. Inspect 100 percent for magnetic indications.
Note
Make certain good contact is made on stud end of mast and

that no arcing exists.
2. Magnetize the part by placing inside a suitable coil such that the long axis of the part is approxi-
mately 90 degrees to the direction of currentflow in the coil and pass approximately 1500 amperes through
the coil. Repeat the operation at approximately one foot increments along the part to assure that an adequate
longitudinal magnetic field is set-up in the full length of the part. Inspect 100 percent for indications.
3. After completion of inspection, demagnetize the part and check with a pocket indicator or compass
to assure complete demagnetization.
Acceptance Criteria.
1. Indications of cracks are cause for rejection regardless of size, location or direction.
2. Surface or sub-surface indications of stringer, shuts, seams, laps, or non-metallic inclusions are
acceptable provided they are within all the following limits. Defects indications exceeding the following
limits shall be rejected.
47130-12
Figure 1-18. Magnetic Particle Inspection of Main Rotor Mast

1-38 A
a. Indications having a direction that is more than 15 degrees off the long axis of the part are
cause for rejection regardless of location or size.
b. Indications having a direction parallel to the long axis of the part, within plus or minus 15
degrees, are acceptable in section "AA", as shown in figure 1-11, provided they do not exceed 1/2 inch
in length. Not more than two (2) 1/2 inch indications shall be allowed for each two (2) square inches of
surface area. The maximum total additive length of all magnetic indications, that exceed 1/16 inch in
length, shall not exceed three inches in section "AA".
c. Indications having a direction parallel to the long axis of the part, within plus or minus 15
degrees, are acceptable in section "BB" as shown in figure 1-11, provided they do not exceed one inch in
length. Not more than two (2) one inch long inclusions shall be allowed for each three square inches of
surface area. The maximum total additive length of all magnetic indications, that exceed 1/16 inch in
length, shall not exceed six inches in section "BB".
d. Indications of surface discontinuities that break over corners or run into fillets are cause
for rejections.
e. Indications in threads, slots, keyways and in the root or side wall of splines are cause for
rejection. Indications or spline crowns are acceptable provided they do not exceed 1/4 inch in length
and not more than one indication to each spline crown.
Note
Intermittent indications over 1/16 inch in length and in line

with one another shall be considered as one continuous de-
fect unless they are separated by at least the length of the
longest indication in the particular line of intermittent line
of indications.
f. Indications that terminate within 1/8 inch of thread areas, keyways, slots or splines shall be
g. Heavyconcentrations of inclusions shall be cause for rejection.
3. Strong magnetic indications where considerable particle buildup is present, indicating the defect
has considerable depth and/or cross section, shall be cause for rejection regardless of length, direction
or location.
4. Indications caused only by a change in section thickness are acceptable.
MAGNAFLUXINSPECTION - COLLECTIVE PITCH SLEEVE (SCISSORSBRACKET) - 47-150-117
Weld and Weld Area:
1. Indications of cracks or lack of fusion are not acceptable regardless of size or location. Removal of
indications is permitted by light sand blast, filing, or grinding provided that not more than 10%of the thick-
ness of the weld is removed. Weld defects which cannot be removed in local removal of 10% of the weld
thickness are rejectable.
2. Indications are often observed which follow the weld bead. These are usually caused by entrapment
and/or change in section and permeability due to the weld bead, and not considered to be cause for re-
jection or rework provided they do not extend to the parent metal.
3. Indications which are caused by a change in section are acceptable regardless of sixe or location.
Tube and Bracket Section:
1. Indications of cracks are not acceptable regardless of size or location. Removal of indications is
permitted by light sand blast, filing, or grinding provided not more than 5% of the total wall thickness of
the tube or total thickness of the bracket material is removed.
1-38 B
2. Indications in the parent material of:
a. Seams, grooves, tears, burrs, laminations, slivers, and pits within 1/2 inch of the weld must
be removed.
b. Inclusions greater than 1/2 inch in length must be removed regardless of location.
3. Indications which are not removed by the rework specified in paragraph 1 are rejectable.
Procedure:
Each sleeve must be inspected by all of the following steps using the wet continuous method conforming
1. Magnetize the entire sleeve by placing a 1/2 inch diameter copper rod through the tube and passing
1500 amperes DC through the part between the clamps. Inspect internal surface, internal spline, tube
section, bracket sections (not transverse sections) and longitudinal welds for indications.
2. Magnetize the sleeve by moving the coil over the bracket section. Magnetize the part using 7000
ampere turns magnetizing force with DC current. Inspect that half of the tube section, transverse bracket
sections, and transverse welds for indications.
Note

amperage:
Ampere turns - number coil turns (on coil nameplate) =
Amperage (Meter).
For a 5 turn coil, 7000 ampere turns - 5 coil turns =

3. Magnetize the sleeve by moving the coil over the tube section 3 inches in from the threaded end.
Magnetize the part using 7000 ampere turns of magnetizing force with DC current. Inspect that half of
the tube section and threaded area for indications.
4. After completing inspection, demagnetize sleeve and check with pocket field indicator or compass.
47150-74
Figure 1-19. Collective Pitch Sleeve

1-39/1-40
Model 47D-1 BELL HELICOPTER COMPANY Section I (Part 1)
INSTRUCTIONS
& OVERHAUL
MAINTENANCE Daily Inspection
DAILY INSPECTION
GENERAL
1. Prior to first flight of the day, conduct visual and operational inspections, including minimum require-
ments outlined below, to determine that helicopter is airworthy and that damage or malfunction has not de-
veloped since last previous inspection. Inspection may be conducted by qualified flight or maintenance per-
sonnel. Corrections necessary as a result of inspections must be performed by properly qualified person-
nel. Details and tolerances included below are for guidance for persons making such corrections.
2. Check that registration and airworthiness certificates are in order and in proper place in cabin.
3. Lubricate as required. (See Lubrication Chart.)
MAIN ROTOR
1. Inspect blade covering for condition of finish, loose areas or blisters, and damage which punctures or
tears fabric.
2. Inspect trim tabs and stainless steel leading edges of blades for security, cracks, dents, distortion,
and punctures.
3. Inspect butt area of blades for checks in wood. (Maximum allowable per blade: Ten checks not more than
0.062 inch total width). Inspect blades for cracks in butt, forward ob butt plates, more than three cracks in
this area is cause for replacement or repair at a factory approved repair station.
4. Inspect blade grip plates, drag brace straps, and drag braces for security, cracks and damage.
5. Inspect hub assembly for general condition and for security of all bolts, nuts, and locking devices.
6. Inspect dynamic stop cables for security, wear, andexcessive number of broken wires. (Maximumallow-
able: Six broken wires in any one-inch length.)
STABILIZER BAR AND DAMPERS
1. Manually move stabilizer bar up and down through full travel to check for proper operation.
2. Inspect stabilizer bar, dampers, and linkage for security and general condition; dampers for evidence
of leaks.
FLIGHT CONTROLS
1. Inspect swashplate and linkage for general condition and security.
2. Inspect all parts of cyclic and collective pitch control systems for security and damage, and for free-
dom of operation through full travel. Eliminate any binding or excessive play. Test friction locks.
3. Operate tail rotor control pedals, checking for free movement through full travel. Observe direction of
blade movement: Left pedal forward, leading edges of blades move outboard, away from tail boom. Right
pedal forward, leading edges of blades move inboard, toward tail boom extension.
4. Inspect tail rotor control linkage for security, andfor binding or excessive play in operation of any part.
a. Inspect cables for security, and for wear or broken wires, especially where operating over pitch change
drum, pulleys, or fairleads. (Maximumallowable: Three broken wires in any one-inch length.)
b. Inspect pitch change drum for wear on sides of cable grooves.
1-41
Section I (Part 1) BELL HELICOPTER COMPANY Model 47D-1
Daily Inspection MAINTENANCE & OVERHAUL INSTRUCTIONS
FLIGHT CONTROLS Cont.
c. Check pitch change link rod-end bearings for roughness, binding, or excessive axial or radial play
(maximum allowable: 0.015 inch) in any position through full travel.
TAIL ROTOR DRIVE SYSTEM
1. Inspect tail rotor blades as follows:

a. Woodblades - Inspect general condition, and for damage which punctures or tears fiberglas covering.
Inspect stainless steel leading edge for cracks, especially in root area.
b. Metal blades - Inspect for dents, scratches, and indications of loosened bonding. (Bond failure re-
quires immediate replacement.)
2. Inspect tail rotor hub for security (delta hingebolt tight, bearings seated firmly on shaft). Check flapping
movement for free operation. Check condition of dust boot and flap-stop bumper washer.
3. Inspect drive shaft, couplings, bearings, and universal joint for security and general condition; shafts
for nicks or scratches.
4. Inspect bearing hangers and caps for security and cracks, especially at forward hanger and weld area
on structure.
5. Check oil level in gear box.
ENGINE MOUNTS
1. Inspect engine mount for security and for dented or damaged tubing. Carefully examine welds for cracks,
particularly around tube clusters at Lord mount clamps. Replace mount immediately if crack exists in
any area.
2. Inspect rubber mounts for security, cracking or deterioration, and for being clean of oil and grease.
3. Inspect sprag linkage for excessive play, security, and damage.
4. Inspect safety cables for security and excessive wear. (Maximumallowable: Six broken wires in any
one-inch length.)
FUEL, OIL AND IGNITION SYSTEMS AND ENGINE COMPARTMENT
1. Inspect fuel and oil lines and hoses for general condition, security, evidence of leaks, and visible damage.
2. Drain any condensed water from fuel strainer and tank sumps. Check security of strainer and shut-off
valve.
3. Check fuel and oil quantities.
4. Inspect and service air intake filter according to operating conditions and filter type used:
a. Flat, oil-saturated type (Air Maze) - Wash clean and re-oil when necessary.
b. Circular, dry type (purolator) - Clean when necessary, keeping element dry.
5. Inspect entire engine and compartment for general condition.

142
BODY AND LANDING GEAR
1. Inspect cabin, center frame, and tail boom structure and fittings for security and damage.
2. Inspect landing gear.
a. Skid type - Inspect skids and shoes for excessive wear; all parts for security, cracks, dents, and cor-
rosion; ground handling wheels for general condition and tire inflation; cross tubes for excessive de-
flection. (Refer to Section II.)
b. Float type - Inspect floats for proper inflation, all parts for security and damage.
OPERATIONAL CHECK
1. Remove main rotor tie-down, check that loose equipment and tools are properly stowed or removed.
2. Start and run-up engine, checkingoperation in accordance with operating instructions in preceding section.
3. Check for leaks in fuel and oil systems.
1-43/1-44
MAINTENANCE
& OVERHAUL INSTRUCTIONS 50 Hour Inspection
50 HOUR INSPECTION
GENERAL
1. Perform inspections outlined below, in addition to complete daily inspection after each 50 hours of
operation.
3. Refer to Mandatory Retirement Schedule for list of parts having prescribed maximum service life.
4. Refer to Maintenance and Overhaul Instructions for details of procedures, adjustments, and specified
tolerances. Refer to engine manufacturer's instructions for inspection requirements on engine and ac-
cessories.
MAIN ROTOR
1. Visually and manually inspect all parts for security, damage, evidence of excessive wear; all linkage
rod-ends for freedom from binding at extremes of travel.
2. Main rotor gimbal ring.
Note
After the main rotor gimbal ring has accumulated 1200 flight
hours or more, the following inspection shall be performed each
50 hours.
a. Prior to inspection, wipe clean the gimbal ring areas around the bores for the trunnion and pillow block bearings
(eight places). Using a 3X magnifying glass, thoroughly inspect the gimbal ring bearing bores for cracks in the areas
adjacent to:
(1) Trunnion bearing caps.
(2) Trunnion seals.
(3) Pillow block bearing caps.
(4) Pillow block seals.
b. If evidence of a crack is found, one of the following inspections must be conducted.
(1) Dye penetrant method.
(2) Fluorescent penetrant method.
c. If a crack is found replace gimbal ring.
MAST AND CONTROLS
1. Visually and manually inspect assembly for security, damage, freedom of operation, and proper adjustment.
2. Check for excessive vertical play in swashplate by manually lifting outer ring. Any appreciable loose-
ness (more than 1/32 inch vertical play Bushing type) requires corrective action. .012" needle bearing type.
Rev. 3 1-45
50 Hour Inspection MAINTENANCE & OVERHAUL INSTRUCTIONS
3. Inspect swashplate control horns for cracks with 10-power magnifyingglass, with control rods discon-
nected and horns thoroughly cleaned.
4. Check A13965 or CSC870-3 dampers, for security, leaks, and proper timing. Remove filler plug and check fluid
level.
TRANSMISSION
1. Visually inspect case and drive assemblies for security, damage, cracks, and evidence of oil leaks.
2. Clean and inspect oil strainers. Check all fittings, plugs, oil lines, and temperature bulb for security.
3. Check tail rotor drive and fan drive assemblies for freedom of operation and for excessive end play.
POWER PLANT
1. Inspect engine and accessories in accordance with engine manufacturer's instructions.

2. Drain engine oil, inspect and clean oil filter, at end of first 25 hours of operation and every 50 hours
thereafter. If metal particles are found, carefully evaluate to determine possible source. Further inspec-
tion shall be warranted with special emphasis on main rotor mast thrust bearing. Inspect oil cooler for
leaks and cleanliness of air passages. Inspect leads of oil temperature bulb for security. Check oil level in
hydraulic boost reservoir; refill if necessary.
3. Clean fuel strainer. Inspect all parts of fuel system for security, evidence of leaks, damage or chafing,
and deterioration of hoses. Check all vents and drains for obstruction; valves and fuel quantity indicator
for proper operation.
4. Inspect cooling fan for security, cracks, damage, or blade misalignment; belts for general condition;
pulleys for damage or misalignment; cooling shroud and baffles for security, damage or obstruction to
air flow.
5. Inspect air intake system for security, cleanliness, obstruction, or damage. Clean filter element (re-
oil if equipped with flat Air Maze filter). When operating in moderately dusty conditions, replace dry
circular-type filter element (if so equipped).
6. Check throttle, mixture, and heat controls for security and proper operation.
7. During dusting operations, clean carburetor float chamber vent screen.
TAIL ROTOR SYSTEM
1. Inspect drive shafts for security, nicks or scratches exceeding 0.002 inch depth, and general condition;
bearing hangers and caps for security and cracks. Check coupling taper nuts for tightness, or tapered
bushing and bolt holes for elongation; bearings for smooth operation.
2. Inspect universal joint for general condition, and for side play in excess of 0.020 inch.
3. Inspect extension shaft housing and support brace for security, cracks, dents, or other damage.
4. Inspect gear box for security, and for evidence of leaks.
5. Inspect pitch change linkage for security, freedom of operation, and evidence of excessive wear. Any
stiffness, binding, roughness, or looseness in pitch changelink rod-ends requires replacement (max. radial
or axial play 0.015 inch).
6. Inspect tail rotor hub for security and freedom of operation on delta hinge bolt and bearings.
1-46 Rev. 3
Model 47D-l BELL HELICOPTER COMPANY Section 1 (Part 1)
MAINTENANCE & OVERHAUL INSTRUCTIONS 50 Hour Inspection
a. If equipped with needle bearings and cup-shaped washers, check fit as follows: Tap delta hinge bolt to
seat one washer snug against hub yoke. Check with feeler gage at opposite side of hub for clearance not
exceeding 0.004 inch between washer lip and hub surface.
7. Inspect tail rotor drive coupling for security of retaining bolt. (Not required if SI 368 has been accomplished.)
FLIGHT CONTROLS
CYCLIC AND COLLECTIVE PITCH CONTROLS

1. Inspect all componentparts of systems for security, freedom of operation, andunobstructed full travel.
Inspect bell cranks, torque tubes or jackshafts, control discs, and push-pull tubes for damage or misalign-
ment. Check all bearings for wear or binding;bungee springs for security and condition.
2. Replace YS112 rod-ends if axialplay exceeds 0.030 inch or radial play exceeds 0.005 inch. Replace RE4F7
or 60R1-2 rod-ends if grease shield is loose, distorted, or kinked.
3. Inspect surfaces, welds, and radii of all support brackets and bell cranks for cracks or other damage.
4. Replace fabroid rod ends on main rotor pitch control links when radial or axial play exceeds 0.012 inch.
TAIL ROTOR CONTROLS
1. Inspect pedals, jackshaft, and linkage for security and freedom of operation; pedal ratchet pawl for
proper adjustment.
2. Inspect cables for wear or corrosion, and for security of turnbuckles and attachment fittings; pulleys
and fairleads for wear or damage.
INSTRUMENTS
1. Inspect instruments for loose or cracked cover glasses, and for condition of range and limit markings.
2. Inspect all lines for security, leaks or obstruction, chafing or other damage; hoses for deterioration;
leads for security.
ELECTRICAL SYSTEMS
1. Inspect battery for security of mounting, corrosion, water level and specific gravity; leads for security;
vents and drains for obstruction.
2. Inspect voltage regulator and relays for security of mounting and connections, general condition, and
operation.
3. Inspect generator and starter for security of mounting and connections and proper operation.
4. Test operation of all switches, circuit breakers, and lights. Visually check all wiring for general con-
dition, insulation, and security.
Rev. 3 1-47
& OVERHAUL
MAINTENANCE INSTRUCTIONS 50 Hour Inspection
CABIN AND STRUCTURE
1. Inspect cabin enclosure and doors for cracks, scratches, and defects of visibility. Check doors for
security, and operation of door latches and emergency release (if so equipped).
2. Inspect seats and safety belts for general condition and security of attachment.
3. Check condition and security of any first aid kits and fire extinguishers.
4. Inspect all structure tubing and fittings for cracks, bends, distortion, corrosion, or other damage; paint
or other protective coating for condition.
a. Inspect center frame tubes for chafing adjacent to cabin fairing. Trim fairing for clearance.
b. Chafing or cuts less than 0.008 inch deep can be dressed out to provide stress-relieving radius. For
repair of deeper cuts in structural tubes, refer to Civil Aeronautics Manual 18.
5. Inspect vibration isolator for security and for evidence of damage at points of attachment to tail boom.
6. Inspect all cowling and fairings for cracks, general condition, and security.
7. If equipped with horizontal stabilizer, inspect condition of fabric covering, exposed structural tubing
for cracks, attachment points for security and excessive play.
a. On adjustable-type stabilizer, inspect aft structural tube for excessive wear. (Tube is 5/8 O.D., .035
wall thickness. Replace stabilizer or tube when wear reduces O.D. more than .020 inch.)
1-48 Rev. 3
MAINTENANCE
100 HOUR INSPECTION
GENERAL
1. Perform following inspections, in addition to complete daily, and 50-hour inspections, after each 100
hours of operation.
tolerances. Refer to engine manufacturer's instructions for inspection requirements on engine and acces-
sories.
POWER PLANT
1. Inspect engine and accessories according to engine manufacturer's instructions.
2. Check fan belt tension. When required, replace belts with matched pair.
MAST CONTROLS
1. When swashplate is fitted with needle-type gimbal bearings, manually tilt swashplate all directions to
check for roughness or brinelling.
2. Check dampers, part number, CSC870-5, for security, leaks, and proper timing, at every 100 hour
inspection.
FLIGHT CONTROLS
1. Check tension of tail rotor control cables.
TAIL ROTOR
1. Install T100373 rigging jig and check complete tail rotor linkage for play, not to exceed 1 1/2 degrees.
Disconnect pitch links and manually turn each blade grip to check freedom of operation and for indications
of bearing roughness or wear.
2. Remove delta hinge bolt for replacement or inspection for wear, as applicable. Check delta hinge bear-
ings for smooth operation by manually rotating inner races.
3. If rotor shaft is Part No. 47-645-077-1, remove rotor to inspect delta hinge bolt hole in shaft for cracks
and for elongation (maximum allowable: .010 inch).
Note
This shaft has 3/8 inch square faces around delta hinge bolt
hole. Shaft of later design measures 7/16 x 1/2 inch on this
face.
1-49/1-50
MAINTENANCE 300 Hour Inspection
300 HOUR INSPECTION
GENERAL
1. Perform following inspections, in addition to complete daily, 50-hour, and 100-hour inspection.

cessories.
POWER PLANT
1. Inspect engine and accessories according to engine manufacturer's instructions. If engine is changed,
flush oil cooler and lines.
2. Check cooling fan index plate shaft for proper seating of retaining ring (if so equipped) in shaft groove
at aft side of fan support.
ENGINE MOUNT
Note
Do not immerse engine mount in paint stripper. If removing

paint, apply stripper with brush.
PART NO. 47-612-135 ENGINE MOUNT
1. Magnaflux gas-welded mount, Part No. 47-612-135-1, every 300 hours. (See applicable Acceptance Stand-
ard below.)
MAGNAFLUX PROCEDURE
1. Inspect each mount by following steps, using wet continuous method conforming to Specification MIL-
1-6868, applying 750 amperes dc or 500 amperes ac. Determine length of any indication by residual method.
a. Magnetize entire mount with one Lord mount clamp against each contact head. Inspect entire mount.
b. Insert copper bar through trunnion bearings, to fit holes as nearly as practical. Place bar between
contact heads, apply current, and inspect bearing areas only.
c. Magnetize each clamp end in coil, and inspect clamp areas only.
d. Magnetize upper frame, placing one corner gusset against each contact plate across narrow end. In-
spect each end in this manner.
e. After completing inspection, demagnetize mount and check with pocket field indicator or compass.
1-51
300 Hour Inspection & OVERHAUL INSTRUCTIONS
MAINTENANCE
MANDATORY
PART NO. 47-612-131 ENGINE MOUNT
1. Magnaflux 47-612-131 mount assembly every 300 hours.

(See Procedure and applicable Acceptance Standard below.)
2. At 1500 hours and each 50 hours thereafter, inspect mount

by following procedure:
a. Remove paint from welded tube cluster at Lord mount

clamp on each side of mount assembly. Use a paint solvent
and do not scrape with metal tools.
b. REQUIRES EXPERIENCED PILOT: Run up engine and

apply collective pitch to greatest extent possible withoutlift-
ing landing gear from ground. Hold helicopter steady while
following step c. is accomplished.
c. Visually inspect stripped tube cluster areas for evidence
of cracks, using inspection mirror (magnifyingtype if avail-
able) for inboard surfaces. Give particular attention to for-
ward tube in cluster at right-hand clamp. (Oilappearing on a
surface which has been wiped clean is probable evidence of
crack and must be examined carefully.) Shut down engine
when this part of inspection is completed.
d. Clean forward upper tube with cloth. Use flashlight and
mirror to inspect area where upper diagonal tubes join for-
ward tube, with particular attention to right diagonal upper
tube at welded joint. In same manner, inspect tubes in areas
of trunnion bearings.
e. Replace mount immediately if crack is foundinany area.
f. After inspection, apply grease or other corrosion pre-
ventive on paint-stripped areas.
RECOMMENDED ACCEPTANCE STANDARD FOR PART NO. 47-612-131 ENGINE MOUNT (See figure 1-20.)
1. Indications of cracks or cold welds at the edge of welds in the Lord mount clamp or trunnion bearing
areas shall be cause for rejection regardless of length or location except when they can be removed by
light sandblast, wire brushing, light filing or grinding, and also providing such methods do not remove
more than 0.005 inch of the base material from any detail of the assembly.
2. Cold welds in any area, other than the above, will not be considered cause for rejection provided they
do not exceed 1/4 inch in length and no more than two such indications appear in any one joint or cluster.
The same procedure as in paragraph 1. above may be used in questionable cases (for true length of indi-
cation it is recommended that the residual method of magnetic particle inspection be used).
3. Indications between the weld metal and the base metal caused by machining ends of the trunnion bearing
or the Lord mount clamp lugs, and which do not extend either into the base metal or the weld metal, should
not be cause for rejection or rework.
4. Indications which appear in the gusset areas and are caused by change in section where the edge of the
gusset is covered by weld, are not cause for rejection or rework.
1-52
& OVERHAULINSTRUCTIONS-
WALL
INDEX O. D. THICKNESS
1 3/4 .035
2 3/4 .049
3 7/8 .058
4 1
47612-56A
Figure 1-20. Tubing Chart 612-131 Engine Mount
5. No seams, laps, or tool marks in tubes are acceptable regardless of their length or direction. Removal
of the above defects may be accomplished by polishing with abrasive cloth providing the outside diameter
of the tube is not reduced below standard tube tolerances.
RECOMMENDED ACCEPTANCE STANDARD FOR GAS-WELDED MOUNT, PART NO. 47-612-135-1 (See
figure 1-21.)
1. Indications of cracks, lack of fusion, or overlaps at edge of welds in Lord mount clamp or trunnion pin
bearing areas shall be cause for rejection regardless of length or location, except when they can be re-
moved by light sandblast, wire brushing, light filing or grinding, providing such methods do not remove
more than 0.005 inch of the base material from any detail of the assembly.
2. Lack of fusion or overlaps in any area, other than above, will not be considered cause for rejection,
provided they do not exceed 1/4 inch in length and not more than two such indications appear in any one
joint or cluster. Procedures in paragraph 1. may be used in questionable cases (for true length of indi-
cation, recommend use of residual method of magnetic particle inspection).
3. Indications caused by machining ends of trunnion pin bearings and Lord mount clamp lugs,'and in which
indication does not extend into basic weld or parent metal, should not be cause for rework or rejection.
4. Indications which appear in any gusset area, causedby change of section where edge of gusset is covered
by weld, are not cause for rework or rejection.
5. Indications in parent metal tubing are acceptable and need not be removed provided localized removal
(as in paragraph 1. above) indicates depth of defect does not exceed 10% of original wall thickness. Indi-
cations of seams, grooves, tears, cracks, burrs, laminations, slivers and pits within 1/2 inch of any weld
must be removed. Presence of indications not removable within 10%allowance shall be cause for rejection.
1-53
Section I (Part I) BELL HELICOPTER COMPANY Model 47D-1
300 Hour Inspection MAINTENANCE A OVERHAUL INSTRUCTIONS
1 1/2 .035 5 3/4 .058
2 5/8 .049 6 3/4 .065
3 5/8 .065 7 7/8 .049
4 3/4 .049 8 7/8 .065
* Items 2 and 7 at these locations on gas-welded mount (Part No. 47-612-135-1).
** Items 3 and 8 at these locations on arc-welded mount (Part No. 47-612-135-1N13, Serial No. A16-41 and subsequent).
47612- 7A
FLIGHT CONTROLS
1. Remove pivot bolts and swivel link bolts from scissor levers and inspect for wear.
2. If dimension in any area of bolt is less than 0.2465 inch, replace bolt.
3. Inspect diameter of bolt holes in bracket for wear. If dimension is 0.2550 or more, bushings must be in-
stalled to restore dimension to 0.2490 inch, plus or minus 0.0005 inch.
1-54
Model 47D-1 BELL HELICOPTER COMPANY Section I (Part I)
600 HOUR INSPECTION
GENERAL
1. These instructions outline minimum requirements for disassembly inspection and overhaul to be per-
formed on listed components at intervals of not more than 600 hours operating time.
2. Accomplish complete daily, 50-hour, 100-hour, and 300-hour inspection requirements in conjunction with
those outlined below
3. Overhaul requirements for engine and accessories will be in accordance with engine manufacturer's
instructions.
5. Refer to pertinent paragraphs and illustrations in Maintenance and Overhaul Instructions for details of
procedures, specified clearances, torque values, tolerances, and methods of adjustment.
6. Inspect all bearings for smooth, free operation before and after assembly. Check parts dimensionally
as necessary to determine extent of wear or proper fit of mating parts.
MAIN ROTOR
1. Disassemble main rotor hub to inspect all parts for damage, distortion, or excessive wear. Inspect
thrust bearing seats on yoke spindles for fretting corrosion.
2. The following applies only to blade grips having a milled flat surface on upper inboard side: If width of
flat is one inch or more, check metal thickness between flat surface and root of thread, and between flat
surface and thread relief undercut. (Minimum allowable thickness: .180 inch.)
a. Inspect grip fillet (refer tofigure 1-22). The inboard radius and bottom of the fillet must have a smooth
finish and be free of nicks or tool marks.
3. Inspect following parts by Magnaflux or Zyglo methods as indicated. M = Magnaflux. Z = Zyglo.
Yoke (See figure 1-23.) M
Gimbal Ring Allen Screws M
Hub Core M
Pillow Block Bolts M
Grip Adapter Nuts M
Bearing Retainer Nuts M
Blade Attachment Bolts M
Drag Braces and Bolts M
Blade Grips and Horns Z
Pillow Blocks (Do not remove pins) Z
Gimbal Ring Sections Z
4. During and after reassembly, check for:

a. Specified clearances and torques.
b. Alignment of blade grips.
c. Blade alignment.
d. Lubrication and freedom of operation.
1-55
0.062
47-120-135; 47-120-252 GRIP
47120-67
Figure 1-22. Inspection - Grip Fillet
MAST AND CONTROLS
1. Remove and disassemble stabilizer bar, damper frame, swashplate and support, transmission cap and
mast bearing assemblies to inspect all parts for damage or excessive wear.
2. Inspect mast for damage or excessive wear, and for security of needle bearing inner race. Check mast
run-out with dial indicator. Check security of mast plug in lower end of mast by observing match-mark and
checking width of gap between mast and plug flange for comparison with dimension stamped on plug. Must
be within plus or minus 0.005 to dimension stamped on mast.
*Control Plate Z
*Swashplate Support Z
Pitch Control Sleeve M
Pitch Control Yoke M
Mast M
Stabilizer Bar Core M
Stabilizer Bar Outer Bar M
Stabilizer Bar Center Frame M
Ring Assembly (Swashplate- M (Refer to
split gimbal P/N 47-150-180) acceptance standard.)
*Bushings or lines must not be removed to Zyglo Control plate and
support.

b. Alignment and adjustment of parts.
c. Lubrication and freedom of operation.
1-56
MAINTENANCE
& OVERHAULINSTRUCTIONS 600 Hour Inspection
1. Use wet, continuous type magnetic particle

inspection, with longitudinal magnetization, 2000
amperes maximum.
FILLET AREA
2. Reject yoke for any indication interpreted as
crack or any surface or subsurface inclusion
formingan angle greater than 10° to longitudinal
axis.
3. Surface or subsurface inclusions parallel to

longitudinal axis within 10° are acceptable when
length does not exceed the following limits.
Region A (both sides)..... 1/2 inches

Region B .......... 1 1/8 inches
Region C, and yoke ring ..... No limit
4. Total length of an inclusion extending from

one region into another shall not exceed the total
length allowed in either region.
A 1" B 5. All areas except regions A, B, and C shall
SYMMETRICAL have same treatment as Region C.
AREA - BOTH SIDES
47120-26C
Figure 1-23. Magnetic Particle Inspection of Hub Yoke
1-56 A
MAINTENANCE
TRANSMISSION
1. Disassemble transmission to inspect all parts for damage or excessive wear, including the following:
a. Case: All sections for general condition; oil line and strainers for leaks, obstruction, or damage.
b. Mast driving flange: All splines and surfaces for burrs or surface damage; shear bolts for any
damage.
c. Remove and disassemble freewheeling unit, to inspect all parts for wear and damage. Inspect springs
for wear and correct radii; inspect spring retainer plates, for wear and cracks; replace as necessary. Check
for free rotation and proper locking during and after reassembly.
d. All gears: Teeth, splines and surfaces for wear, chipping, scoring, cracks and other damage.
e. All bearings, rollers, races, and cages for smooth operation and freedom from wear or damage.
f. Clutch: Shoes for glazed or excessively worn linings and worn pins or bushings; drum for dimen-
sional tolerances, out-of-round, scoring, or evidence of excessive heating. (Blue on drum is not cause
for rejection.)
Tail Rotor Drive Assembly Sleeve Z

Fan Drive Assembly Sleeve Z
Transmission Case (All Sections) Z
Attachment and Through Bolts M
Upper Ring Gear M
Upper Sun Gear M
Upper and Lower Spiders M
Pinion Pins M
Pinion Bearing Inner Races M
Pinion Gears M
Driving Flange M
Shear Bolts M
Freewheeling Ring Gear M
Freewheeling Outer Ring M
Freewheeling Rollers M
Lower Sun Gear M
Fan Drive Bevel Gear M
Accessory Drive Gear M
Clutch Pivot Pins M
Gear - Tail Rotor Drive Assembly M
Gear - Generator Drive Assembly M
Gear - Fan Drive Assembly M
Pulley Retaining Bolt and Cones - Fan Drive M
a. Free rotation and positive locking of freewheeling assembly.
b. All specified clearances and torques.
c. Proper tooth contact patterns and backlash of spiral bevel gears.
d. Clutch drum for running true.
e. Freedom of operation of complete assembly.
ADAPTER PLATE
1. Inspect trunnion pin holes in adapter plate for wear.
Adapter Plate (Oil scoop not removed) Z
Trunnion Pins M
1-57
MAINTENANCE
ENGINE MOUNT
1. Magnaflux Arc - Welded Mount, (Figure 1-21) Part No. 47-612-135-1N13 (Serial No. A16-41 and Sub.)
at 600, 1200, 1800 and 2400 Hrs. as follows:
RECOMMENDED ACCEPTANCE STANDARD FOR ARC-WELDED MOUNT, PART NO. 47-612-135-1N13

(Serial No. A16-41 and subsequent). (See figure 1-21.)
1. Removal of indications is permitted by light sandblast, filing or grinding, provided that not more than
10% of thickness of welds or parent metal is removed. Rework areas must blend smoothly with adjacent
metal.
2. Indications are often observed which follow edge of weld bead. These are usually caused by entrap-
ment or change in section primarily due to weld bead, and are not considered cause for rejection or re-
work, provided they do not extend into parent metal.
3. Indications between weld metal and parent metal exposed by machining ends of bearings or lugs are
acceptable, provided indication does not extend into weld or parent metal.
4. Indications which are caused by change in section are acceptable, regardless of length or location.
5. Indications in parent metal tubing are acceptable and need not be removed provided localized removal
(as in paragraph 1. above) indicates depth of defect does not exceed 10% of original wall thickness. Indi-
cations of seams, grooves, tears, burrs, laminations, slivers and pits within 1/2 inch of any weld must
be removed. Presence of indications not removable within 10% allowance shall be cause for rejection.
POWER PLANT
1. Magnaflux crankshaft coupling and check splines for excessive wear.
2. Inspect engine and accessories in accordance with engine manufacturer's instructions. Check adapter
plate hold-down studs for specified projection at minimum torque.
3. Inspect engine mount as specified in 300-hour inspection instructions.
ENGINE AND COOLING SYSTEM.
1. Clean and flush oil cooler and lines when engine is changed or overhauled.
2. Clean and inspect cooling fan bearings.
3. Remove and Magnafluxindex plate assembly, P/N 47-669-118. (Refer to acceptance standard.)
POWER PLANT CONTROLS.
1. Inspect throttle, mixture and fuel control systems.
TAIL ROTOR SYSTEM
TAIL ROTOR HUB
1. Remove and disassemble tail rotor hub to inspect all parts for excessive wear, corrosion, or damage.
2. Inspect following parts by Magnaflux method:
Hub Yoke M
Pitch Change Head M
Blade Grip Retaining Bolts M
Blade Grip Sleeve Nuts M
1-58
MAINTENANCE
& OVERHAULINSTRUCTIONS-
- 600 Hour Inspection
TAIL ROTOR SYSTEM Cont.
3. During reassembly and installation, check for:
a. All specified clearances and torques.

b. Freedom of operation of all bearings and linkage.
TAIL ROTOR GEAR BOX
1. Remove and disassemble gear box for inspection of all parts for damage or excessive wear.
2. Inspect following parts by Magnaflux or Zyglo as indicated. M = Magnaflux. Z = Zyglo.

Gear Box Housing (all parts) Z
Pinion and Rotor Shafts M
Gears (matched set) M
3. During and after reassembly, perform following inspections:

b. Mating of marked gear teeth, proper contact pattern, and specified backlash.
c. Oil level and freedom of operation of assembly.
4. Inspect pitch change shaft for run-out. Maximum 0.060.
DRIVE SHAFTS, UNIVERSAL JOINT, AND EXTENSION SHAFT
1. Remove and disassemble all sections of tail rotor drive shaft, and extension shaft and housing, to inspect
all parts for wear, corrosion, or damage.
Extension Housing Tube and Yoke Z
Shafts (all sections) M
a. Run-out and alignment.
b. Fit of tapered sleeve nuts on couplings and universal joint.

c. All specified clearances and torques.
d. Freedom of operation.
BODY AND TAIL BOOM
1. Inspect visually for cracks, dents or bends, and security of sealing screws or rivets in all structural
tubing.
1-59/1-60
ROTATING AND FLIGHT CONTROL TUBES
1. Remove following control tubes:
Note
The following control tubes are installed within a 30 degree angle of the
vertical axis of the helicopter.
a. Remove rotating control tubes between scissors and mixing lever.
b. Remove collective pitch control tube between bellcrank assembly and control assembly.
c. Remove lateral cyclic control tube between lower bellcrank and upper bellcrank. Remove control tube
between upper bellcrank, with link assembly attached,and swashplate.
d. Remove fore and aft cyclic control tube between bellcrank and disc assembly. Remove disc assembly.
2. Remove end fitting from control tubes and disc as follows:
a. Mark fittings and tube ends to ensure fitting is assembled in original position.
b. Remove both end fittings by carefully drilling off rivet heads and drive out rivets. Do not enlarge rivet
holes in tube or fitting.
3. Inspect each control tube for internal corrosion using a light and borescope or equivalent inspection means.
Note
Control tubes with double drilled rivet holes, sharp nicks, scratches or
internal corrosion are considered unserviceable.
4. Clean and refinish acceptable control tubes as follows:
a. Remove all paint and primer from internal surface of control tubes, using steel wire brush on steel control
tubes and bristle brush on aluminum control tubes, with Methyl-Ethyl-Ketone..
Note
Internal surface must be completely clean to ensure adhesion of protec-

tive film.
b. Add three parts of thinner (Toluene TT-T-548) to four parts of zinc chromate primer, by volume, and mix
thoroughly.
c. Apply primer to inside of control tubes, coat entire internal surface while rotating control tube. Allow excess
primer to drain. Wipe excess from fitting area, leaving a light coat. Allow six hours minimum drying time prior to
further finishing.
5. Mix aluminum paint as follows:
The following will provide approximately one gallon. If a small quantity is required, reduce all quantities propor-
tionally.
a. Dissolve sixteen ounces of aluminum pigment (TT-P-320A) paste (Type II Class A) or powder (Type I Class A)
in a small amount of thinner (TT-T-266).
b. Add aluminum pigment to one gallon of clear cellulose nitrate lacquer (TT-L-32).
(Rev. 1) 1-60A
1200 Hour Inspection MAINTENANCE&OVERHAUL INSTRUCTIONS
ROTATING AND FLIGHT CONTROL TUBES Cont
c. Add equal volume of thinner to lacquer and mix thoroughly. Strain through a paint strainer.
6. Apply aluminum lacquer to inside of control tube, coat entire internal surface while rotating control tube. Allow
excess lacquer to drain. Wipe excess from fitting area, leaving a light coat. Allow 2 hours before installing end
fittings.
Note
Rod ends, fittings, and clevises must be plated or treated; and must not
exhibit any corrosion. Replace parts that have inadequate finish.
7. Hollow ends may require refilling. If adhesive filler is damaged when the-rivets were driven out, remove old
filler and fill with hard epoxy adhesive Metal Set A4 or equivalent. Allow adhesive to cure 24 hours before drilling
holes.
Note
Outside surface of control tube assembly may be primed prior to

applying sealant. Sealant will adhere to chemically treated metal or
fully cured zinc chromate surface.
8. Apply proseal 890-B2 to I.D. of control tubes and O.D. of end fittings, at faying surface, before assembly.
Install end fittings in control tube.
9. Dip MS20163-5P rivets in proseal, and install. MS20613-6P rivets (oversize) may be used. Replace any steel
control tube that requires rivets larger than MS20613-6P rivets.
a. On aluminum rotating control tubes, use MS20470-AD5 rivets. Use of oversize rivets is not approved on
aluminum rotating control tube assemblies.
10. Seal each end of control tube assembly and around rivets with proseal 890-B2 sealant. Apply sealant as shown
on figure 1-23A control tube sealing (typical). Cure sealant at room temperature for 72 hours.
Note
Control tubes may be reinstalled when sealant is not tacky (approxi-

mately 24 hours). Do not use heat to cure sealant.
11. Reinstall all control tubes and check rigging. Tighten jam-nuts and install all cotter pins.
1-60B (Rev. 1)
MAINTENANCE & OVERHAUL INSTRUCTIONS 1200Hour Inspection
APPLY SEALANT (PROSEAL 890-B2)

TO BASE OF RIVET HEADS
SEALANT
APPLY BEAD OF SEALANT
TO EACH END AS SHOWN 47150-1002
APPLY SEALANT
(PROSEAL 890-B2)
TO RIVET HEADS
ADD BEAD OF SEALANT TO EACH SEALANT

END AS SHOWN 47150-1003
47150-1003
Figure 1-23A. Control Tube Sealing (typical)
(Rev. 1) 1-60C/1-60D
MAINTENANCE Special Inspection
SPECIAL INSPECTION
INSPECTION OF HELICOPTER AFTER HARD LANDING
Accomplish the following inspection immediately after the helicopter has been subjected to a hard landing
or when it is suspected a hard landing has been made. Carefully examine the following installations for
damage.
Note
If the hard landing causes a severe pitching of the pylon, the

two engine accessory housing sections, oil pump housing and
sump must be removed for fluorescent penetrant.
1. Inspect all parts of landing gear for damage. Inspect all tubes for cracks and cross-tubes for excessive
deflection.
2. Inspect structure and center frame. Inspect all structural tubing for cracks, bends, distortion, and
damage. Check security and condition. of bolts that attach the tail boom to center frame. Check sprag
mounts, safety cables, and attachment points. Check engine sump, accessory housing, oil lines, and fuel
tanks and lines.
3. Carefully examine all flight control push-pull tubes, disc assemblies, link-rods, bellcranks, and cables.
Inspect rod-ends and bellcrank bearings.
4. Inspect tail boom extension and tail rotor guard. Examine tail rotor blades. If damage to the tail rotor
is found, carefully inspect the following:
a. Tail rotor drive shaft.
b. Universal joint.
c. Tail boom extension shaft.
d. Tail rotor gear box.
5. Inspect main rotor dynamic stop cables. Remove and inspect static stop. If damage to the static stop is evident,
remove and disassemble main rotor. Use magnetic particle or fluorescent penetrant process to inspect all parts.
Visually inspect bearings.
6. Inspect stabilizer bar installation. Check tie-rods carefully.

7. Remove and disassemble main rotor mast. Use a magnifying glass and inspect thrust bearings for
creased or banded balls.
MANDATORY
If the mast thrust bearing was damaged remove and disas-
semble transmission completely. Inspect carefully and re-
place all damaged parts.
SUDDEN STOPPAGE-MAIN ROTOR-POWER OFF
Accomplish this inspection after the main rotor has been stopped suddenly by striking an object while
rotating freely (not being driven by the engine). While the damage to the main rotor blades will undoubtedly
be obvious, component parts of the main and tail rotor systems may have sustained from minor to severe
damage.
Rev. 3 1-61
Special Inspection MAINTENANCE & OVERHAUL INSTRUCTIONS
SUDDEN STOPPAGE-MAIN ROTOR-POWER OFF Cont.
Note
If metal tail rotor blades have struck water, at near oper-
ating RPM; power on or power off, they must be scrapped
even though there is no visible damage to blades.
1. Remove and disassembly main rotor. Examine main rotor blades.
Note
If condition of blades is such that repairs cannot be made

in accordance with the blade repair section of this manual,
return blades to an approved repair station for disposition.
2. If one or both blades are damaged to the extent that the steel core shows through the wood at any point,
or if a drag brace fitting, or equalizer horn is damaged or distorted, the two engine accessory housings, oil pump
housing and oil sump must be removed for fluorescent penetrant inspection. Also the main rotor hub assembly,
mast controls assembly and mast must be inspected by magnetic particle and fluorescent penetrant process, check
hub dimensionally and mast for concentricity. Visually inspect bearings, dynamic stop cables and static stop.
MANDATORY
"Mainrotorgrips,PartNos.47-120-135-1, 135-2, 135-3and
47-120-252-1 must be replaced if they are presently instal-
led, or have been previously installed, on a main rotor hub
assembly that has been subjected to sudden stoppage of the
rotor at operating rpm. They must also be replaced if they
are, or have been installed, on a main rotor assembly that
incurred damage to the extent that necessitated replacement
of a main rotor blade due to chordwise cracks beyond the
limits defined in the Maintenance and Overhaul Manual.
3. Visually inspect stabilizer bar outer tube for bends; also examine welded joint at inboard end of outer bar.
4. Use a magnifyingglass to inspect mast thrust bearings for damaged balls.
5. Remove transmission and check the following.
a. Transmission mounting bolts.

b. Adapter plate and all mounting studs.
c. Trunnion pins.
d. Structural tubing of engine mounting frame.
e. All transmission parts (if condition exists as described in step 2).
6. Inspect engine sprag mountinstallation. Inspect sprag mount safety cables and fittings. Inspect tail rotor
drive shaft and universal joint. If the tail rotor drive shaft is broken or twisted, remove, disassemble and
inspect the following:
a. Tail rotor drive shaft installation.
1-62 Rev. 3
MAINTENANCE
& OVERHAUL INSTRUCTIONS Special Inspection
b. Tail rotor drive assembly.

c. Tail boom extension.

Note
If the tail rotor drive shaft is satisfactory and the trans-

mission turns freely, remove tail rotor drive assembly.
Inspect assembly and drive gear carefully.
7. Carefully examine all flight control system push-pull tubes, disc assemblies, link-rods, bellcranks and
cables. Inspect rod-end and bellcrank bearings.
SUDDEN STOPPAGE-TAIL ROTOR-POWER OFF

Accomplish this inspection immediately after the tail rotor has been stopped suddently by striking an object
while being driven by the main rotor (centrifugal clutch disengaged). While the damage to the blades will
undoubtedly be obvious, component parts of the system may have sustained from minor to severe damage.
Note
If metal tail rotor blades have struck water, at near opera-

ting rpm; power on or power off, they must be scrapped even
though there is no visible damage to blades.
1. Remove and disassemble tail rotor. Inspect tail rotor blades.
Note
Return blades to the factory for inspection if their condition

is questionable.
2. Carefully inspect all attachment parts. Visually inspect all bearings. Examine tail rotor drive shaft
installation. Inspect all bushings and bolt holes for elongation.
Note
If the Tail Rotor Hub has been subjected to shock loading

through the Tail Rotor Blades to the extent the Tail Rotor
Blades require replacement or any part of the Tail Rotor
Drive System is damaged, the hub must be replaced.
If all sections of drive shaft are satisfactory remove drive

assembly from transmission and inspect shaft for run-out
and gear teeth for damage. Check run-out of rotor shaft.
Check gear box for freedom of operation and proper back-
lash of gears.
3. If the tail rotor drive shaft or universal joint is broken or twisted, remove, disassemble and inspect
the following:

1-63
Special Inspection & OVERHAUL INSTRUCTIONS
MAINTENANCE
SUDDEN STOPPAGE-TAIL ROTOR-POWER ON

1. Inspect tail rotor and tail rotor drive systems in the same manner as for "POWEROFF" and in addi-
tion, Magnafluxthe drive shafts and gears in the tail rotor gear box. Zyglo inspect the blade grips.
Note

SUDDEN STOPPAGE-MAIN ROTOR-POWER ON
Accomplish this inspection immediately after the main rotor has been stopped suddenly by striking an
object while being driven by the engine.
Note
Perform the same inspection as for "POWER OFF" and

the following:
1. Remove and disassemble transmission. Inspect all parts carefully, giving particular attention to free-
wheeling parts.
2. Inspect adapter plate and trunnions. Carefully examine all flight control systems.
Note
RPM - TACHOMETER NEEDLE SEPARATION
When the Engine Tachometer needle advances beyond Rotor

Tachometer needle under power, "Engine overspeeds beyond
Rotor" the mast drive flange shear screws MUSTbe inspec-
ted, for offset shearing. Check shear screws by inserting a
3/16 inch drill into head of shear screw, if drill cannot be
inserted, remove shear screw and check O.D. for offset
shearing. If any indication of shearing is evident, all shear
screws MUSTbe replaced.
1-64
MAINTENANCE INSTRUCTIONS Mandatory Retirement Schedule
&OVERHAUL
MANDATORY RETIREMENT SCHEDULE
WARNING
Some parts are installed as original equipment on both

military and commercial helicopters and may have a lower
retirement life and/or (T.B.O.) Time Between Overhaul
when used on a military helicopter than when used on a
commercial helicopter. In addition circumstances sur-
rounding their use may call for operation of the military
helicopter outside of the approved military flight envelope.
Consequently, parts that have been used on military
helicopters should NOT be used on commercial helicopters.
ITEM PART NUMBER REPLACE AT
MAIN ROTOR SYSTEM
Hub Yoke, Steel 47-120-177 3600 hrs.

Mast 47-130-114 Unlimited
TAIL ROTOR SYSTEM
Tail Rotor Blades (Metal) 47-642-102 (All Dash Numbers) 600 hrs.
Pitch Change Links 47-641-032-1 50 hrs.
Delta Hinge Bolt 47-641-031-1 100 hrs.
Delta Hinge Bearings KP5A or K5A 100 hrs.
Blade Grip Retaining Bolts 47-641-052-1 300 hrs.
Blade Grip Retaining Bolts 47-641-052-3 or-5 600 hrs.
Rotor Shaft 47-645-077 900 hrs.
Hub Yoke 47-641-025-1 1200 hrs.
Hub Yoke 47-641-057-1 1200 hrs.
Hub Yoke 47-641-025-7 or -9 2500 hrs.
Hub Yoke 47-641-057-7 or -9 (except as 2500 hrs.
listed below)
47-641-057-9 Serial Numbers
N29-1246 thru N29-1266 400 hrs.
N29-1298 thru N29-1452 400 hrs.
N29-10453 thru N29-10488 400 hrs.
N29-10501 thru N29-10525 400 hrs.
Pitch Change Bearing 47-641-146 (R-4-AF4) 100 hrs.
Pitch Change Bearing S1RP 100 hrs.
Pitch Change Bearing 7R4AX1C 100 hrs.
Pitch Change Bearing 47-641-131-1 600 hrs.
POWER PLANT
Fan Belts (Matched Sets) 47-661-026-1 100 hrs.

Fan Belts (Matched Sets) 47-661-028-1 100 hrs.
Fan Belts (Matched Sets) 47-661-041 (All dash numbers) 600 hrs.
Engine Mount 47-612-131-1 2500 hrs.
Engine Mount (gas or arc welded) 47-612-135-1 2500 hrs.
(Rev. 4) 1-65/1-66
Model 47G BELL HELICOPTER COMPANY Section I (Part 2)
DAILY INSPECTION
GENERAL
ments outlined below, to determine that helicopter is airworthy and that damage or malfunction has not de-
veloped since last previous inspection. Inspection may be conducted by qualified flight or maintenance per-
sonnel. Corrections necessary as a result of inspections must be performed by properly qualified person-
nel. Details and tolerances includedbelow are for guidance for persons making such corrections.
MAIN ROTOR WOOD BLADES

1. Inspect blade covering for condition of finish, loose areas or blisters, and damage which punctures or
tears fabric.
2. Inspect trim tabs and stainless steel leading edge of blades for security, cracks, dents, distortion,
and punctures.
3. Inspect butt areaof blades for checks in wood. (Maximum allowable per blade: Ten checks not more than
0.062 inch total width.) Inspect blade for cracks in butt, forward of butt plates, more than three cracks in
this area is cause for replacement or repair at a factory approved repair station.
4. Inspect blade grip plates, drag brace straps, and drag braces for security, cracks and damage.
5. Inspect hub assembly for general condition and for security of all bolts, nuts, and locking devices.
6. Inspect dynamic stop cables for security, wear, and excessive number of broken wires. (Maximum
allowable: Six broken wires in any one-inch length.)
MAIN ROTOR HUB ASSEMBLY.

1. Check security of blade attachment bolts and hub retaining nut.
2. Inspect hub assembly for general condition and security of bolts and nuts. Check freedom of operation of
gimbal bearings by rocking assembly up and down in a spanwise direction. Release friction control on con-
trol stick, move control stick in a lateral direction and check freedom of operation of bearings in pillow
block and gimbal ring.
3. Inspect static stop (if installed with metal blades). If a permanent set or other signs of excessive hard
contacts from gimbal ring are evident, disassemble andcarefully inspect pillow blocks, gimbal rings, bear-
ings, and pillow block bolts.
4. Dynamic Stop Cables - Replace any cable that shows more than six wires broken in any one inch of length.
If corroded or badly worn, the cable shouldbe replaced although the number of broken wires is less than that
specified for replacement. Observe attachment of dynamic stop cables.
ENGINE MOUNT
1. Inspect mount assembly for security of installation and for dented or damaged tubing. Carefully inspect
welds (particularly at tube cluster and mount housing) for cracks. Replace mount assembly immediately if
cracks are found.
1-1
Section I (Part 2) BELL HELICOPER COMPANY Model 47G
Daily Inspection & OVERHAUL INSTRUCTIONS
MAINTENANCE

1. Inspect stabilizer bar for general condition and security. Inspect dampers for security, general condi-
tion, security of link rods, and evidence of leaks. Move stabilizer bar slowly up and down (full travel) and
check dampers for proper operation. Check fluid level on CSC870-5damper. If level is below lower mark
check damper timing.
SWASHPLATE AND CONTROLS SYSTEM (MAIN ROTOR)

1. Inspectswashplate for general condition, security of attachment, security of controls and push-pull tubes
to swashplate levers. Move control stick in all directions (fore, aft, and laterally) and note freedom of
operation of swashplate gimbal bearings. Operate main rotor pitch control levers, and check swashplate
sleeve, swivel links, and scissor levers for freedom of operation. Check security of travel stops. Inspect
control plate, lateral and fore and aft horns for cracks.
2. Move cyclic and collective sticks through full travel in all directions, checking for freedom of operation
and lost motion. Excessive lost motion (other than allowed by elongated hole in hydraulic cylinder valve
body) in the control system is unsatisfactory and should be eliminated.
3. Test operation of friction control on control sticks for proper operation. With friction released, check
cyclic and collective sticks for security, condition, and binding.
4. Inspect linkage of all control systems for security and condition of bearings. Replace YS112 rod ends
when axial play is over 0.030 inchor radial play is over 0.005 inch. Replace fabroid rod ends on main rotor
pitch links and control system when axial or radial play exceeds 0.012 inch.
5. Inspect all componentparts of systems for security of mounting, freedom of operation and unobstructed
full travel. Inspect shafts, bellcranks, and controlpush-pulltubes for surface damage, alignment, and elon-
gated bolt holes. Inspect bellcrank bearings and bolt for wear, binding, and lubrication. Inspect hydraulic
boost cylinders for leaks and security, light weepage is acceptable.
6. Inspect surface, radii, and welds of all supporting brackets for cracks, damage and security of mounting.
POWER PLANT AND ENGINE COMPARTMENT

A. Perform Daily Inspection as specified in engine manufacturer's operators manual and the following items:
1. Inspect engine for cracks, leaks, security and evidence of loose bolts and nuts.
2. Inspect baffles for general condition and security.
3. Inspect cooling fan blades for cracks, damage and alignment. Inspect fan belts and pulleys for general
condition, wear, cracks and breaks. Check adjustment of fan belts.
4. Inspect engine and sprag rubber mounts for cracks and deterioration. Check clamp bolts on engine Lord
mounts for security.
5. Inspect sprag mount rods and adapter for general condition, dents, cracks, damage, and security. Ex-
amine clevises and bushings for excessive wear.
6. Sprag safety cables - Replace any cables that show more than six wires broken in any one inch length.
If corroded or badly worn the cable should be replaced although the number of wires broken is less than
specified for replacement.
7. Inspect hot-air exhaust shrouds and carburetor hot-air control valve for cracks, general condition, and
mounting.
8. Inspect throttle, mixture, carburetor heat, and fuel shut-off controls for general condition and security.
Check controls for freedom of operation and full operating range.
1-2
MAINTENANCE
& OVERHAUL INSTRUCTIONS Daily Inspection
POWER PLANT AND ENGINE COMPARTMENT Cont.

9. Inspect all fuel, oil, hydraulic lines and hoses for general condition. Inspect for evidence of leaks, chaf-
ing, security and position of attaching clamps. Tighten or repair connections as necessary. Replace flex
lines, hoses and ducts if exterior shows signs of deteriorations.
10. Drain fuel strainer, oil tank and fuel tank sumps, and carburetor drain. Check fuel and oil quantities.
11. Check general condition of engine compartment.
12. Inspect air cleaner when operating under dusty conditions. Clean filter by removing and tapping lightly
or using light air pressure applied to inside (hold nozzle 12 to 18 inches from filter). Replace air intake
filter at 25 hours if operating under extreme dusty conditions. Replace at 50 hours when operating under
moderately dusty conditions.
13. Replace filter element if manifold pressure shows drop due to filter clogging.
14. Inspect oil level in hydraulic boost control reservoir. Refill as necessary. (Figure 1-7.)
15. Check oil cooler for cleanliness of air passages.
TRANSMISSION
1. Inspect transmission case and drive assemblies for cracks, oil leaks, damage, and security of mounting.
NOTE
Oil leaks, rough operation in any drive assembly, or end play

in tail rotor or cooling fan drive is cause for immediate dis-
assembly and complete inspection. (Refer to Section IV.)
2. Inspect all fittings, plugs, oil lines, and temperature bulbs for leaks and security.
SYNCHRONIZED ELEVATOR
1. Inspect attachment brackets and pulley brackets for cracks, particularly at the weld area.
2. Inspect for security of attachment bolts, safetying, dents, and corrosion.
3. Inspect for freedom of operation through full range of travel.
4. Inspect fore and aft cable attachment fittings for security.
5. Inspect synchronized elevator control cables fore and aft, especially where running over pulleys or
through fairleads, for wear and broken wires. If three wires are broken in any area, replace cable. If cor-
roded or badly worn, cable must be replaced even through no broken wire is found.
TAIL ROTOR BLADES AND HUB ASSEMBLY

1. Check tail rotor blades for security of bonding, cracks, and scratches. If bonding shows any indication of
loosening, or cracks exist, blades must be replaced immediately.
3. Inspect pitch change linkage for wear, alignment, freedom of operation, and security.
4. Inspect tail rotor hub for general condition and security.

1-3
Section I (Part 2) BELL HELICOPTER COMPANY Model 47G
TAIL ROTOR BLADES AND HUB ASSEMBLY Cont.
5. Inspect, metal tail rotor blades, for cracks, as follows: (See figure 1-30.)
a. The tail rotor grips in an area one inch inboard of the root end of the blade shell
b. The area surrounding the rivets which attach the blade shell to the grip.
c. Along the inboard six inches of the trailing edge of the blade shell.
d. If cracks are found in any location, or permanent deformation is found, the tail rotor blades must be
removed prior to further flight.
6. Inspect tail rotor wood blades as follows: Inspect general condition, and for damage which punctures or
tears fiberglas covering. Inspect stainless steel leading edge for cracks, especially in root area.
TAIL ROTOR DRIVE AND CONTROL SYSTEM
1. Inspect gear box for security of mounting and evidence of oil leaks.
2. Check for excessive heat after shutdown following engine run.
3. Check oil level in tail rotor gear box.

4. Inspect tailboom extension housing for cracks, dents, scratches, and security of attachment to structure.
Check end sleeve flange for any movement indicating spot weld failure.
5. Inspect drive shaft for general condition, dents, cuts, scratches, and evidence of fatigue. Inspect bear-
ing housings for cracks and security. If screws are loose, check for elongated holes. Inspect coupling taper
nuts for security.
6. Inspect tail rotor drive shaft bearings for general condition.
7. Inspect splined couplings of tail rotor drive for excessive play in splines.
8. Inspect universal joint for general condition and excessive wear. Replace joint if end play in needle
bearings exceeds 0.020 inch maximum.
9. It is mandatory for shafts which have cuts or scratches over 0.002 inch deep be replaced.
10. Inspect pitch change drum for security and freedom of operation. Inspect cables for wear and fraying
over pulleys, or through fairleads. Replace any cable that shows more than three wires broken in any one
inch length, limited to any two areas of any one cable. If corroded or badly worn, replace cable if number
of broken wires is less than that specified for replacement.
11. Inspect condition and security of turnbuckles, fairleads, and control rods. Operate control pedals,
checking for freedom of movement and full travel Observe movement of blades while operating pedals,
(left pedal forward, leading edges of blades move outboard, right pedal forward, leading edges of blades
move inboard).
12. Check for axial or radial play of pitch change control link bearings. If axial or radial play exceeds
0.015 inch in either rod end, replace rod end.
13. Inspect pedals and connecting push pull tubes for security and freedom of operation.
14. Check cables for attachment at turnbuckles, security, alignment through pulleys, proper tension, and
proper seating of ball ends in drum sockets. Inspect all pulleys and fairleads for security and excessive
wear; brackets for damage.
14
MAINTENANCE
& OVERHAUL INSTRUCTIONS Daily Inspection

1. Inspect fuel tanks, straps, supports, and lines for general condition, evidence of chafing, and security.
2. Inspect cabin, center frame, and tailboom structure and fittings for security and damage.
3. Inspect landing gear according to type:
a. Skid type - Inspect skids and shoes for excessive wear; all parts for security, cracks, dents, kinks,
and corrosion; ground handling wheels for general condition and tire inflation; cross tubes for excessive
deflection. (Refer to Section X.)
b. Float type - Inspect floats for proper inflation, and all parts for security and damage.
4. Inspect vibration isolator for security and evidence of damage at points of attachment to tailboom.
INSTRUMENTS, ELECTRICAL,AND PITOT SYSTEMS
1. Inspect instruments for broken, cracked or loose cover glass, and condition of range and limit markings.
2. Inspect battery for evidence of spilled electrolyte, security of mounting, and general condition. Check
battery drain tube for unobstructed drainage.
3. Inspect general condition of all wiring, insulated tubing, and clips. Test operation of all switches and
circuit breakers. Check navigation and landing lights and rotating beacons for operation and security of
mounting.
4. Inspect generator and starter for security.

5. Drain static and pitot tubes at drain plug if water in system is suspected.
GENERAL
1. Remove all loose objects from helicopters (handtools, rigging jigs, protractors, etc.) and remove main
rotor tie-down prior to run up.
2. Check that registration and airworthiness certificates are in their proper place in the cabin, and in
order. Check log book for being current.
ENGINE RUN-UP
NOTE
Engine and main rotor tachometer needles shall be synchronized

at all speeds greater than 1700 RPM with the collective control
stick in the full down position. Rapid application of collective stick
or throttle below 2800 RPM may cause centrifugal clutch slippage.
The clutch will be considered satisfactory if there is no slippage
when hovering at maximum gross weight with 3000 engine RPM.
Clutch slippage under these conditions shall be reason for clutch
disassembly and inspection. (Refer to Section IV.)
1. Start engine and run-up in accordance with instructions outlined in Model 47G Flight Manual
1-5
OPERATIONAL CHECK
1. Check operation of instruments, fuel and oil pressure, cylinder head temperature, engine and transmis-
sion oil temperatures. Check fuel, oil, and hydraulic lines for leaks. Check operation of magnetos at 3100
RPM with collective pitch lever full down. Refer to Flight Manual for allowable magneto drop.
1-6
MAINTENANCE
& OVERHAULINSTRUCTIONS- 50 Hour Inspection
50 HOUR INSPECTION
GENERAL
1. Perform inspections outlined below, in addition to complete daily inspection.
4. Refer to engine manufacturer's instructions for inspection requirements on engine and accessories.
5. Refer to pertinent paragraphs of Maintenance and Overhaul Instructions for details of procedures,
adjustments, and specified tolerances.
MAIN ROTOR
1. Visually and manually inspect all parts for security, damage, evidence of excessive wear; all linkage rod-ends for
freedom from binding at extremes of travel.
Note
hours or more, the following inspection shall be performed
each 50 hours.
a. Prior to inspection, wipe clean the the gimbal ring areas around the bores for the trunnion and pillow
block bearings (eight places). Using a 3X magnifying glass, thoroughly inspect the gimbal ring bearing bores for cracks
in the areas adjacent to:
(2) Trunnion seals.
MAST AND CONTROLS
1. Visually and manually inspect assembly for security, damage, excessive wear, freedom of operation,
and proper adjustment.
Rev. 3 1-7
2. Check for excessive vertical play in swashplate by manually lifting outer ring. Any appreciable looseness
(more than 1/32 inch vertical play) requires corrective action. (Bushings Only) Needle bearing type 0.012".
3. Inspect swashplate control horns for cracks with 10-power magnifying glass, with control rods dis-
connected and horns thoroughly cleaned.
4. Check A13965 or CSC870-3 dampers, for security, leaks, and proper timing.
TRANSMISSION
1. Visually inspect case and drive assemblies for security, damage, cracks, and evidence of oil leaks.
2. Clean and inspect oil strainers. Check all fittings, plugs, oil lines, and temperature bulb for security;
flexible oil line for deterioration.
3. Inspect tail rotor drive coupling for security of retaining bolt (not required if SI 368 has been accomplished) I
and for wear or chipping of splines.
POWER PLANT
1. Inspect engine and accessories in accordance with engine manufacturer's instructions.
2. Drain engine oil, inspect and clean oil filter, at the end of first 25 hours of operation and every 50 hours
thereafter. If metal particles are found,carefully evaluateto determine possible source. Further inspection
shall be warranted with special emphasis on main rotor mast thrust bearing. Inspect oil cooler for leaks
and cleanliness of air passages. Inspect leads of oil temperature bulb for security. Check oil level in hy-
draulic boost reservoir; refill if necessary.
3. Clean fuel strainer. Inspect all parts of fuel system for security, evidence of leaks, damage or chafing,
and deterioration of hoses. Check all vents and drains for obstruction; valves and fuel quantity indicators
for proper operation.
4. Inspect cooling fan for security, cracks, damage, or blade misalignment; belts for general condition;
pulleys for damage or misalignment; cooling shroud and baffles for security, damage, or obstruction to
air flow.
5. Inspect air intake system for security, cleanliness, damage, or obstruction. When operating in moder-
ately dusty conditions, replace dry circular-type air filter (if so equipped).
6. Check throttle, mixture and heat controls for security and proper operation.
7. During dusting operations, clean carburetor float chamber vent screen.
TAIL ROTOR SYSTEM

1. Inspect all accessible drive shafts for security, nicks or scratches exceeding 0.002 inch depth, and
general condition; bearing hangers and caps for security and cracks. Check coupling taper nuts for tight-
ness; bearings for smooth operation.
2. Inspect universal joint for general condition, and for side play in excess of 0.020 inch.
3. Inspect extension shaft housing and support brace for security, cracks, dents or other damage.
4. Inspect gear box for security, and for evidence of leaks.
5. Check pitch change linkage for security, freedom of operation, and evidence of excessive wear. Any
stiffness, binding, roughness, or looseness of pitch change link rod-ends require replacement (max. radial
and axial play 0.015 inch).
1-8 Rev. 3
6. Inspect tail rotor hub for security and freedom of operation on delta hinge bolt and bearings. Check
fit of cup-shaped washers: Tap delta hinge bolt to seat one washer snug against machined surface of hub
yoke. Check with feeler gage at opposite side of hub for clearance not exceeding 0.004 inch between lip
of washer and hub surface.
FLIGHT CONTROLS
CYCLIC AND COLLECTIVE PITCH CONTROLS
1. Inspect all component parts of systems for security, freedom of operation, and unobstructed full travel.
Inspect bell cranks, torque tubes or jack-shafts, control discs or hydraulic power cylinders, and push-
pull tubes for damage or misalignment. Check all bearings for wear or binding; bungee springs (on ships
without hydraulic irreversible valves) for security and condition.
2. Replace YS112 rod ends if axial play exceeds 0.030 inch or radial play exceeds 0.005 inch. Replace
RE4F7 or 60R1-2 rod ends if grease shield is loose, distorted or kinked.
3. Inspect surfaces, welds, and radii of all support brackets and bell cranks for cracks or other damage.
4. Replace fabroid rod ends on main rotor pitch control links when radial or axial play exceeds 0.012 inch.
HYDRAULIC BOOST SYSTEM
1. Inspect filter elements in pressure line and reservoir vent line, replace if required.
Rev. 3 1-8A/1-8B
MAINTENANCE
FLIGHT CONTROLS Cont.

SYNCHRONIZEDELEVATOR
1. Inspect elevator for security and for freedom of operation through full travel; hinges and attachment
brackets for cracks.
2. Inspect control cables, fittings, jackshaft and linkage for security, condition, and freedom of operation.
TAIL ROTOR CONTROLS
1. Inspect pedals, jackshaft, and linkage for security and freedom of operation; pedal ratchet pawl for
proper adjustment.
2. Inspect cables for wear or corrosion, and for security of turnbuckles and attachment fittings; pulleys
and fairleads for wear or damage.
INSTRUMENTS
1. Inspect instrument for loose or cracked cover glasses, and for condition of range and limit markings.
2. Inspect all lines for security, leaks or obstruction, chafing or other damage; hoses for deterioration;
leads for security.
ELECTRICAL SYSTEMS
1. Inspect battery for security of mounting,corrosion, water level and specific gravity; leads for security;
vents and drains for obstruction.
2. Inspect voltage regulator and relays for security of mounting and connections, general condition, and
operation.
3. Inspect generator and starter for security of mountingand connections and proper operation.
4. Test operation of all switches, circuit breakers, and lights. Visually check all wiring for general con-
dition, insulation, and security.
CABIN AND STRUCTURE

1. Inspect cabin enclosure and doors for cracks, scratches, and defects of visibility. Check doors for
security, and operation of door latches and emergency release.
2. Inspect seats and safety belts for general condition and security of attachment.
3. Check condition and security of any first aid kits and fire extinguishers.
4. Inspect all structural tubing and fittings for cracks, bends, distortion, corrosion, or other damage;
paint or other protective coating for condition.
5. Inspect vibration isolator for security and for evidence of damage at points of attachment to tail boom.
1-9/1-10
100 HOUR INSPECTION
GENERAL
1. Perform following inspections, in addition to complete daily, and 50-hour inspection.
cessories.
POWER PLANT
1. Inspect engine and accessories according to engine manufacturer's instructions.
2. Check fan belt tension. When required, replace belts with matched pair.
MAST CONTROLS
1. When swashplate is fitted with needle-type gimbal bearings, manually tilt swashplate all directions to
check for roughness or brinelling.
2. Check damper, part number, CSC870-5, for security, leaks and proper timing.
FLIGHT CONTROLS
1. Check tension of elevator and tail rotor control cables.
TAIL ROTOR
1. Install T100373 rigging jig and check complete tail rotor linkage for play, not to exceed 1 1/2 degrees.
Disconnect pitch links and manually turn each blade grip to check freedom of operation and for indications
2. Remove and inspect delta hinge bolt for wear. Check delta hinge bearings for smooth operation by
manually rotating inner races.
1-11/1-12
MAINTENANCE
300 HOUR INSPECTION
GENERAL
1. Perform following inspections, in addition to complete daily, 50-hour, and 100-hour inspections.
cessories.
POWER PLANT
1. Inspect engine and accessories according to engine manufacturer's instructions. If engine is changed,
flush oil cooler and lines.
FLIGHT CONTROLS
1. Helicopters having 1/4 inch pivot bolts and swivel link bolts, remove from scissor levers and in-
spect for wear.
a. If dimension in any area of bolt is less than 0.2465 inch, replace bolt.
b. Inspect diameter of bolt holes in bracket for wear. If dimension is 0.2550 or more, bushings must
be replaced to restore dimensions 0.2490 inch, plus or minus 0.0005 inch.
2. Helicopters having 5/16 inch pivot bolts and swivel link bolts, remove from scissor levers and in-
spect for wear.
a. If dimensions in any area of bolt is less than 0.3090 inch, replace bolt.
b. Inspect diameter of bolt holes in bracket for wear. If dimensions is 0.3175 or more, bushings must
be replaced to restore dimensions 0.3120 inch plus or minus 0.0005 inch.
ENGINE MOUNT
(See figure 1-20.)
1. Magnaflux engine mount as follows:
a. Gas-welded mount, Part No. 47-612-135-1, every 300 hours. (See 3 below for Acceptance Standard.)
Note
paint, apply stripper with brush.
2. Procedure: Inspect mount by following steps, using wet continuous method, conforming to Specifi-
cation MIL-I-6868, applying 750 amperes DC or 500 amperes AC. Determine length of any indication by
residual method.
1-13
300 Hour Inspection & OVERHAULINSTRUCTIONS
MAINTENANCE
WALL WALL
INDEX 0. D. THICKNESS INDEX 0. D. THICKNESS
1 1/2 .035 5 3/4 .058
2 5/8 .049 6 3/4 .065
3 5/8 .065 7 7/8 .049
4 3/4 .049 8 7/8 .065
* Items 2 and 7 at these locations on gas-welded mount (Part No. 47-612-135-1).
** Items 3 and 8 at these locations on arc-welded mount(Part No. 47-612-135-1N13, Serial No. A16-41 and subsequent).
417612-57A
ENGINE MOUNT Cont.

contact heads, apply current, and inspect bearing areas only.
d. Magnetize upper frame, placing one corner gusset against each contact plate across narrow end.
Inspect each end in this manner.
e. After completing inspection, demagnetize mount and check with pocket field indicator or compass.
3. Recommended Acceptance Standard for gas-welded mount, Part No. 47-612-135-1:
a. Indications of cracks, lack of fusion, or overlaps at edge of welds in Lord mount clamp or trunnion
pin bearing areas shall be cause for rejection, regardless of length or location, except when they can be
removed by light sandblast, wire brushing, light filing or grinding, providing such methods do not re-
move more than 0.005 inch of the base material from any detail of the assembly.
b. Lack of fusion or overlaps in any area, other than above, will not be considered cause for rejection,
provided they do not exceed 1/4 inch in length and not more than two such indications appear in any one
1-14
MAINTENANCE
ENGINE MOUNT Cont.

joint or cluster. Procedures in paragraph a. may be used in questionable cases (for true length of indi-
cation, recommended use of residual method of magnetic particle inspection).
c. Indications caused by machining ends oftrunnionpinbearings and Lord mount clamp lugs, and in which
indication does not extend into basic weld or parent metal, shall not be cause for rework or rejection.
d. Indications which appear in any gusset area, caused by change of section where edge of gusset is
covered by weld, are not cause for rework or rejection.
e. Indications in parent metal tubing are acceptable and need not be removed provided localized removal
(as in paragraph a. above) indicates depth of defect does not exceed ten percent of original wall thickness.
Indications of seams, grooves, tears, cracks, burrs, laminations, slivers and pits within 1/2 inch of any
weld must be removed. Presence of indications not removable within ten percent allowance shall be
1-15/1-16
Model 47G BELL HELICOPER COMPANY Section I (Part 2)
MAINTENANCE
600 HOUR INSPECTION
GENERAL
1. Procedures outlined for 600 hour inspection of these components consist of manual operation of assem-
blies through all possible movements while observing carefully for any deviation from normal action, feel,
or appearance. Intent is to determine serviceability for continued operation or need for corrective action.
When doubt exists, apply more thorough inspection methods as necessary to reveal true condition.
2. Accomplish complete daily, 50-hour, 100-hour, and 300-hour inspection requirements in addition to
inspection outlined below.
3. Overhaul requirements for engine and accessories shall be in accordance with engine manufacturer's
instructions.
specified clearances, torque values, tolerances, or methods of adjustment.
MAIN ROTOR HUB
1. With pitch controls links and equalizer links disconnected, manually rotate each blade grip on yoke
spindle. Check freedom of operation and for indications of bearing roughness or wear.
2. Tilt rotor on spanwise and chordwise axis, checking gimbal ring bearings for any binding, excessive
play, or indications of roughness or wear.
3. Investigate and correct any faulty conditions.
MAST AND CONTROLS

1. Disconnect damper links from stabilizer bar. Manually check freedom of bar movement throughout
travel, and for indications of roughness or wear in pivot bearings.
2. Manually check for proper end play at stabilizer bar trunnions.
3. Disconnect control rods from swashplate horns. Disconnect swivel links. Grasping outer ring, rotate
and tilt swashplate all directions to check freedom of operation and for indications of roughness or wear
in carrier bearings, gimbal pins and bearings. Manually check for excessive vertical or horizontal play
in bearings, bushings, or pins.
4. Manually check swivel links and scissor levers for freedom of operation and condition of bearings.
5. Visually inspect all accessible areas of mast for indication of damage. Raise swashplate support and
transmission cap sufficiently to rotate and carefully check main rotor mast bearing for smoothness of
operation, excessive radial and/or axial looseness and verification that retaining nut is properly secured.
1-17
MAINTENANCE
TRANSMISSION
1. With transmission removed, disassemble to extent required for following inspections:
a. Remove and disassemble freewheeling unit, to inspect all parts for wear and damage. Inspect springs
for wear and correct radii, inspect spring retainer plates, for wear and cracks, replace as necessary.
Check for free rotation and proper locking during and after reassembly.
b. Remove clutch spider and shoe assembly. Visually inspection condition of shoe linings, drum, and spider
bearing. Manually and visually check for excessive wear of pivot pins and bushings.
c. Without further disassembly, unless faulty conditions are found, inspect all other sub-assemblies
for acceptable general condition, gear tooth wear patterns, and freedom of bearing operation.
ENGINE MOUNT
1. Magnaflux arc-welded mount (figure 1-1) Part No. 47-612-135-1 N13, (Serial No. A16-41 and subsequent)
at 600, 1200, 1800, and 2400 hours as follows:
2. Recommended Acceptance Standard for arc-welded mount, Part No. 47-612-135-1N13 (Serial No. A16-
41 and subsequent):
a. Removal of indications is permitted by light sandblast, filing or grinding, provided that not more than
10 percent of thickness of welds or parent metal is removed. Rework areas must blend smoothly with
adjacent metal.
b. Indications are often observed which follow edge of weld bead. These are usually caused by entrap-
ment or change in section primarily due to weld bead, and are not considered cause for rejection or re-
work, provided they do not extend into parent metal.
c. Indications between weld metal and parent metal exposed by machining ends of bearings or lugs are
acceptable, provided indication does not extend into weld or parent metal.
d. Indications in parent metal tubing are acceptable and need not be removed provided localized removal
(as in paragraph a. above) indicates depth of defect does not exceed 10 percent of original wall thickness.
Indications of seams, grooves, tears, burrs, laminations, slivers and pits within 1/2 inch of any weld must
be removed. Presence of indications not removable within 10 percent allowance shall be cause for rejection.
ADAPTER PLATE
1. Visually inspect adapter plate for general condition, security of studs and oil scoop, and excessive wear
at trunnion pin holes.
POWER PLANT
1. Inspect engine and accessories in accordance with engine manufacturer's instructions. When engine is
changed or overhauled, clean and flush oil cooler and lines. Check adapter plate hold-down studs for
specified projection at minimum torque.
2. Inspect engine mount as specified in 300-hour inspection instructions.
3. Inspect fan for general condition and free rotation; support for security.
1-18
MAINTENANCE
- 600 Hour Inspection
POWER PLANT Cont.

4. Check adjustment of carburetor controls.
5. Inspect generator for general condition of brushes, brush holders, springs, and commutator. Manually
check freedom of rotation and for indications of bearing roughness or wear.
6. Test operation and adjustment of voltage regulator and relays.
7. Drain fuel tanks, remove and clean finger screens.
TAIL ROTOR SYSTEM

1. Disconnect external shaft sections at splined couplings and universal joint. Clean and inspect splined
couplings on shafts and transmission drive assembly for wear and general condition.
2. Visually inspect gear box and extension shaft assembly. Manually turn shafts to check for freedom of
operation, normal feel of gear meshing and backlash, and indications of bearing roughness or wear.
Closely inspect gear box oil, during change, for metal particles or foreign matter.
3. Conduct rigid visual inspection of tail rotor blades for dents, nicks, scratches, or other damage.
5. If equipped with hub yoke having undercut fillet radius around root of each spindle (Part No. 47-641-
025-1 or -7, and 47-641-057-1 or -7), disassemble to inspect these fillet radius areas with 10-power
magnifying glass for-corrosion or pitting. (Replace and lubricate felt washers at reassembly.)
HYDRAULIC FLIGHT CONTROLS

1. Make thorough visual inspection for cracks in all parts of cylinder support and bell crank assemblies,
including attachment brackets.
2. Check for excessive radial play of cylinder trunnions in bushings of supports and bell cranks.
3. Test system operating pressure, adjust relief valve as necessary.
1-19/1-20
MAINTENANCE
1200 HOUR INSPECTION
GENERAL
2. Accomplish complete daily, 50-hour, 100-hour, 300-hour and 600-hour inspection requirements in con-
junction with those outlined below.
instructions.
procedures, specified clearances, torque values, tolerances, and methods of adjustment.
MAIN ROTOR
a. Inspect grip fillet (Refer to Figure 1-22). The inboard radius and bottom of the fillet must have a smooth
finish and be free of nicks or tool marks.
Yoke (See figure 1-23.) M

Hub Core M
Grip Adapter Nuts (See figure 1-15) M
Drag Braces and Bolts (Clevis - See figure 1-17.) M
c. Blade alignment.
MAST AND CONTROLS

1-21
MAST AND CONTROLS Cont.

run-out with dial indicator. Check security of mast plug in lower end of mast by observing match-mark
and checking width of gap between mast and plug flange for comparison with dimension stamped on plug
plus or minus 0.005 inch to dimension stamped on plug.
3. Inspect following parts by Magnaflux or Zyglo methods as indicated. M = Magnaflux Z = Zyglo.

*Control Plate Z
Mast M
Stabilizer Bar Outer Bar M
Stabilizer Bar Center Frame Z
Ring Assembly (Swashplate - Split Gimbal) M (Refer to accept-
*Bushings or liners must not be removed to Zyglo control plate and support. ance standard)
FLIGHT CONTROLS
1. Zyglo inspect fore-and-aft cyclic control bellcrank bracket mounted on front of transmission.
TRANSMISSION
b. Mast driving flange: All splines and surfaces for burrs or surface damage; shear bolts for any damage.
c. Inspect retainer of freewheeling unit, for wear, cuts and fracture. Inspect rollers and roller slots in
ring gear, for flat spots, burrs, brinelling and damage. Inspect springs for wear and correct radii, inspect
spring retainer plates, for wear and cracks, replace as necessary, check parts dimensionally.
e. All bearings, rollers, races, and cages for smooth operation and freedom from wear or damage.
f. Clutch: Shoes for glazed or excessively worn linings and worn pins or bushings; drum for dimensional
.tolerances, out-of-round, scoring, or evidence of excessive heating. (Blue on drum is not cause for re-
jection.)

1-22
TRANSMISSION Cont.
Transmission Case (All sections) Z
Upper Ring Gear M
Upper Sun Gear M
Pinion Pins M
Pinion Gears M
Driving Flange M
Shear Bolts M
Lower Sun Gear M
Clutch Pivot Pins M
Pulley Retaining Bolt and Cones - Fan Drive M


ADAPTER PLATE

Trunnion Pins M
POWER PLANT
3. Remove and magnaflux index plate Part No. 47-669-118 or 47-669-801. (Refer to acceptance standard.)
4. Inspect engine mount as specified in 300, 600 and 1200 hour inspection instructions. (Refer toaccept-
ance standards or for mount Part No. 47-612-171 use acceptance standards below.)
1-23
ENGINE AND COOLING SYSTEM

3. Remove and Magnaflux index plate assembly, P/N 47-669-118 or 47-661-801. (Refer to acceptance
standard.)
POWER PLANT CONTROLS

1. Inspect throttle, mixture and fuel controls systems.
HYDRAULIC BOOST SYSTEM

1. When operating under dusty conditions remove and clean two restrictors part Number 3R1643 or 97205,
however, at the 200-hour inspection the restrictors must be removed and cleaned.
ENGINE MOUNT
(See Figure 1-25)
ITEM O.D. WALL THICKNESS
1. 5/8 .035
2. 3/4 .035
3. 7/8 .065 47612-6
4. 5/8 .065
Figure 1-25. Tubing Chart 47-612-171 Engine Mount

1-24
MAINTENANCE
a. Inspect arc-welded mount (figure 1-23) Part No. 47-612-171 every 1200 hours. (See below for
acceptance standard.)
Note

paint, apply stripped with brush.
2. Procedure: Inspect mount by following steps, using wet continuous method, conforming to Speci-
fications MIL-I-6868, applying 750 amperes DC or 500 amperes AC. Determine length of any indication
by residual method.
a. Magnetize entire mount with one Lord mount clamp against each contact head. Inspect entire
mount.
b. Insert copper bar through trunnion bearings, to fit holes as nearly as practical. Place bar
between contact head, apply current, and inspect bearing areas only.
d. Magentize upper frame, placing one corner against each contact plate across narrow end.
Inspect each end in this manner.
e. After completing inspection, demagnetize mount, check with compass or pocket field indicator.
3. Recommended acceptance standard for arc-welded mount, Part No. 47-612-171:
a. Cracks are not acceptable regardless of size or location.
b. Removal of indications is permitted by light sandblast, filing or grinding provided that not
more than ten percent of the thickness of welds or parent metal is removed. Rework areas must blend
and merge smoothly with adjacent metal.
c. Indications are often observed which follow the edge of the weld bead. These are usually
caused by entrapment and/or change in section, primarily due to the weld bead, and are not considered
to be cause for rejection, or rework provided the indication does not extend into the parent metal.
d. Indications between the weld metal and parent metal exposed by machining the ends of bearings
or lugs are acceptable provided the indication does not extend into weld or parent metal.
e. Indications which are caused by change in section are acceptable regardless of length or
location.
f. Indications in parent metal tubing are acceptable and need not be removed provided localized
removal, using techniques as in paragraph (b) above, indicates that the depth of the defect does not exceed
ten percent of the original wall thickness. Indications of seams, grooves, tears, burrs, laminations,
slivers, and pits within 1/2 inch of any weld must be removed. Presence of indications not removable
within ten percent allowance shall be cause for rejection.
TAIL ROTOR SYSTEM

TAIL ROTOR HUB
1-25
MAINTENANCE
2. Inspect following parts by Magnaflux method:
Hub Yoke M
Pitch Change Head M

TAIL ROTOR GEAR BOX
2. Inspect following parts by Magnaflux or Zyglo as indicated. M = Magnaflux Z = Zyglo.
Gear Box Housing (all parts) Z

Gears (matched sets) M
3. During and after reassembly, perform followinginspections:
b. Mating of marked gear teeth, proper contact pattern, and specified backlash.
DRIVE SHAFTS, UNIVERSAL JOINT, AND EXTENSION SHAFT
1. Remove and disassemble all sections of tail rotor drive shaft, and extension shaft and housing, to in-
spect all parts for wear, corrosion, or damage.
Extension Housing Tube and Yoke Z

Shafts (all sections) M
BODY AND TAIL BOOM

1. Inspect visually for cracks, dents or bends, and security of sealing screws or rivets in all structural
tubing.
1-26
Model 47G BELL HELICOPTER COMPANY _Section I (Part 2)
Note
b. Remove collective pitch control tube between power cylinder and idler.
c. Remove lateral cyclic control tube between power cylinder and torque tube assembly. Remove control
tube between torque tube assembly and swashplate.
d. Remove fore and aft cyclic control tube between power cylinder and lever. Remove control tube between
lever and swashplate.
2. Remove end fitting from control tubes as follows:
a. Mark fittings and tube ends to ensure fitting is assembled in original position.
b. Remove both end fittings by carefully drilling off rivet heads and drive out rivets. Do not enlarge rivet
holes in tube or fitting.
Note
a. Remove all paint and primer from internal surface of control tubes, using steel wire brush on steel control
tubes and bristle brush on aluminum control tubes, with Methyl-Ethyl-Ketone,
Note

tive film.
b. Add three parts of thinner (Toluene TT-T-548) to four parts of zinc chromate primer, by volume, and
mix thoroughly.
c. Apply primer to inside of control tubes, coat entire internal surface while rotating control tube. Allow
excess primer to drain. Wipe excess from fitting area, leaving a light coat. Allow six hours minimum drying time
prior to further finishing.
tionally.
a. Dissolve sixteen ounces of aluminum pigment (TT-P-320A) paste (Type II Class A) or powder (Type I
Class A) in a small amount of thinner (TT-T-266).
(Rev. 1) 1-26A
1200Hour Inspection MAINTENANCE & OVERHAUL INSTRUCTIONS
6. Apply aluminum lacquer to inside of control tube, coat entire internal surface while rotating control tube.
Allow excess lacquer to drain. Wipe excess from fitting area, leaving a light coat. Allow 2 hours before installing
end fittings.
Note
Rod ends, fittings, and clevises must be plated or treated; and must not
7. Hollow ends may require refilling. If adhesive filler is damaged when the rivets were driven out, remove old
filler and fill with hard epoxy adhesive Metal Set A4 or equivalent. Allow adhesive to cure 24 hours before drilling
holes.
Note

8. Apply proseal 890-B2 to I.D. of control tubes and O.D. of end fittings, at faying surface, before assembly.
Install end fittings in control tube.
9. Dip MS20613-5P rivets in proseal and install. MS20613-6P rivets (oversize) may be used. Replace any steel
control tube that requires rivets larger than MS20613-6P rivets.
10. Seal each end of control tube assembly and around rivets with proseal 890-B2 sealant. Apply sealant as
shown on figure 1-23A control tube sealing (typical). Cure sealant at room temperature for 72 hours.
Note

1-26B (Rev. 1)
SPECIAL INSPECTION

damage.
Note
If the hard landing causes a severe pitching of the pylon

the two engine accessory housings sections, oil pump housing
and sump must be removed for fluorescent penetrant inspection.
(Franklin engine only.)
1. Inspect skids and cross tubes for cracks and excessive deflection.
2. Inspect structure and center frame. Inspect all structural tubing for cracks, bends, distortion, and
damage. Check security and condition of bolts that attach the tail boom to center frame.
3. Carefully examine all flight control push-pull tubes, hydraulic boost system (if so equipped), link-rods,
bellcranks, and cables. Inspect rod-ends and bellcrank bearings.
b. Universal joint.
5. Inspect main rotor dynamic stop cables. Remove and inspect static stop. If damage to the static stop is evident,
remove and disassemble main rotor. Use magnetic particle or fluorescent penetrant process to inspect all parts.
Visually inspect bearings.

7. Remove and disassemble main rotor mast. Use a magnifying glass and inspect thrust bearings for
creased or banded balls.
MANDATORY
If the mast thrust bearing was damaged, remove and dis-
assemble transmission completely. Inspect carefully and
replace all damaged parts.
Rev. 3 1-27
Section 1 (Part 2) BELL HELICOPTER COMPANY Model 47G

Accomplish this inspection after the main rotor has been stopped suddenly by striking any object including
tail boom while rotating freely (not being driven by the engine). While the damage to the main rotor blades
will undoubtedly be obvious, component parts of the main and tail rotor systems and engine may have
sustained from minor to severe damage.
1. Remove and disassembly main rotor. Examine main rotor blades.
Note
If condition of blades is such that repairs cannot be made

in accordance with the blade repair section of this manual,
return blades to an approved repair station for disposition.
2. If one or both blades are damaged to the extent that the steel core shows through the wood at any point,
or equalizer ham is damaged or distorted, the two engine accessory housings, (Franklin engine only) must be
removed for fluorescent penetrant inspection. Also the main rotor hub assembly, mast controls assembly and mast
must be inspected by the magnetic particle and fluorescent penetrant process. Check hub dimensionally and mast for
concentricity. Visually inspect bearings, dynamic stop cables and static stop.
MANDATORY
"Mainrotorgrips, PartNos. 47-120-135-1, 135-2, 135-3 and
47-120-252-1 must be replaced if they are presently instal-
led, or have been previously installed, on a main rotor hub
assembly that has been subjected to sudden stoppage of the
rotor at operating rpm. They must also be replaced if they
are, or have been installed, on a main rotor assembly that
incurred damage to the extent that necessitated replacement
of a main rotor blade due to chordwise cracks beyond the
limits defined in the Maintenance and Overhaul Manual.
3. Visually inspect stabilizer bar outer tube for bends; also examine welded joint at inboard end of outer bar.
4. Use a magnifyingglass to inspect mast thrust bearings for damaged balls.
c. Trunnion pins.
e. All transmission parts (if condition exists as described in step 2).
1-28 Rev. 3
MAINTENANCE
& OVERHAUL INSTRUCTIONS Special Inspection
SUDDEN STOPPAGE-MAIN ROTOR- POWER OFF Cont.

6. Inspect engine sprag mount installation. Inspect sprag mount safety cables and fittings. Inspect tail rotor
drive shaft and universal joint. If the tail rotor drive shaft is broken or twisted, remove, disassemble and
inspect the following:
Note
If the tail rotor drive shaft is satisfactory and the trans-
mission turns freely, remove tail rotor drive assembly.
Inspect assembly and drive gear carefully.
7. Carefully examine all flight control system push-pull tubes, hydraulic boost system (ifso equipped),
link-rods, bellcranks and cables. Inspect rod-end and bellcrank bearings.
8. When blade impact is violent to the extent that the drag brace is sheared and the aft side of the blade butt
contacts the aft outboard side of the hub grip, it is mandatory that the complete hub assembly be replaced.
Also the mast controls assembly and the mast must be inspected by the Mangnaflux or Zyglo process. Check
for concentricity. Visually inspect bearings, dynamic stop cables and static stop.

Accomplish this inspection immediately after the tail rotor has been stopped suddentlyby striking an object
undoubtedly be obvious, component parts of the system may have sustained from minor to severe damage.
Note
If metal tail rotor blades have struck water, at near opera-

ting rpm; power on or power off, they must be scrapped even
though there is no visible damage to blades.
Note
Return blades to the factory for inspection if their condition

is questionable.
installation. Inspect all coupling pins for damage and holes for elongation.
Note

If all sections of drive shaft are satisfactory remove drive

assembly from transmission and inspect shaft for run-out
and gear teeth for damage. Check run-out of rotor shaft.
Check gear box for freedom of operation and proper back-
lash of gears.
1-29
SUDDEN STOPPAGE-TAIL ROTOR-POWER OFF Cont.

3. If the tail rotor drive shaft or universal joint is broken or twisted, remove, disassemble and inspect
the following:


Accomplish this inspection immediately after the main rotor has been stopped suddenly by striking an
object while being driven by the engine.
Note
Perform the same inspection as for "POWEROFF"and add

the following:
wheeling parts.
2. Inspect adapter plate and trunnions. Carefully examine all flight control systems.

1. Inspect tail rotor and tail rotor drive systems in the same manner as for "POWER OFF" and in addi-
tion, Magnaflux the drive shafts and gears in the tail rotor gear box. Zyglo inspect the blade grips.
Note
If the Tail Rotor Hub has been subjected to shock landing

1-30
MAINTENANCE & OVERHAUL INSTRUCTIONS Mandatory Retirement Schedule
WARNING

ITEM PART NO. REPLACE AT
MAIN ROTOR SYSTEM
Hub Yoke 47-120-177-1 3600 Hrs.

Mast 47-130-114-11 Unlimited
TAIL ROTOR SYSTEM
Pitch Change Links 47-641-032-1 50 Hrs.

Tail Rotor Blades (Metal) 47-642-102 All dash numbers 600 Hrs.
Blade Grip Retaining Bolts 47-641-052-1 300 Hrs.
Blade Grip Retaining Bolts 47-641-052-3 or-5 600 Hrs.
Hub Yoke 47-641-025-1 1200 Hrs.
Hub Yoke 47-641-057-1 1200 Hrs.
Hub Yoke 47-641-025-7 or -9 2500 Hrs.
Hub Yoke 47-641-057-7 or -9 (except as listed below) 2500 Hrs.
N29-1246 thru N29-1266 400 Hrs.
N29-1298 thru N29-1452 400 Hrs.
N29-10453 thru N29-10488 400 Hrs.
N29-10501 thru N29-10525 400 Hrs.
Tail Rotor Hinge Bolt 47-641-031-1, 100 Hrs.
Tail Rotor Hinge Bearing KP5A 100 Hrs.
Pitch Change Bearing 47-641-146 (R-4-AF4) 100 Hrs.
Pitch Change Bearing SIRP 100 Hrs.
Pitch Change Bearing 7R4AXIC 100 Hrs.
Pitch Change Bearing 47-641-131-1 600 Hrs.
POWER PLANT
Fan Belts (Matched Sets) 47-661-041 (All dash numbers) 600 Hrs.
Engine Mount (Gas or Arc Welded) 47-612-135-1 2500 Hrs.
(Rev. 4) 1-31/1-32
Model 47G-2 BELL HELICOPTER COMPANY Section I (Part 3)
MAINTENANCE
& OVERHAULINSTRUCTIONS Daily Inspection
DAILY INSPECTION
Note
There are three vulnerable areas of the main metal rotor blades
that are susceptible to corrosion; the edges of doublers, the trim
tab, and the butting area of the aluminum skin to the stainless steel
leading edge. These areas should be examined routinely for: (1) any
break nick or heavy local abrasion of the paint finish and (2) any lift-
ing of the paint system (this can cover an area no larger than a pencil
point). Where the paint finish is lifted, remove a small area of the
paint with an X-acto knife or similar tool and check with a magnifying
unit. Corrosion will appear as a white spot. Where a break is made in
the paint system, check with a magnifying unit for evidence of white
corrosion. In both instances, use an eraser to lightly abrade the pos-
sible corrosion suspect area. If light abrading removes all traces of
suspected corrosion, it is either not corrosion or light surface oxida-
tion. Retouch area in accordance with standard instructions. This type
preventive maintenance can greatly reduce blade refinishing due to
possible corrosion.
In the event of high alkaline or caustic material has caused corrosion
on a blade, this corrosion will appear as black residue in place of the
white. This would be considered an unusual condition but possible
under certain industrial environments.
GENERAL
ments outlined below, to determine that helicopter is airworthy and that damage or malfunction has not
developed since last previous inspection.
4. Inspection may be conducted by qualified flight or maintenance personnel. Corrections necessary as a
result of inspections must be performed by properly qualified personnel. Details and tolerances included
below are for guidance for persons making such corrections.
MAIN ROTOR METAL BLADES

1. Inspect skins, grip and drag reinforcing and reinforcing laminates daily for nicks, scratches, dents and
security of attachment. (Refer to figure 1-26.)
2. Polish out all nicks and scratches not in excess of the following depths. Nicks and scratches in excess
of the following are cause for replacement.
a. 0.012 inch, inboard of station 140 and running within 15 degrees of spanline.
b. 0.008 inch, inboard of station 140 and running within 75 degrees of the chordline.
c. 0.020 inch, outboard of station 140.
3. Sharp dents in excess of the following are cause for replacement.
a. 0.020 inch, inboard of station 140.
b. 0.060 inch, outboard of station 140.

1-1
Section I (Part 3) BELL HELICOPTER COMPANY Model 47G-2
MAIN ROTOR METAL BLADES Cont.

4. Non-sharp dents in excess of the following depths are cause for replacement.
a. 0.060 inch, inboard of station 140.
b. 0.120 inch, outboard of station 140.
CAUTION
Dents should be inspected closely for nicks, scratches and cracks. If

nicks and scratches exist in a sharp dent and the total depth is in ex-
cess of that permitted in item 3, above, it is cause for replacement.
If nicks or scratches exist in any dent and the total depth is in excess
of item 4, above, it is cause for replacement. If a crack exists in any
dent, or at any location it is cause for replacement.
GRIP PLATES DOUBLERS STA 140 STAINLESSSTEEL LEADINGEDGE
STA 11.8 STA 33.75 STA 158.063 STA 190.75 STA 210.75
STA 15.8
DRAGPLATES MINIMUMTWOINCHRADIUS
Any nick or scratch in this area in excess of 0.008 inch.

Sharp dents in excess of 0.020 inch. REPLACE BLADE
Non sharp dents in excess of 0.060 inch.
Nicks or scratches which go through the outer skin.

Sharp dents in excess of 0.060 inch. REPLACE BLADE
Non sharp dents in excess of 0.120 inch.
SPAR SKIN
STAINLESSSTEELLEADINGEDGE TRAILING EDGESTRI
47100-11E
Figure 1-26. Metal Blades

1-2
MAIN ROTOR METAL BLADES Cont.

5. Edge voids in any one bond line of the grip or drag reinforcing plates in excess of 15 percent of the total
length of the bond line are cause for replacement. Any edge void in the grip or drag reinforcing plates in
excess of 0.090 inch in depth or 2.25 inches in length is cause for replacement. Any edge void in the out-
board five inches of a reinforcing laminate or outboard two inches of a grip reinforcing plate or outboard
one inch of a drag reinforcing is cause for replacement.
6. Inspect trailing edge daily for nicks, tears, notches, dents and security of attachment of skins to trailing
edge strip.
a. Nicks, tears and notches outboard of laminates may be repaired by removing material on a minimum
radius of two inches. If material has tobe removed more than 0.20 inch forward of trailing edge strip, it is
cause for replacement.
b. Dents outboard of laminates and not in excess of 0.30 inch in depth are permissible. All other dents
which do not extend into the trailing edge strip may be lightly worked back in place. If damage extends
into trailing edge strip, it is cause for replacement.
c. Edge voids in trailing edge are permissible providing they do not extend forward to the bond be-
tween the outer and inner skin or the bond between the inner skin and trailing edge strip.
7. Inspect steel leading edge daily for nicks, scratches and security of attachment.
a. Polish out all nicks and scratches inboard of station 140.
b. Edge voids in excess of six inches in length or a total of 18 inches on a side or 0.180 inch in depth
are cause for replacement. Any void in the inboard five inches of the leading edge in excess of 0.30 inch
depth is cause for replacement.
8. Inspect blade finish for bare spots, cracks, and blisters. Inspect finish for evidence of corrosion. Pin
head blisters in the finish are usually the first indication that corrosion is occuring beneath finish. Treat
and remove corrosion and refinish in accordance with instructions in Section II (Part 2.)
MAIN ROTOR HUB ASSEMBLY

1. Check security of blade attachment bolts and hub retaining nut.
2. Inspect hub assembly for general condition and security of bolts and nuts. Check freedom of operation
of gimbal bearings by rocking assembly up and down in a spanwise direction. Release friction control on
control stick, move control stick in a lateraldirection and check freedom of operation of bearings in pillow
block and gimbal ring.
3. Inspect static stop (if installed with metal blades). If a permanent set or other signs of excessive hard
contacts from gimbal ring are evident, disassemble and carefully inspect pillow blocks, gimbal rings, bear-
ings, and pillow block bolts.
4. Dynamic Stop Cables - Replace any cable that shows more than six wires broken in any one inch of
length. If corroded or badly worn, the cable should be replaced although the number of broken wires is less
than that specified for replacement. Observe attachment of dynamic stop cables.
ENGINE MOUNT
1. Inspect mount assembly for security of installation and for dented or damaged tubing. Carefully inspect
welds (particularly at tube cluster and mount housing) for cracks. Replace mount assembly immediately
if cracks are found.

1. Inspect stabilizer bar for general condition and security. Inspect dampers for security, general condi-
tion, security of link rods, and evidence of leaks. Move stabilizer bar slowly up and down (full travel) and
1-3
Daily Inspection & OVERHAUL INSTRUCTIONS
MAINTENANCE
STABILIZER BAR AND DAMPERRS Cont.

check dampers for proper operation. Check fluid lever on CSC870-5 damper. If level is below lower mark
check damper timing.
SWASHPLATE AND CONTROLS SYSTEM (MAIN ROTOR)

1. Inspect swashplate for general condition, security of attachment, security of controls and push pull tubes
to swashplate levers. Move control stick in all directions (fore, aft, and laterally) and note freedom of op-
eration of swashplate gimbal bearings. Operate main rotor pitch control levers, and check swashplate
sleeve, swivel links, and scissor levers for freedom of operation. Check security of travel stops. Inspect
control plate, lateral and fore and aft horns for cracks.
2. Move cyclic and collective stick through full travel in all directions, checking for freedom of operation
and lost motion. Excessive lost motion (other than allowed by elongated hole in hydraulic cylinder valve
body) in the control system is unsatisfactory and should be eliminated.
3. Test operation of friction control on control sticks for proper operation. With friction released, check
cyclic and collective sticks for security, condition, and binding.
4. Inspect linkage of all control systems for security and condition of bearings. Replace YS112 rod ends
when axial play is over 0.030 inch or radial play is over 0.005 inch. Replace fabroid rod ends on main
rotor pitch links and control system when axial or radial play exceeds 0.012 inch.
5. Inspect all component parts of systems for security of mounting, freedom of operation and unobstruc-
ted full travel. Inspect shafts, bellcranks, and control push-pull tubes for surface damage, alignment, and
elongated bolt holes. Inspect bellcrank bearings and bolt for wear, binding, and lubrication. Inspect hydrau-
lic boost cylinders for leaks and security, light weepage is acceptable.
6. Inspect surface, radii, and welds of all support brackets for cracks, damage, and security of mounting.
POWER PLANT AND ENGINE COMPARTMENT

A. Perform Daily Inspection as specified in engine manufacturer's operators manual and the following items
1. Inspect engine for cracks, leaks, security and evidence of loose bolts and nuts.
2. Inspect baffles for general condition and security.
3. Inspect cooling fan blades for cracks, damage and alignment. Inspect fan belts and pulleys for general
condition, wear, cracks and breaks. Check adjustment of fan belts.
4. Inspect engine and sprag rubber mounts for cracks and deterioration. Check clamp bolts on engine Lord
mounts for security.
5. Inspect sprag mount rods and adapter for general condition, dents, cracks, damage, and security. Ex-
amine clevises and bushings for excessive wear.
6. Sprag safety cables - Replace any cables that show more than six wires broken in any one inch length.
If corroded or badly worn the cable should be replaced although the number of wires broken is less than
specified for replacement.
7. Inspect hot-air exhaust shrouds and carburetor hot-air control valve for cracks, general condition,
and mounting.
8. Inspect throttle, mixture, carburetor heat, and fuel shut-off controls for general condition and security.
Check controls for freedom of operation and full operating range.
9. Inspect all fuel, oil, hydraulic lines and hoses for general condition. Inspect for evidence of leaks, chaf-
ing, security and position of attaching clamps. Tighten or repair connections as necessary. Replace flex
lines, hoses and ducts if exterior shows signs of deterioration.
1-4
MAINTENANCE
POWER PLANT AND ENGINE COMPARTMENT Cont.

10. Drain fuel strainer, oil tank and fuel tank sumps, and carburetor drain. Check fuel and oil quantities.
11. Check general condition of engine compartment.
12. Inspect air cleaner when operating under dusty conditions. Clean filter by removing and tapping lightly
or using light air pressure applied to inside (hold nozzle 12 to 18 inches from filter). Replace air intake
filter at 25 hours if operating under extreme dusty conditions. Replace at 50 hours when operating under
moderately dusty conditions.
13. Replace filter element if manifold pressure shows drop due to filter clogging.
14. Inspect oil level in hydraulic boost control reservoir. Refill as necessary.
15. Check oil cooler for cleanliness of air passage.
TRANSMISSION
1. Inspect transmission case and drive assemblies for cracks, oil leaks, damage, and security of mounting.
Note
Oil leaks, rough operation in any drive assembly, or end play in tail
rotor or cooling fan drive is cause for immediate disassembly and com-
plete inspection. (Refer to Section IV.)
2. Inspect all fittings, plugs, oil lines, and temperature bulbs for leaks and security.
1. Inspect attachment brackets and pulley brackets for cracks, particularly at the weld area.
2. Inspect for security of attachment bolts, safetying, dents, and corrosion.
3. Inspect for freedom of operation through full range of travel.
4. Inspect fore and aft cable attachment fittings for security.
5. Inspect synchronized elevator control cables fore and aft, especially where running over pulleys or
through fairleads, for wear and broken wires. If three wires are broken in any area, replace cable. If cor-
roded or badly worn, cable must be replaced even though no broken wire is found.
TAIL ROTOR BLADES AND HUB ASSEMBLY

1. Check tail rotor blades for security of bonding, cracks, and scratches. If bonding shows any indications
of loosening, or cracks exist, blades must be replaced immediately.
3. Inspect pitch change linkage for wear, alignment, freedom of operation, and security.
4. Inspect tail rotor hub for general condition and security.

5. Inspect, metal tail rotor blades, for cracks, as follows: (See figure 1-27.)
a. The tail rotor grips in an area one inch inboard of the root end of the blade shell.
b. The area surrounding the rivets which attach the blade shell to the grip.
1-5
TAIL ROTOR BLADES AND HUB ASSEMBLY Cont.

c. Along the inboard six inches of the trailing edge of the blade shell.
d. If cracks are found in any location, or permanent deformation is found, the tail rotor blades must
be removed prior to further flight.
TAIL ROTOR DRIVE AND CONTROL SYSTEM

1. Inspect gear box for security of mounting and evidence of oil leaks.
2. Check for excessive heat after shutdown following engine run.
3. Check oil level in tail rotor gear box.
4. Inspect tailboom extension housing for cracks, dents, scratches, and security of attachment to structure.
Check end sleeve flange for any movement indicating spot weld failure.
5. Inspect drive shaft for general condition, dents, cuts, scratches, and evidence of fatigue. Inspect bear-
ing housings for cracks and security. If screws are loose, check for elongated holes. Inspect coupling taper
nuts for security.
6. Inspect tail rotor drive shaft bearings for general condition.
7. Inspect splined couplings of tail rotor drive for excessive play in splines.
8. Inspect universal joint for general condition and excessive wear. Replace joint if end play in needle
bearings exceeds 0.020 inch maximum.
9. It is mandatory that shafts which have cuts or scratches over 0.002 inch deep be replaced.
10. Inspect pitch change drum for security and freedom of operation. Inspect cables for wear and fraying
over pulleys, or through fairleads. Replace any cable that shows more than three wires broken in any one
inch length, limited to any two areas of any one cable. If corroded or badly worn, replace cable if number
of broken wires is less than that specified for replacement.
11. Inspect condition and security of turnbuckles, fairleads, and control rods. Operate control pedals,
checking for freedom of movement and full travel. Observe movement of blades while operating pedals,
(left pedal forward, leading edges of blades move outboard, right pedal forward, leading edge of blades
move inboard).
47-642-102METAL TAIL ROTORBLADE (REF)
47642-55
Figure 1-27. Tail Rotor Blade - Inspection Areas

1-6
MAINTENANCE
TAIL ROTOR DRIVE AND CONTROL SYSTEM Cont.

12. Check for axial or radialplay of pitch change control link bearings. If axial or radial play exceeds 0.015
inch in either rod end, replace rod end.
13. Inspect pedals and connecting push pull tubes for security and freedom of operation.
14. Check cables for attachment at turnbuckles, security, alignment through pulleys, proper tension, and
proper seating of ball ends in drum sockets. Inspect all pulleys and fairleads for security and excessive
wear; brackets for damage.

1. Inspect fuel tanks, straps, supports, and lines for general condition, evidence of chafing, and security.
2. Inspect cabin, center frame, and tailboom structure and fittings for security and damage.
3. Inspect landing gear according to type:
a. Skid type - Inspect skids and shoes for excessive wear; all parts for security, cracks, dents, kinks,
and corrosion; ground handling wheels for general condition and tire inflation; cross tubes for excessive
deflection. (Refer to Section X.)
b. Float type - Inspect floats for proper inflation, and all parts for security and damage.
4. Inspect vibration isolator for security and evidence of damage at points of attachment to tailboom.
INSTRUMENTS, ELECTRICAL,AND PITOT SYSTEMS

1. Inspect instruments for broken, cracked or loose cover glass, and condition of range and limit markings.
2. Inspect battery for evidence of spilled electrolyte, security of mounting, and general condition. Check
battery drain tube for unobstructed drainage.
3. Inspect general condition of all wiring, insulated tubing, and clips. Test operation of all switches and
circuit breakers. Check navigation and landing lights and rotating beacons for operation and security of
mounting.
4. Inspect generator and starter for security.

5. Drain static and pitot tubes at drain plug if water in system is suspected.
GENERAL
1. Remove all loose objects from helicopters (hand tools, rigging jigs, protractors, etc.), and remove
main rotor tie-down prior to run up.
2. Check that registration and airworthiness certificates are in their proper place in the cabin, and in
order. Check log book for being current.
ENGINE RUN-UP
Note
Engine and main rotor tachometer needles shall be synchronized at all
speeds greater than 1700 RPM with the collective control stick in the
full down position. Rapid application of collective stick or throttle be-
low 2800 RPM may cause centrifugal clutch slippage. The clutch will
be considered satisfactory if there is no slippage when hovering at
maximum gross weight with 3000 engine RPM. Clutch slippage under
these conditions shall be reason for clutch disassembly and inspection
(Refer to Section IV.)
1-7
ENGINE RUN-UP Cont.

1. Start engine and run-up in accordance with instructions outlined in Model 47G-2 Flight Manual.
OPERATIONAL CHECK
1. Check operation of instruments, fuel and oil pressure, cylinder head temperature, engine and transmis-
sion oil temperatures. Check fuel, oil, and hydraulic lines for leaks. Check operation of magnetos at 3100
RPM with collective pitch lever full down. Refer to Flight Manual for allowable magneto drop.
1-8
MAINTENANCE
& OVERHAULINSTRUCTIONS- - 50 Hour Inspection
50 HOUR INSPECTION
The 50 Hour Inspection consists of a complete daily plus the following

items:
1. Lubricate all components per Lubrication Chart (Figure 1-8.)
2. Power Plant inspection to be conducted per engine manufacturers operators manual.
3. Drain engine oil, inspect and clean oil filter at the end of first 25-hour operation and every 50-hours
thereafter. If metal particles are found, carefully evaluate to determine possible source. Further inspec-
tion shall be warranted with special emphasis on main rotor mast thrust bearing.
4. If A13965 Houdaille dampers are installed, check damper fluid level and timing.
Note
hours or more, the following inspection shall be performed
each 50 hours.
a. Prior to inspection, wipe clean the gimbal ring areas around the bores for the trunnion and pillow block bearings
(eight places). Using a 3X magnifying glass, thoroughly inspect the gimbal ring bearing bores for cracks in the areas
adjacent to:
(2) Trunnion seals.
Rev. 3 1-9/1-10
MAINTENANCE INSTRUCTIONS
& OVERHAUL 100 Hour Inspection
100 HOUR INSPECTION
GENERAL
1. Accomplish a complete daily inspection, 50-hour inspection and the inspection outlined below:
MAIN ROTOR
1. Inspect dynamic stop cable assemblies for proper adjustment.
POWER PLANT AND ENGINE COMPAPTMENT

1. Power plant inspection to be conducted per engine manufacturers operators manual.
2. Inspect all accessible nuts and bolts for tightness and security.
3. Inspect intake and exhaust systems for security, cracks, damage, and evidence of leaks.
4. Check cooling fan for security of mounting.
5. Check generator voltage output.
6. Lubricate cam box.
7. Remove and clean fuel strainer element.
Note
When operating in dusty conditions, inspect hydraulic system filters in

pressure line and reservoir vent line at 50-hours. Clean pressure line
filter element and replace vent filter elements as necessary. Under
normal conditions, inspect and clean or replace element at 100 hours.
CONTROLS
1. Disconnect control rod from control ring horns, and clean horns with suitable cleaning solvent. Inspect
horns with 10 power magnifying glass to determine if a crack or cracks exist. If cracks are found, remove
swashplate and replace immediately.
2. Inspect taper bushings and bolts in lateral jackshaft at transmission for security.
3. Check CSC870-5dampers for security, leaks, and proper timing.
TRANSMISSION
1. Inspect through bolts and transmission to adapter plate bolts for security and tightness.
TAIL ROTOR SYSTEM

1. Inspect female coupling at transmission for end play (not required if 368SI is accomplished). If end play
exists remove boot and forward shaft, and inspect teeth and splines for wear.
2. Install the T100373 rigging jig check complete tail rotor linkage for play, not to exceed 1 1/2 degree.
Disconnect pitch links and manually turn each blade grip to check freedom of operation and for indication
3. Remove and inspect delta hinge bolt for wear. Check delta hinge bearings for smooth operation by man-
ually rotating inner races.
1.11

4. Drain and refill gear box. Lockwire all plugs.
a. Metal particles in oil is cause for immediate disassembly of gear box for complete inspection.
5. Inspect cable quadrant and connecting push pull tubes for security and freedom of operation. Check se-
curity of quadrant stops and cable attachments and guards. Check cable tension.
1. Check elevator control cables for proper tension.
2. Inspect elevator support brackets to tailboom for cracks.
STRUCTURE BODY AND TAIL BOOM

1. Inspect cabin enclosure and window area, for cracks, scratches, and transparency. Inspect door hinges
for security. Test operation of door latches and emergency release, if installed.
2. Inspect seats and safety belts for condition and security of attachment. Test operation of catches on
safety belts. Inspect condition and security of first aid kit and fire extinguisher, if installed.
3. Inspect all structure tubing and fittings for cracks, cuts, bends, corrosion, distortion, and damage.
Inspect protective coating on all tubing and refinish if necessary.
4. Inspect center frame tubing for chafing. Cuts or chafing less than 0.008 inch deep may be dressed out
with crocus cloth to provide a radius to relieve stress. If tubes are cut deeper than 0.008 inch repair ac-
cording to Federal Aviation Authority Manual No. 18.
INSTRUMENTS, ELECTRICAL AND PITOT SYSTEMS

1. Inspect battery cable terminals for condition, security, and corrosion.
2. Inspect battery relay, voltage regulator, and electrical connections for condition and security.
3. Inspect all electrical wiring, terminals and cannon plugs for condition, corrosion and security.
4. Inspect all instrument lines for leaks and security. Inspect condition of flex lines. Replace when ex-
terior of lines show signs of deterioration.
5. Inspect pitot tube and static holes for condition and freedom from foreign material.
1-12
MAINTENANCE
& OVERHAULINSTRUCTIONS 600 Hour Inspection
600 HOUR INSPECTION
GENERAL
1. Procedures outlines for 600 hour inspection of these components consist of manual operation of assem-
blies through all possible movements while observing carefully for any deviation from normal action, feel,
or appearance. Intent is to determine serviceability for continued operation or need for corrective action.
When doubt exists, apply more thorough inspection methods as necessary to reveal true condition.
2. Accomplish complete daily, 50-hour and 100-hour, inspection requirements in addition to inspection
outlined below.
3. Overhaul requirements for engine and accessories shall be in accordance with engine manufacturer's
instructions.
5. Refer to pertinent paragraphs and illustrations in Maintenance and Overhaul Instructions for details
of specified clearances, torque valves, tolerances, or methods of adjustment.
MAIN ROTOR HUB

1. With pitch control links and equalizer links disconnected, manually rotate each blade grip on yoke spindle.
Check freedom of operation and for indications of bearing roughness or wear.
2. Tilt rotor on spanwise and chordwise axis, checking gimbal ring bearings for any binding, excessive
play, or indications of roughness or wear.
3. Investigate and correct any faulty condition.
MAST AND CONTROLS

1. Disconnect damper links from stabilizer bar. Manually check freedom of bar movement throughout
travel, and for indications of roughness or wear in pivot bearings.
2. Manually check for proper end play at stabilizer bar trunnions.
3. Disconnect controlrods from swashplate horns. Disconnect swivel links. Grasping outer ring, rotate and
tilt swashplate all directions to check freedom of operation and for indications of roughness or wear in
carrier bearings, gimbal pins and bearings. Manually check for excessive vertical or horizontal play in
bearings, bushings, or pins.
4. Manually check swivel links and scissor levers for freedom of operation and condition of bearings.
5. Visually inspect all accessible areas of mast for indication of damage. Raise swashplate support and
transmission cap sufficiently to rotate and carefully check main rotor mast bearing for smoothness of
operation, excessive radial and/or axial looseness and verification that retaining nut is properly secured.
7. Helicopters having 5/16 inch pivot bolts and swivel link bolts, remove from scissor levers and inspect
for wear.
a. If dimension in any area of bolt is less than 0.3090 inch, replace bolt.
b. Inspect diameter of bolt holes in bracket for wear. If dimension if 0.3175 or more, bushings must
be replaced to restore dimension 0.3120 inch plus or minus 0.0005 inch.
1-13
600 Hour Inspection & OVERHAULINSTRUCTIONS
MAINTENANCE
TRANSMISSION
1. With transmission removed, disassemble to extent required for following inspections:
a. Remove and disassemble freewheeling unit, toinspect allparts for wear and damage. Inspect springs
for wear and correct radii, inspect spring retainer plates, for wear and cracks, replace as necessary.
Check for free rotation and proper locking during and after reassembly.
b. Remove clutch spider and shoe assembly. Visually inspect condition of shoe linings, drum, and
spider bearings. Manually and visually check for excessive wear of pivot pins and bushings.
c. Without further disassembly, unless faulty conditions are found, inspect all other sub-assemblies
for acceptable general condition, gear tooth wear patterns, and freedom of bearing operation.
d. Replace shear bolt (Part No. 47-620-485-1) in upper spider assembly.
3. Remove and clean oil strainers.
ENGINE MOUNT
1. Magnaflux arc-welded mount (figure 1-24) Part No. 47-612-135-1 N13, (Seial No. A16-41 and subsequent)
at 600, 1200, 1800, and 2400 hours as follows:
2. Recommended Acceptance Standard for arc-welded mount, Part No. 47-612-135-1 N13 (Serial No. A16-
41 and subsequent):
a. Removal of indications i permitted by light sandblast, filing or grinding, provided that not more than
10 percent of thickness of welds or parent metal is removed. Rework areas must blend smoothly with ad-
jacent metal.
b. Indications are often observed which follow edge of weld bead. These are usually caused by entrap-
ment or change in section primarily due to weld bead, and are not considered cause for rejection or rework,
provided they do not extend into parent metal.
c. Indications between weld metal and parent metal exposed by machining ends of bearings or lugs
are acceptable, provided indication does not extend into weld or parent metal.
d. Indications in parent metal tubing are acceptable and need not be removed provided localized re-
moval (as in paragraph a. above) indicates depth of defect does not exceed 10 percent of original wall thick-
ness. Indications of seams, grooves, tears, burrs, laminations, slivers and pits within 1/2 inch of any weld
must be removed. Presence of indications not removable within 10 percent allowance shall be cause for
rejection.
ADAPTER PLATE
1. Visually inspect adapter plate for general condition, security of studs and oil scoop, and excessive wear
at trunnion pin holes.
POWER PLANT
1. Inspect engine and accessories in accordance with engine manufacturer's instructions. When engine is
changed or overhauled, clean and flush oil cooler and lines. Check adapter plate hold-down studs for spec-
ified projection at minimum torque.
2. Inspect for general condition, free rotation and support for security.
3. Inspect fan for general conditionand free rotation; support for security.
1-14
MAINTENANCE
POWER PLANT Cont.

4. Check adjustment of carburetor controls.
5. Inspect generator for general condition of brushes, brush holders, springs, and commutator. Manually
check freedom of rotation and for indication of bearing roughness or wear.
6. Test operation and adjustment of voltage regulator and relays.
7. Drain fuel tanks, remove and clean finger screens.
8. Check reading of fuel quantity indicators with a measured amount of fuel in tanks.
TAIL ROTOR SYSTEM

1. Disconnect external shaft sections at splined couplings and universal joint. Clean and inspect splined
couplings on shafts and transmission drive assembly for wear and general condition.
2. Visually inspect gear box and extension shaft assembly. Manually turn shafts to check for freedom of
operation, normal feel of gear meshing and backlash, and indications of bearings roughness or wear.
Closely inspect gear box oil, during change, for metal particles for foreign matter.
3. Conduct rigid visual inspection of tail rotor blades for dents, nicks, scratches, or other damage.
HYDRAULIC FLIGHT CONTROLS

1. Make thorough visual inspection for cracks in all parts of cylinder support and bellcrank assemblies,
including attachment brackets.
2. Check for excessive radial play of cylinder trunnions in bushings of supports and bellcranks.
3. Test system operating pressure, adjust relief valve as necessary.
1-15/1-16
200 HOUR INSPECTION
GENERAL
2. Accomplish complete daily, 50-hour, 100-hour and 600-hour inspection requirements in conjunction
with those outlined below.
instructions.
5. Refer to pertinent paragraphs and illustrations in Maintenance and Overhaul Instructions for details
of procedures, specified clearances, torque values, tolerances, and methods of adjustment.
6. Inspect all bearings for smooth, free operation before and after assembly. Checkparts dimensionally
MAIN ROTOR
a. Inspect grip fillet (Refer to figure 1-22). The inboard radius and bottom of the fillet must have a
smooth finish and be free of nicks or tool marks.
Yoke (See figure 1-23) M

Hub Core M
Grip Adapter Nuts (Figure 1-15) M
Drag Braces and Bolts
(Clevis - See figure 1-17) M
c. Blade alignment.
MAST AND CONTROLS

1-17
MAST AND CONTROLS Cont.

run-out with dial indicator. Check security of mastplug in lower end of mast by observing match-mark and
checking width of gap between mast and plug flange for comparison with dimension stamped on plug plus
or minus 0.005 inch to dimension stamped on plug.
*Control Plate Z
Mast M
Stabilizer Bar Outer Frame M
Stabilizer Bar Center Frame Z
Ring Assembly (Swashplate-Split Gimbal) M (Refer to acceptance
Standards)
*Bushings or lines must not be removed to Zyglo control plate and support.
FLIGHT CONTROLS
1. Zyglo inspection fore-and-aft cyclic control bellcrank bracket mounted on front of transmission.
TRANSMISSION
b. Mast driving flange: All splines and Surfaces for burrs or surface damage; shear bolts for any
damage. Replace shear. bolts, Part No. 47-620-485-1.
c. Inspect retainer of freewheeling unit, for wear, cuts, and fracture. Inspect rollers and roller slots
in ring gear, for flat spots, burrs, brinelling and damage. Inspect springs for wear and correct radii, in-
spect spring retainer plates, for wear and cracks, replace as necessary, check parts dimensionally.
e. All bearings, rollers, races, and cages for smoothoperation and freedom from wear or damage.
f. Clutch: Shoes for glazed or excessive worn linings and worn pins or bushings; drum for dimen-
sional tolerances, out-of-round, scoring, or evidence of excessive heating. (Blue on drum is not cause for
rejection.)
2. Inspect following parts by Magnalfux or Zyglo methods as indicated. M = Magnaflux. Z = Zyglo.

Transmission Case (ALL sections) Z
Upper Ring Gear M
1-18
MAINTENANCE
TRANSMISSION Cont.
Upper Sun Gear M
Pinion Pins M
Pinion Gears M
Driving Flange M
Shear Bolts M
Lower Sun Gear M
Clutch Pivot Pins M
Pulley Retaining Bolt and Cones -
Fan Drive M
ADAPTER PLATE
2. Inspect following parts by Magnaflux or Zyglo methods as indicated. M = Magnaflux, Z = Zyglo.

Trunnion Pins M
POWER PLANT
3. Remove and magnaflux index plate, Part No. 47-669-118 or 47-669-801. (Refer to acceptance standard.)
4. Inspect engine mount as specified in 600 and 1200 hour inspection instructions. (Refer to acceptance
standards or for mount Part No. 47-612-171 use acceptance standards, figure 1-25.)
ENGINE AND COOLING SYSTEM


1-19
Section I (Part 3) BELL HELICOPTER COMPANY - Model 47G-2
POWER PLANT CONTROLS

1. Inspect throttle, mixture and fuel control systems.
ENGINE MOUNT
(See figure 1-25.)
a. Inspect arc-welded mount Part No. 47-612-171 every 1200 hours. (See below for acceptance stand-
ard.)
ITEM O.D. WALL THICKNESS
1. 5/8 .035
2. 3/4 .035
3. 7/8 .065
4. 5/8 .065 47612-6
Figure 1-28. Tubing Chart 47-612-171 Engine Mount

1-20
MAINTENANCE. OVERHAUL INSTRUCTIONS 1200Hour Inspection
ENGINE MOUNT Cont.

Note
Do not immerse engine mount in paint stripper. If removing paint,

apply stripper with brush.
2. Procedure: Inspect mount by following steps, using wet continuous method, applying 750 amperes DC or 500
amperes AC. Determine length of any indication by residual method.
contact head, apply current, and inspect bearing areas only.
d. Magnetize upper frame, placing one corner against each contact plate across narrow end. Inspect
each end of this manner.
e. After completing inspection, demagnetize mount, check with compass or pocket field indicator.
3. Recommended acceptance standard for arc-welded mount, Part No. 47-612-171:
a. Cracks are not acceptable regardless of size or location.

b. Removal of indications is permitted by light sandblast, filing or grinding provided that not more than
ten percent of the thickness of welds or parent metal is removed. Rework areas must blend and merge
smoothly with adjacent metal.
c. Indications are often observed which follow the edge of the weld bead. These are usually caused by
entrapment and/or change in section, primarily due to the weld bead, and are not considered to be cause
for rejection, or rework provided the indication does not extend into the parent metal.
d. Indications between the weld metal and parent metal exposed by machining the ends of bearings or
lugs are acceptable provided the indication does not extend into weld or parent metal.
e. Indications which are caused by change in section are acceptable regardless of length or location.
f. Indications in parent metal tubing are acceptable and need not be removed provided localized re-
moval, using techniques as in paragraph (b) above, indicates that the depth of the defect does not exceed
ten percent of the original wall thickness. Indicationsof seams, grooves, tears, burrs, laminations, slivers,
and pits within 1/2 inch of any weld must be removed. Presence of indications not removable within ten
percent allowance shall be cause for rejection.
TAIL ROTOR SYSTEM

TAIL ROTOR HUB
2. Inspect following parts by magnetic particle method: I
Hub Yoke M
Pitch Change Head M
(Rev.1) 1-21
1200Hour Inspection MAINTENANCE & OVERHAUL INSTRUCTIONS

TAIL ROTOR GEAR BOX
2. Magnetic particle (Code M) or fluorescent penetrant (Code F) the following parts as indicated.
Code
Gear Box Housing (all parts) F
Gears (matched sets) M
3. During and after reassembly, perform following inspections:
b. Matingof marked gear teeth, proper contact pattern, and specified backlash.
DRIVE SHAFTS, UNIVERSAL JOINT AND EXTENSION SHAFT
1. Remove and disassemble all sections of tail rotor drive shaft, and extension shaft and housing, to inspect all parts
for wear, corrosion, or damage.
2. Magnetic particle (Code M) or fluorescent penetrant (Code F) the following parts as indicated.
Code
Extension Housing Tube and Yoke F
Shafts (all sections)(fwd, main, aft M
and extension)
a. Procedure - Magnetic particle inspection.
Note
Each shaft shall be inspected by the following procedure using the wet
continuous method.
(1) Magnetize the shaft by passing 1000 amperes dc current longitudinally through the shaft. Inspect the
shaft completely for indications.
(2) Place the shaft in the coil such that the long axis of the shaft is 90 ° to the direction of current flow
through the coil. Magnetize the shaft using 5000 ampere turns magnetizing force with DC current. Inspect the shaft
100 percent for indications in one foot increments.
b. Acceptance Criteria.
(1) Magnetic indications interpreted as cracks, seams, laps, or shuts are cause for rejection, i.e., imperfections
which are or have been voids.
(2) Magnetic indications of stringers or non-metallic inclusions will be acceptable if they are within the
following limits. Indications less than 1/64 inch in length are not considered ratable. On rejectable shafts all ratable
inclusions and their positions will be noted.
1-22 (Rev. 1)
Model 47G-2 BELL HELICOPER COMPANY Section I (Part 3)
TAIL ROTOR SYSTEM Cont
(a) Indications of inclusions parallel to the longitudinal axis of the shaft (±15 ° ) are acceptable provided
they do not exceed one inch in length. The total length of multiple indications within any six inch length of shaft shall
not exceed three inches.
(b) Indications oriented at an angle of more than 15° off the longitudinal axis shall be rejected if their
length is 1/2 inch or more.
c. After completion of the inspection, demagnetize the shaft and check with a field indicator to assure removal
of the residual field.
BODY AND TAIL BOOM
1. Inspect visually for cracks, dents or bends, and security of sealing screws or rivets in all structural tubing.
Note
b. Remove collective pitch control tube between power cylinder and idler.
c. Remove lateral cyclic control tube between power cylinder and torque tube assembly. Remove control tube
between torque tube assembly and swashplate.
d. Remove fore and aft cyclic control tube between power cylinder and lever. Remove control tube between lever
and swashplate.
2. Remove end fitting from control tubes as follows:
a. Mark fittings and tube ends to ensure fitting is assemblied in original position.
b. Remove both end fittings by carefully drilling off rivet heads and drive out rivets. Do not enlarge rivet holes
in tube or fitting.
(Rev. 1) 1-23
Note
a. Remove all paint and primer from internal surface of control tubes, using steel wire brush on steel control tubes
and bristle brush on aluminum control tubes, with Methyl-Ethyl-Ketone.
Note

tive film.
b. Add three parts of thinner (Toluene TT-T-548) to four parts of zinc chromate primer, by volume, and mix
thoroughly.
c. Apply primer to inside of control tubes, coat entire internal surface while rotating control tube. Allow excess
primer to drain. Wipe excess from fitting area, leaving a light coat. Allow six hours minimum drying time prior to
further finishing.
tionally.
a. Dissolve sixteen ounces of aluminum pigment (TT-P-320A) paste (Type II Class A) or powder (Type I Class A)
in a small amount of thinner (TT-T-266).
6. Apply aluminum lacquer to inside of control tube, coat entire internal surface while rotating control tube. Allow
excess lacquer to drain. Wipe excess from fitting area, leaving a light coat. Allow 2 hours before installing end fittings.
Note
Rod ends, fittings, and clevisesmust be plated or treated; and must not
7. Hollow ends may require refilling. If adhesive filler is damaged when the rivets were driven out, remove old filler
and fill with hard epoxy adhesive Metal Set A4 or equivalent. Allow adhesive to cure 24 hours before drilling holes.
Note

8. Apply proseal 890-B2 to I.D. of control tubes and O.D. of end fittings, at faying surfaces, before assembly. Install
end fittings in control tube.
9. Dip MS20613-5P rivets in proseal and install. MS20613-6P rivets (oversize) may be used. Replace any steel control
tube that requires rivets larger than MS20613-6P rivets.
1-24 (Rev. 1)
10. Seal each end of control tube assembly and around rivets with proseal 890-B2 sealant. Apply sealant as shown on
figure 1-23A, control tube sealing (typical). Cure sealant at room temperature for 72 hours.
Note

(Rev. 1) 1-25/1-26
MAINTENANCE
& OVERHAULINSTRUCTIONS Special Inspection
SPECIAL INSPECTION

damage.
1. Inspect skids and cross tubes for cracks and excessive deflection.
2. Inspect structure and center frame. Inspect all structuraltubing for cracks, bends, distortion, and dam-
age. Check security and condition of bolts that attach the tail boom to center frame.
3. Carefully examine all flight control push-pull tubes, hydraulic boost system (if so equipped), link-rods,
bellcranks, and cables. Inspect rod-ends and bellcrank bearings.
b. Universal joint.

5. Inspect main rotor dynamic stop cables. Remove and inspect static stop. If damage to the static stop is
evident, remove and disassemble main rotor. Use magnetic particle or fluorescent penetrant process to inspect all
parts. Visually inspect bearings.
7. Remove and disassemble main rotor mast. Use a magnifying glass and inspect thrust bearings for creased
or banded balls.
If the mast thrust bearings was damaged, remove and disassemble

transmission completely. Inspect carefully and replace all damaged
parts.

Accomplish this inspection after the main rotor has been stopped suddenly by striking any object including
tail boom while rotating freely (not being driven by the engine). While the damage to the main rotor blades
will undoubtedly be obvious, component parts of the main and tail rotor system and engine may have sus-
tained from minor to severe damage.
Rev. 3 1-26A

1. Remove and disassemble main rotor. Examine main rotor blades.
Note
If condition of blades is such that repairs cannot be made in accor-

dance with the blade repair section of this manual return blades to
an approved repair station for disposition.
2. Visually inspect stabilizer bar outer tube for bends; also examine welded joint at inboard end of outer
bar.
3. Use a magnifying glass to inspect mast thrust bearings for damaged balls.
c. Trunnion pins.
e. All transmission parts (if condition exists as described in step 2.)
5. Inspect engine sprag mount installation. Inspect sprag mount safety cables and fittings. Inspect tail
rotor drive shaft and universal joint. If the tail rotor drive shaft is broken or twisted, remove, disassemble
and inspect the following:

-c. Tail boom extension.

Note
If the tail rotor drive shaft is satisfactory and the transmission

turns freely, remove tail rotor drive assembly. Inspect assem-
bly, and drive gear carefully.
6. Carefully examine all flight control system push-pull tubes, hydraulic boost system (if so equipped),
link-rods, bellcranks and cables. Inspect rod-end and bellcrank bearings.
7. This criteria is applicable to 47-120-252-7 grips only. When blade impact is violent to the extent that the drag
brace is sheared and the aft side of the blade butt contacts the aft outboard side of the hub grip, it is mandatory
that the complete hub assembly be replaced.Also the mast controls assembly and the mast must be inspected by the
magnetic particle or fluorescent penetrant process.Check for concentricity. Visually inspect bearings, dynamic stop
cables and static stop.
8. This criteria is applicable to 47-120-135-3 and 47-120-252-1 grips only. Grips must be replaced if the main rotor
hub assembly has been subjected to sudden stoppage of the rotor at operating RPM. They must also be replaced on a
main rotor assembly that has incurred damage to the extent that necessitated replacement of the main rotor blade
due to chordwise cracks beyond the limits defined in Section II.
1-26B Rev. 3

Accomplish this inspection immediately after the tail rotor has been stopped suddenly by striking an object
undoubtly be obvious, component parts of the system may have sustained from minor to severe damage.
Note
If metal tail rotor blades have struck water, at near operating rpm;
power on or power off, they must be scrapped even through there is
no visible damage to blades.
Note
Return blades to the factory for inspection if their condition is

questionable.
installation. Inspect all coupling pins for damage and holes for elongation.
Note
If the Tail Rotor Hub has been subjected to shock loading through
the Tail Rotor Blades to the extent the Tail Rotor Blades require
replacement or any part of the Tail Rotor Drive System is dam-
aged, the hub must be replaced.
If all sections of drive shaft are satisfactory remove drive assem-

bly from transmission and inspect shaft for run-out and gear teeth
for damage. Check run-out of rotor shaft. Check gear box for free-
dom of operation and proper backlash of gears.
3. If the tail rotor drive shaft or universal joint is broken or twisted, remove, disassemble and inspect the
following:


Accomplish this inspection immediately after the main rotor has been stopped suddenly by striking an ob-
ject while being driven by the engine.
Note
Perform the same inspection as for "POWER OFF" and add the
following:
wheeling parts.
Rev. 3 1-26C
SUDDEN STOPPAGE-TAIL ROTOR-POWER OFF Cont.

2. Zyglo inspect adapter plate and Magnaflux trunnion pins. Carefully examine all flight control system.
3. Magnaflux inspect engine mount.

1. Inspect tail rotor and tail rotor drive systems in the same manner as for "POWEROFF" and in addition
Magnaflux the drive shafts and gears in the tail rotor gear box. Zyglo inspect the blade grips.
Note
If the Tail Rotor Hub has been subjected to shock landing through
the Tail Rotor Blades to the extent the Tail Rotor Blades require
replacement or any part of the Tail Rotor Drive System is dam-
aged, the hub must be replaced.
MAIN ROTOR OVERSPEED

Main Rotor overspeeds in excess of 360 rpm, but less than 400 rpm, inspect main rotor blades for cracks,
dents, loose drag brace bolts, loose stainless steelleading edges, loose tip plates and blisters. Rotor over-
speed in excess of 400 rpm, requires the removal of the blades and a comprehensive inspection performed
by an authorized rotor blade overhaul station.
RPM-TACHOMETER NEEDLE SEPARATION

When the Engine Tachometer needle advances beyond Rotor Tachometer needle under power, "Engine over-
speeds beyond Rotor" the mast drive flange shear screws MUSTbe inspected, for offset shearing. Check
shear screws by inserting a 3/16 inch drill into head of shear screw, if drill cannot be inserted, remove
shear screw and check O.D. for offset shearing. If any indication of shearing is evident, all shear screws
MUST be replaced.
1-26D Rev. 3
MAINTENANCE & OVERHAUL INSTRUCTIONS Mandatory Retirement Schedule
WARNING

ITEM PART NUMBER REPLACE AT
MAIN ROTOR SYSTEM
Main Rotor Grips 47-120-252-7 2500 Hrs.

(Metal Blades)
Hub Yoke 47-120-177-1 3600 Hrs.
Mast 47-130-114-11 Unlimited
Main Rotor Blades (Metal) 47-110-250-13 3000 Hrs.
TAIL ROTOR SYSTEM
Tail Rotor Blades (Metal) 47-642-102 All dash numbers 600 Hrs.
Blade Grip Retaining Bolts 47-641-052-1 300 Hrs.
Blade Grip Retaining Bolts 47-641-052-3 or -5 600 Hrs.
Hub Yoke 47-641-025-1 1200 Hrs.
Hub Yoke 47-641-057-1 1200 Hrs.
Hub Yoke 47-641-025-7 or -9 2500 Hrs.
Hub Yoke 47-641-057-7 or -9 (except as listed below) 2500 Hrs.
N29-1246 thru N29-1266 400 Hrs.
N29-1298 thru N29-1452 400 Hrs.
N29-10453 thru N29-10488 400 Hrs.
N29-10501 thru N29-10525 400 Hrs.
Pitch Change Bearing 47-641-146 (R-4-AF4) 100 Hrs.
Pitch Change Bearing SIRP 100 Hrs.
Pitch Change Bearing 7R4AXIC 100 Hrs.
Pitch Change Bearing 47-641-131-1 600 Hrs.
POWER PLANT
Fan Belts (Matched Sets) 47-661-041 (All dash numbers) 600 Hrs.
Engine Mount (gas or arc welded) 47-612-135-1 2500 Hrs.
Engine Mount 47- 612-171- All Dash Numbers 2500 Hrs.
TRANSMISSION
Shear Screw 47-620-485-1 600 Hrs.
(Rev. 4) 1-27/1-28
Models 47D-1, 47G & 47G-2 BELL HELICOPTER COMPANY Section II (Part 1)
Section II- Part 1

Main Rotor System
2-1. MAIN ROTOR SYSTEM. (Applicable for all linkage which interconnects grips. Rotor is mounted
Model 47D-1, 47G, and 47G-2, thru Serial No. 2453.) on the mast through a splined, universal type gimbal
ring from which the hub yoke is suspended. Dynamic
2-2. DESCRIPTION. The instructions contained in stop cables connect the hub to the stabilizer bar for
this section of the handbook provides the mechanic compensating action in abrupt maneuvers or gusty
with instructions for maintenance, overhaul and ad- winds.
justment of the main rotor and mast controls in-
stallation necessary to maintain the helicopter in 2-5. TROUBLE SHOOTING- MAIN ROTOR INSTAL-
flying condition, with exception of rigging which is LATION. The following outline lists conditions which
covered in Section VII. may be encountered in flight test after installation of
main rotor. Before making adjustments, carefuldiag-
2-3. MAIN ROTOR INSTALLATION. (Figure 2-1.) nosis by pilot and mechanic is recommended, since
it is sometimes difficult to distinguish between simi-
2-4. DESCRIPTION. The main rotor installation on lar indications of unlike conditions. Also recommend
the Model 47 helicopters is a two blade, semi-rigid any adjustments be made in small increments, and
type. Blades are constructed of laminated wood clearly recorded for reversal if effect is wrong.
covered with lacquered fiberglas cloth and fitted
with metal reinforcing plates for attachment to the
hub. Blade grips are mounted 180 degrees apart on Vibrations occurring once per revolution of the main
machined spindles of a one piece forged steel yoke. rotor (slow enough to count) are termed 1:1 vibrations.
Pitch control of the blades is provided through link- Direction, vertical or lateral, in which they are felt
age attached to horns on the grips, and equalizer by crew is significant in determining cause.
47100-2
Figure 2-1. Main Rotor Installation

2-1
Section II (Part 1) BELL HELICOPTER COMPANY Models 47D-1, 47G & 47G-2
MAINTENANCE
Vibrations occurring twice per revolution of main Indication Probable

rotor (too fast to count) are termed 2:1 vibrations. of Trouble Cause Remedy
Direction is not significant.
(b) Bumping See (b) under
High frequency vibration, or buzz, does not originate in maneuvers 1:1 Lateral
from main rotor.
Collective Incorrect Adjust counter-
Indication Probable Remedy pitch control counterweights
of Trouble Cause Remedy creeping in
creeping in weights
weights
normal cruise
1:1 Lateral
vibration Rotor RPM Minimum Adjust both
high or low pitch blade pitch control
(a) In hover or Spanwise out- Dynamically in autoroation angle incor- rods
forward flight of-balance balance with rect
tape
Erratic Rotor un- Sweep both
Chordwise Dynamically nudging of stable on blades aft
out-of-balance balance by cyclic con- long axis
sweeping blade trol stick
"Hub rock" Adjust equalizer

links 2-6. BALANCING - MAIN ROTOR.
(b) Bumping One dynamic Rig dynamic stop
in abrupt stop cable too cables. (Section a. Rotor can be balanced on or off the helicopter.
maneuvers short. (2:1 if VII.) If removed, place rotor on stand, Tool No. 47-976-
both cables 002-1-T203. If not removed, park helicopter on level
short) surface in still air, and disconnect pitch control link
rods from pitch horns and dynamic stop cables from
Sprag mount Readjust sprag stabilizer bar. Secure blades in low pitch position
weak or one mount system by fastening counterweights together with a length of
safety cable or replace parts. lockwire around counterweights together with alength
too short. (Section V.) of lockwire around counterweights shafts belowweights,
(2:1 if both to give blades approximately a five degree pitch
sides) angle.
1:1 Vertical b. In following checks, repeat all level readings for

vibration (or verification before making corrections. If rotor fails
bounce) to return consistently to same position, this is prob-
able indication of excessive friction in gimbal bear-
(a) In hover Rotor out-of- Adjust trim tabs ings for which corrective action is required. Gimbal
and forward track bearings should not be pressure lubricated just prior
flight to balance checks.
(b) In forward Climbing Compare high and c. Balance corrections should not be attempted on a
flight but not blade low speed track. rotor immediately after it has been standing exposed
hover Adjust in damp weather. If resulting vibration is not too
severe, one or two hours flight or operating time
2:1 Vibrations is recommended to dispel effects of moisture before
checking balance.
(a) In hover Mast mis- Adjust sprag
or forward aligned mounts. (Section d. Check spanwise balance with small spirit level
flight V.) placed on upper surface of hub yoke, as nearly as
possible on mast center line. Tilt rotor slightly, re-
Excessive Replace worn lease, and observe bubble as it settles.
play in parts. Preload
spray mount- lateral sprag e. Adjust spanwise balance as closely as possible
ing rods. (Section by adding weight in tip of blade which tends to re-
V.) main high (or by removing weight, if existing, from
low blade tip). Remove cotter pin and threaded plug
Elevator Adjust elevator to place any small weights, of total amount required,
buffeting cable tension. in recess provided in tip near leading edge. Reinstall
(Section VII.) plug and secure with cotter pin.
2-2
Note
During flight test, further adjustments

may be required for dynamic balance.
Follow steps i. and j. if required.
i. For dynamic spanwise balance, suggest use of

two-inch width masking tape as trial weight in cor-
recting 1:1 lateral vibration. Place one full wrap of
THIRD MARK j. For dynamic chordwise balance, sweep one blade

slightly aft by shortening drag brace. Index-mark
drag brace before adjustment. (Refer to step g.) Ad-
just in small increments, approximately 1/8 wrench
flat. Tighten lock-nuts and record adjustment. If rotor
flies rougher, return drag brace to original position
and try adjustment of opposite drag brace.
FIRST MARK 2-7. ALIGNING BLADES - MAIN ROTOR.
SECOND MARK a. Remove main rotor and place on suitable block

on stand or bench. Support each blade with tool No.
47-976-002-1-T202 so that it has no twist or bend.
(Figure 2-3.) Remove nuts and washers from pillow
block bolts, and lift gimbal ring and pillow blocks
Figure 2-2. Marking Drag Brace from hub yoke.
b. Insert a close tolerance bolt through link attach-

ment hole in each pitch horn. Place aligning bar,
Note T101747, chordwise on hub yoke with ends of bar
directly below bolts in pitch horns. Use C-clamps
On 47-110-120-30 blades, remove ballast to hold bolts in contact with bar. (Figure 2-4.)
cap from tip of blade, place weight in-
side cap and reinstall cap on blade. c. Attach a linen thread to one blade with masking
f. Place spiritlevel chordwise on hub yoke, rock hub

slightly and observe bubble as it settles.
g. Adjust chordwise balance by shorteningdragbrace
on light (high) side to sweep blade slightly aft. Adjust
in small amounts, tightening lock-nuts before repeat-
ing level reading. Index mark drag brace, before ad-
justment, by holding straight edge along drag brace
and place mark on each end of fitting and on wrench
flat (or point) on same line, so that original align-
ment can be restored if necessary. (See figure 2-2.)
CAUTION
Never sweep a blade forward of alignment

position. 47110-2
b. After static balancing, install rotor or reconnect

linkage. (Refer to paragraph 2-15.) Figure 2-3. Blades Supported to Remove Droop
2-3
MAINTENANCE
does not align with scribe marks on grips, (slightly and another to use tracking stick. With engine op-
touch scale) loosen lock-nuts on drag braces and ad- erating at cruise RPM, apply collective pitch until
just drag braces as necessary to bring thread and helicopter is almost ready to become airborne but
mark into alignment. Thread should be within 1/64 skids remain on ground. Hold steady in this condition
inch of each outboard grip mark. during tracking.
Note
CAUTION
Thread must be aligned with outboard
mark on blade grip within 1/64 inch; also,
any difference in alignment of blades If operator is not an experienced pilot, tie
must not exceed 1/64 inch (if one blade is helicopter down for this procedure.
forward 1/128 inch, opposite blade must
not be further aft than 1/128 inch). If e. Tracker should stand in clear view of pilot, facing
alignment is not within tolerance, remove direction toward which rotor turns, with stick slanted
rotor, align blades to hub and reinstall upward in same direction. (Figure 2-7.) At pilot's
main rotor. signal, carefully raise rubber tip to touch rotor near
blade tips.
e. Insert wire into inspection holes at end of drag
braces to make certain rod ends extend into tube far f. After engine
examine blade tips
enough to cover inspection holes. Tighten lock-nuts. tracking marks. Make any necessary tab adjustments
Recheck alignment. Torque blade attachment bolts before removing marks. (Refer to paragraph 2-9.)
1200 to 1400 inch-pounds.
2-9. ADJUSTING TRIM TABS - MAIN ROTOR.
f.f. Remove
Remove thread,
thread, mirrors
mirrors oror squares,
squares, C-clamp,
C-clamp, a. Check rotor track. (Refer to paragraph 2-8.) If
and aligning bar from assembly. Install gimbal ring
assembly. Connect links to pitch horns. Checkbalance blade tips are not equally marked, bend trim tab on
of main rotor. Install main rotor assembly. (Refer to low blade up 1/32 inches with
T101246fixture
paragraph 2-15.) marks, record adjustment and test fly helicopter.
Repeat procedure until vertical 1:1 vibration is no
2-8. TRACKING - MAIN ROTOR. This is a ground longer present in flight.
procedure, in which hovering flight is simulated, to Note
determine whether rotor blades followsame path or
which blade flies lower. In conjunction with flight test
reports, it is a basis for trim tab adjustments to Any lateral vibration should be corrected
eliminate 1:1 vertical vibration by correcting track. before attemptingadjust-
ment.
a. Tracking stick can be made from a light wooden
pole by attaching a short tongue of rubber 1/8 to 1/4
inch
inch thick,
thick, to
to extend
extend beyond
beyond one
one end
end of
of pole.
pole. Rubber Difference should
Rubber not be adjusted to not exceed
smooth 1/16 inch.
operation If rotor
within can-
this limit,
should be stiff enough to recover quickly after bend-
ing, but flexible enough to avoid marring blade.
Weaken stick by notching wood near rubber tip, for
break-away if struck by blade c. Remove pitch control link-rods, between mixing
levers and pitch horns on blade grips and check for
b. Coat rubber tip lightly with any suitable compound equal length as outlined in Section VII. Reinstall link-
which will leave visible but easily removed marks on
blades. Suggest red lead mixed with lubricating oil
to make thick paste.
d. Check hub yoke for chordwise level reading, with
c. For first track of new or overhauled rotor, trim swashplate and stabilizer bar set level. If yoke is not
tabs on both blades should be "at trail". This is a level, this is a faulty rigging condition and will pro-
neutral position, bent neither up nor down, aligned duce what is commonly called "hub rock". Level hub
with blade chordline. Use slotted side of T101246 chordwise by adjusting equalizer links as necessary.
fixture to straighten tabs as necessary. Check for
equal tab settings by holding unslotted straight-edge e. If any adjustment was required in steps c. and d.,
of fixture chordwise against underside of blade and repeat test flight and any necessary tracking cor-
.
tab, with graduated scale extending up past trailing rections.
edge. (Figure 2-6.) Sight along trailing edge of tab, f. If rotor now operates smoothly but trim tab
note scale reading at lower edge of tab as reference differential exceeds 1/16 inch, adjust linkage to in-
for subsequent adjustment. crease pitch of blade with high tab, relative to op-
posite blade. This procedure, as in step g. is com-
d. Tracking requires one man to operate helicopter monly called "grip rolling".
2-5
Section II (Part 1) BELL HElUCOPTER COMPANY Models 47D-1, 47G & 47G-2
MAINTENANCE
SUGGESTED MATERIAL
2 .125 x 2.1 x 9.6 x 24-T3

1 .040 x 1.4 x 9.1 x 24-T3
1 .040 x .6 x 1.9 x 24-T3
14 AN4216AD4 Rivets
-A|l .040 Min.

Trim Tab (Ref.)--. . 1 .040 M n.
.06R. 12 --- 9-1/2"
..----......
'... -.."" .... ·Rivets-
iveI \| Fi -" 3 / 4 "|-- -_9 5 Equal Spaces- -I|
1/2" _< I_/16 X

~/ ^^^ ,~ ~Posit
ionFor-' I"'- 1"-4-1/2-+ /.1-2R.-4
L/ Position For Measuring
ll BendingTab~d1Straight 1- 2-1/2 EdgeE /
Trim Tab Angle
47120-39
Figure 2-6. T101246 Trim Tab Fixture
Note h. Track by "climbing blade" procedure when appli-

cable. (Refer to paragraph 2-10.)
Total adjustment, in all procedures, of any
one equalizer link must not exceed two Note
lull turns from the prescribed lengthatin-
stallation. (Refer to paragraph 2-55.)Keep When satisfactory results cannot be ob-
these links as nearly equal length as pos- tained by these methods and those out-
sible. Check thread engagement at safety lined in trouble shooting, it is recommend-
hole in rod-ends when adjusting. ed that rotor be removed to recheck align-
ment balance, and rigging.
g. Disconnect either link from equalizer beam on
trailing side of blade with highest trim tab. Shorten i. When rotor is adjusted to smooth operation, con-
this link 1/2 turn for each 1/16 inch difference in tinue flight test to accomplish any necessary adjust-
trim tab setting. Lengthen either link on opposite ment of autorotational RPM, counterweights or blade
equalizer beam same number of half-turns. Lengthen stability.
pitch control link-rod attached to pitch horn of same
blade (with high trim tab) same number of half-turns. 2-10. ADJUSTING CLIMBING BLADE - MAIN
Reconnect all linkage. Bend highest trim tab down ROTOR. "Climbing blade" or "crossover" is an
according to amount compensated by linkage adjust- unusual condition in which a main rotor can be tracked
ment. Record all adjustments. Repeat tracking check and adjusted for smooth operation in hovering, but
and flight test. has a 1:1 vertical vibration in forward flight. When
suspected, be sure all normal procedures for track-
Note ing adjustment have been properly performed before
applying following procedure.
If 1:1 lateral vibration appears in flight
test after grip rolling procedure, it is a. Check track of blades with collective pitch con-
probably that pitch control rod became trol full down and engine at idle speed.
slightly too long due to thread differential
between this rod and equalizer link. Re- b. After stopping rotor, check for low blade as in-
adjust pitch control rod to set hub yoke dicated by low-speed tracking marks. This blade will
level. also be the "climbing blade" in flight. Reasoning:
2-6
MAINTENANCE
47710 31
Figure 2-7. Tracking Main Rotor Blades
Since this blade is able to climb into track at hover, c. If unstable condition is no longer present in next
it must be climbing further out-of-track in flight. test flight, no further adjustment is recommended. If
instability still exists, procedure may be repeated as
c. Bend trim tab on opposite blade up 1/32 inch. Ob- necessary but not to exceed total of five flats (ap-
serve for improved condition in test flight. Make proximately 5/6 turn of drag brace rod) from original
further adjustments as necessary for smooth operation alignment.
in flight, rather than for track in ground procedure.
Note
d. Limits of trim tab differential will be observed
and conditions made as in normal adjustment. (Refer Never sweep a blade forward of original
to paragraph 2-9.) alignment position.
2-11. SWEEPING BLADES - MAIN ROTOR. Thefol- d. Adjust counterweights, if necessary due to changed
lowing procedure can be used to improve an unstable collective forces. (Refer to paragraph 2-13.)
condition of the main rotor. This condition can be
recognized in flight as an erratic nudging of cyclic 2-12. ADJUSTING AUTOROTATION SPEED - MAIN
control stick. Do not use this procedure before initial ROTOR. Followingprocedures are for final adjustment
blade alignment and check flight have been accom- of low pitch blade angles to obtain prescribed rotor
plished. RPM in autorotative descents. These tests should be
made after tracking and trouble shooting procedures
a. Index-mark each drag brace before making any have been accomplished.
adjustment. Hold a straight edge along trailing side
of brace to place pencil marks (non-carbon) on each a. If any adjustments have been made on pitch con-
end and on hexagonal shoulder of tube. trol linkage, check low pitch blade angle before auto-
rotational flight. (Refer to Section VII.)
CAUTION b. Test flight should provide information on the
following:
Do NOT mark with scribe or punch. 1. During first flight after rigging collective pitch
system, check main rotor RPM in autorotation. Gross
b. Loosen lock-nuts on one drag brace and shorten weight will effect autorotation RPM so that it should
by turning rod until mark on hexagonal shoulder is be adjusted in the configuration and gross weight at
1/2 wrench flat from alignment with marks on end which the helicopter will be operated. Make an auto-
fitting. Tighten lock-nuts. Shorten opposite drag brace rotation descent with the collective pitch control full
exactly same amount in same manner, so that both down at an indicated airspeed of 50 MPH and check
blades are swept aft equally. Record adjustment. for a rotor speed of approximately 340 RPM. Then in
2-7
MAINTENANCE
an autorotation descent at an indicated airspeed of 50

MPH execute a moderate flare. Rotor speed should
not exceed 360 RPM in the flare.
2. If rotor speed was below 340 RPM in autorota-

tion at 50 MPH airspeed, decrease blade angle in low
pitch by shortening both link-rods which connect -
pitch horns to stabilizer bar mixing levers. If rotor
speed exceeds 360 RPM in flare, increase blade angle
in low pitch by lengthening both link-rods. Adjust
rods evenly in 1/2 turn increments. Repeat test flight
after adjustment.
c. If rotor speed was within limits in step b., low 47100-4
pitch blade angle is satisfactory. If rotor speed was
high, lengthen both pitch control rods (mixing levers Figure 2-8. Removing Main Rotor
to pitch horns) evenly in 1/2 turn increments. If rotor
speed was low, shorten both pitch control rods in
same manner. Recheck blade track, and repeat test c. Position blades at approximately five degrees
flight after adjustment. (or at an angle where equalizer beams are level).
Take up slack in cables by operating hoist, inspect
2-13. ADJUSTING COUNTERWEIGHTS- MAIN cables at each hub grip, then slowly raise the main
ROTOR. Amountof counterweights on blade grips will rotor. Station a man at the hub to guard against
be determined in flight test, to compensate any damage to splines or mast threads, and a man at
tendency of the collective pitch control stick to creep each blade tip to guide the rotor. When clear of heli-
downward or upward when not held rigidly in normal copter, lower rotor to a convenient height andremove
cruising flight. dynamic stop cables from lugs of pillow block bearing
caps, if hub is to be disassembled.
a. For initial flight, new or overhauled rotor must
have not less than six counterweight washers Part d. Lower rotor and position on rotor stand, 47-976-
No. 61-103-120-1. 003-1-T203. Remove split cone from mast.
b. Counterweights must always be equal on both 2-15. INSTALLATION - MAIN ROTOR.

blades.
a. Clean mast threads, splines, cone seat and split
control stick, add weight. To correct upward creep, cone with dry cleaning solvent, Federal Specification
control weight.
reduce To correct upward creep, P-S-661. Examine splines for nicks, burrs, or
scratches, and dress with a fine India stone, if
d. A solid weight Part No. 47-110-239-8, weighing necessary. Apply a light coat of lubricating grease,
2.23 pounds, is provided for use when thickness of Specification No. MIL-G-7187, to splines. Install
required
in washers
weightcannot be accommodated split cone on mast. Apply a thin coat of white lead
on rod, This weight is counterbored. base anti-seize compound, Specification No. JAN-A-
669, to mast threads.
e. Maximum allowable weight on one blade grip is N
one solid weight and two washers. (Total weight 2.5
pounds.)
Split cones are matched in pairs and must
2-14. REMOVAL - MAIN ROTOR. be replaced by matched pair when neces-
sary.
a. Straighten tang on lock-washer that secures main
rotor hub retaining nut. Using retaining nut wrench, b. Position a suitable hoist over the hub. Attach
T101381, turn the nut counterclockwise and remove hoisting sling, T100220, by wrapping each cable twice
from mast. Lift off the lock-washer and static stop. around each blade grip near the hub. Engage hook,
(Remove dynamic flap restraint if installed.) Dis- then take up slack by operating hoist.
connect pitch control links from blade grip pitch horns.
Disconnect dynamic stop cables from stabilizer bar Note
center frame.
Align color markings of control rods with
b. Position a suitable hoist directly over the mast. blade they control by turning stabilizer
Attach rotor sling, T100220, by wrapping each end bar.
twice around each blade grip near the hub. Engage
hook on cable end: take up slack in cables. (Figure c. Position blades at approximately five degrees (or
2-8.) at an angle where equalizer beams are level). Place
2-8
MAINTENANCE
tension on cables; inspect cables at each blade shank;

then raise rotor assembly and position directly over
mast. Station a man at each blade tip to prevent
swinging and a man at the hub to direct lowering, and
to guard against damage to the mast threads or the
mast splines. Make sure rotor is located 90 degrees
to the stabilizer bar, align splines, and lower rotor
until it rests on the cone. Remove hoisting sling.
2-8A
MAINTENANCE
Note and lukewarm water. Dry blades thoroughly with a

soft cloth to restore luster.
It is permissible to increase the core pin
holes to, 0.140to0.146" diameter, as shown 2-20. INSPECTION - MAIN ROTOR BLADES. Refer
on figure 2-23. to inspection section of Section I.
2-21. INSPECTION - OVERHAUL MAIN ROTOR

BLADES.
d. Align pins in bottom of static stop with holes in
top of trunnion and install static stop, lock-washer, a Determine if center of gravity pin is located
(install dynamic flap restraint if removed) and main within acceptable tolerance. The center of gravity
rotor hub retaining nut. Torque main rotor retaining pin, or actual center of gravity of the blade should
nut 125 to 175 foot-pounds, using wrench, T101381. not be located in excess of 3.449 inches aft of the
Bend at least two lugs of lock-washer upward to lock leading edge of the blade, as measured along the
retaining nut. Match color bands on pitch control chord line If the center of gravity pin, or actual
link-rods with those on pitch horns, and connect links center of gravity is in excess of this dimension the
to pitch horns on blade grips. main rotor blades should be removed and returned to
an approved repair station.
e. Connect dynamic stop cables to stabilizer bar by
inserting each cable terminal through its respective b. Determine if the center of pressure pin is in its
fitting and installing brass grommet, spacer, spring, proper location. To be properly located, the center
washer, nut and lock-nut. Pass a safety wire through of pressure pin should be installed at station 142.38
hole and loop over cable attaching fitting between cable from the root or 68.37 inches from the tip of the
and bar. Make loop long enough to permit free cable blade and 2.84 inches aft of the leading edge of the
action but short enough so that cable fitting will not blade, as measured along the chord line. If the center
fall free of attaching fitting in the event of cable of pressure pin is not located properly, remove and
breakage. relocate to above dimensions. (Fill original hole with
Testor's cement.)
f. Adjust dynamic stop cable. (Refer to Section III.)
Track main rotor blades. (Refer to paragraph 2-8.) c. Inspect fiberglas covering for any indications of
looseness and/or cracks. If fiberglas is found to be
2-16. MAIN ROTOR BLADES. loose, blades should be removed and returned to ap-
proved repair station for thorough inspection and
2-17. DESCRIPTION.Main rotor blades constructed rework as required. Extent of cracks in fiberglas
of laminated wood and covered with lacquered fiber- shall determine whether or not blades are to be re-
glas cloth are installed on the helicopter. For pro- moved and returned to repair station, or repaired in
tection a stainless steel cap is installed onthe leading accordance with paragraph 2-33. Inspect main rotor
edge. Fixed trim tabs located near the outboard end blade finish for general condition.
of the trailing edge of each blade may be adjusted
(by bending) to track blades. Each blade is secured d. Rigging and alignment of the main rotor hub and
to the grips by a special bolt passing through the blade assembly is to be accomplished in strict ad-
root of the blade and metal plates which are attached herence with instructions contained in paragraph 2-7.
to the top and bottom of each blade root. These metal (Make certain, when aligning blades, that the center
plates extend over the trailing edge of the blade to of pressure pin locations are used, not the center of
provide attachment lugs for the blade dragbrace. gravity pin location.)
2-18. REMOVAL - MAIN ROTOR BLADES. 1. Balancing of the main rotor hub and blade as-
sembly must be accomplished in accordance with
a. Remove main rotor assembly. (Refer to paragraph instructions in paragraph 2-6. At no time should
2-14.) blades be swept forward after correct alignment has
been determined according to procedure in paragraph
b. Check color code on blade tips and grips. (Refer 2-6.
to paragraph 2-54.)
2. Adjustment of trim tabs for tracking and pro-
c. Disconnect drag brace from attachment lug on cedure for rolling of grips to obtain proper track
blades. Remove attachment bolt from grip and blade, and trim tab settings is to be accomplished in strict
Lift tip of blade slightly, and slide blade free of grip adherence to instructions outlined in paragraph 2-8.
and place in a suitable stand. Remove opposite blade Limits of adjustments to equalizer beam links and
in same manner, pitch links must not be exceeded.
2-19. CLEANING - MAIN ROTOR BLADES. Wash e. Main rotor adjustments accomplished on flight
blades with a sponge and any good non-alkaline soap line to eliminate flight discrepancies.
2-9
MAINTENANCE
1. At no time are blades to be swept forward i. Install or relocate 302-20-4 pins at center of
of original alignment as specified in paragraph 2-6. gravity and stamp (if necessary) location on blade
data plate. Finish head of pins with aluminized lac-
2. Entries outlining any and all adjustment to the quer. If pin is moved to new location, fill original
main rotor equalizer beam links, pitch links, and/or hole with Testor's cement. Check opposite blade in
drag braces should be completely and clearly entered same manner.
in the ships log by the maintenance personnel making
such adjustments. j. Install main rotor blades. (Refer to paragraph
2-47.) Install main rotor. (Refer to paragraph 2-15.)
2-22.
2-22.LOCATING
LOCATING CENTER
CENTER OF
OF GRAVITY
GRAVITY -- MAIN
MAIN 2-23. REPAIR - MAIN ROTOR BLADES. The main
ROTOR.
rotor blades may be repaired in accordance with the
a.a. Remove
Remove main
main rotor
rotor blades.
blades. (Refer
(Refer to
to paragraph
paragraph following paragraphs. If adequate facilities are not
2-18.)
available, it is recommended that damaged blades be
returned to an approved repair station for inspection,
b. Place two V-blocks about three feet apart on a repair, or replacement.
suitable stand. Position a round tube approximately
four feet long and two and one-half inchesin diameter 2-24. REWORK OF TRIM TABS. (Figure 2-9.)
on the V-blocks so that tube is resting on each V-
block. Fit a bolt or some other device at one end of Note
the tube to facilitate rotation. Place a level spanwise
on the upper surface of the tube, insert shims under Accomplish these modifications only on
low V-block, if necessary, to level tube. flush-type trim tabs of smooth contour
main rotor blades, Part No. 47-110-120-
c. Position blade spanwise on tube so that leading 50 through Serial No. P6340. Purposes of
edge is at right angles to the tube. Shift blade until modification, to provide more secure at-
approximate balance point has been reached. Place tachment and to eliminate difficulty in
a level on blade in spanwise direction, center it with bending tabs, have been accomplished by
respect to tube, and check for level condition. Rotate redesign on subsequent blades.
tube to level blade. Be sure to keep level centered
over tube. a. Using No. 29 drill held at right angles to upper
surface of blade, drill five holes through blade and
d. Attach two center heads to end of scales, and both plates of tab, locating holes along a line 0.625
slide square head on scales so that when scales are inch forward of blade trailing edge, with centers of
held in vertical position, crotches of center heads will end holes 1/2 inch from ends of tab and other three
extend downward and bubble in square head indicates holes equally spaced between. Using No. 19 drill,
scale is vertical. Stretch a string across blade, and enlarge holes by drilling through upper tab plate
draw taut against edge of scales. Mark points on blade only. Tap each hole through blade and lower tab
in line with string. Mark line between points using plate, using No. 8-32 NC2A tap. Install five truss
suitable straight edge. Use soft lead pencil to scribe
mark on blade.
e. Turn blade clockwise on tube so that mark on

blade forms a 45 degree angle with string across
blade. Recheck blade for level position. .50
f. Make another mark on blade in line with string

long enough to intersect first line.
18 HOLES
g. Rotate blade counterclockwise on tube so that 1/8"DIA.
first mark on blade forms a 45 degree angle in op- EXISTING
posite direction with string. Check level position of RIVET EQUAL
blade. SPACES
h. Make a third mark in line with string long enough

to intersect first two lines. The point of intersection .62
of the lines is the center of gravity location.
Note
If intersection of lines does not coincide

with original center of gravity location,
recheck procedure to eliminate possibil-
ity of error. Figure 2-9. Rework of Trim Tabs
2-10
MAINTENANCE
head machine screws (AN526-8-32) from top of blade.

File lower ends of screws, as necessary, so that
1 1/2 threads extend below lower plate of tab. Note:
ALLOWABLE CORRODED AREA a
b. If difficulty is experienced in bending trim tabs, NOT TO EXCEED 50% OF AREA
drill eighteen equally spaced 1/8 inch holes along line IN ANY QUADRANT
between two rivets in tab, aft of blade trailing edge.
2-25. REMOVING FRETTING CORROSION FROM

BUTT PLATES AND BLADE GRIPS.
a. Wash plates and grips thoroughly with dry cleaning

compound, Federal Specification P-S-661.
b. Polish out fretted area, using crocus cloth, Federal

Specification P-C-458. Remove only sufficient material
to clean up area. Maximumdepth of repair is limited
to 0.020 inch. Blend edges of repaired areas into
contour. (Figure 2-10.)
BEFORE AFTER
CAUTION DRESSING DRESSING
The number of repairs permitted on either TYPICAL PIT (SECTION)

surface (plate or grip) is limited by the
following factor: A sufficient amount of 47110-35C
the original surface must remain to per-
mit accurate depth measurements. Figure 2-10. Removing Fretting Corrosion
c. Apply one coat of zinc chromate primer to repaired
surface, and allow to dry thoroughly.
upper surface of strap. Fill hole with a paste made of
2-26. REPAIRING ATTACHMENT SCREW HOLES - litharge and glycerin, and install an AN550-14-10
DRAG BRACE STRAP. flat head wood screw. Clean access litharge from
blade. Install blade. (Refer to paragraph 2-47.)
a. Remove rotor blade. (Refer to paragraph 2-18.)
Remove loose or broken screws from blade. Do not Note
remove drag brace strap. Place butt of blade on bed
plate of a drill press, and support blade so that holes If a screw is found to be loose but condi-
will be drilled normal to contour, and prevent damage tion of screw hole does not appear to jus-
to blade. Place suitable blocking between blade and tify plugging procedure, remove screw,
bed plate to prevent any rocking. Insert a 0.250 inch fill hole with a paste made of litharge
drill in chuck, and adjust press, or place a suitable and glycerin, and reinstall screw. Inspect
stop on drill, to drill a hole 1 1/4 inches deep from frequently until repair is determined to be
upper surface of drag brace attachment strap. adequate. If any doubt exists, repair by
plugging procedure.
b. Prepare a spruce dowel 0.244 inch diameter, and
1 1/8 inches long. (Difference in diameter of hole 2-27. REMOVAL OF FAIRING COMPOUND EC1184
and dowel is to provide for a glue line.) Mix a portion FOR RE PLACEMENT WITH NARMCO
of resorcinol type glue in accordance with manufac- RESIN 3133, AT EDGES OF STAINLESS
turer's instructions. Blade and glue must be at room STEEL LEADING EDGE.
temperature of 23.9°C (75 F) minimum. Thoroughly
clean and dry surfaces to be glued. Coat dowel and Note
hole with glue, and insert dowel into place. Make
certain dowel is bottomed in hole. Allow sufficient Part No. 47-110-120-50 blades with Serial
time for glue to dry thoroughly before proceeding No. P-7903 and subsequent have Narmco
with step c. Resin 3133 installed on delivery. To use
Narmco, all EC1184 putty should be re-
c. Drill a No. 16 (0.177 inch) hole in exact center of moved. If EC1184 is partially coming out,
dowel to a depth of one inch as measured from upper no patching with Narmco is permitted.
surface of strap. Use a 0.250 inch diameter drill, and
drill a hole to adepthof 13/32 inch, as measured from a. Clean blade with soap and water. Rinse and dry.
2-11
MAINTENANCE
b. Surface treatment. a. Use a No. 44 drill, (0.086 inch) and drill holes
1/2 inch apart and 1/4 inch from edge of stainless
Prior to application of Narmco fairing compound, steel cap in loosened area. Countersink holes lightly
surface to be faired shall be prepared in accordance with 82 degree countersink. (Figure 2-11.)
with the applicable Finish Specifications.
b. Apply resorcinol type glue after thoroughly clean-
1. Mix sixty (60) grams of Narmco 3133, part "B" ing surfaces to be glued and making certain surfaces
to forty (40) grams of part "A". are dry. Blade and glue must be at room temperature
23.89°C (75°F) minimum. Prepare glue inaccordance
2. Allow the mixture to stand fifteen (15) minutes with manufacturer's instructions. Force glue under
before applying. stainless steel leading edge with spatula or other
suitable tool. Install AN550-2-2 head wood screws
d. Demarcation of area. and tighten securely.
Trace a penciled line 3/4 to 7/8 inch aft of and c. When glue is dry, clean surface around screws
parallel to the stainless steel leading edge. Apply a with carbon tetrachloride. Apply stainless steel flux,
1.5 inch wide strip of acetate fiber tape along the and cover heads of all screws with lead and tin
penciled line with the leading edge of the tape follow- (50-50) solder.
ing the line. Apply another 1.5 inch wide strip of tape d. Wash off excess flux with a 10 per cent baking
on the stainless steel leading edge with the aft edge soda solution. Wash with clean water. File off excess
of the tape flush with the aft edge of the stainless steel. solder, and sand smooth with fine emery cloth.
Note Balance blades. (Refer to paragraph 2-6.)
It is important that the storage require- 2-30. REPAIRING HOLES OR CRACKS IN STAIN-
ment for Narmco No. 3133 be complied LESS STEEL LEADING EDGE CAP. Holes or cracks
with. There is a six months storage life in stainless steel leading edge cap can be sealed by
at 40°F to 60°F. When stored in higher soldering as follows:
temperatures it deteriorates rapidly. Re-
commend storage by refrigeration. Note
2-28. REPAIRING CHECKS IN BLADE BUTT. Any crack (maximum 3) 1 inch or less in
length can be repaired
CAUTION a. Drill a small hole at each end of crack to prevent

.;_: ........-...... : crack from spreading. Clean surface with carbon
tetrachloride.
This
This repair
repair is
is permissible
permissible onlyonly if
if 10
10 or
or b. Apply stainless steel soldering flux. Solder, using
less checks
0.062 inch less. having
or exist, gap of
total checks
If 10 ora more (50-50) solder. Neutralize excess flux
are present, or the total gap is more than cent soluton File flush.
0.062 inch, the blade must be returned to REPAIRING
repair
approved
station for repair2-31.
an approved repair station for repair or REPAIRINGFIBERGLAS BYPATCHING. Small
FIBERGLASBYPATCHING. Small
If more
replacement. If
replacement. more than cracks exist
than 33 cracks exist holes, breaks, or rips in the fiberglas cloth can be
in blade butt forward of butt plates, it is repaired by patching as follows:
cause for replacement or repair at a fac- Note
tory approved repair station.
a. Fill checks with 3M adhesive filler No. EC612, The overlay patch described in this para-
(Minnesota Mining and Manufacturing Co.). Apply graph should be considered only as an
filler with a putty knife. emergency repair, and should be replaced
by a permanent patch as quickly as possi-
b. Allow filler to dry at least one hour, then apply ble.
five brush coats of adhesive sealer No. EC498
(Minnesota Mining and Manufacturing Co.) to complete a. Remove aluminized lacquer adhesive with lacquer
area. Allow at least one hour drying time between thinner for several inches around break. Apply five
coats. coats of clear lacquer adhesive, thinned approxi-
mately 25 per cent, to area from which aluminized
2-29. REPAIRING LOOSE STAINLESS STEEL LEAD- lacquer has been removed. Allow each coat to dry
ING EDGE. If stainless steel leading edge pulls away thoroughly.
from the wood underneath, it must be repaired im-
mediately. Use the following procedure to make re- b. Trace a penciled line 3/4 to 7/8 inch aft of and
pairs up to approximately six inches. If the separation parallel to the stainless steel leading edge.
exceeds this amount, return blades to an approved
repair station for repairs. c. Apply a 1.5 inch wide strip of acetate fiber tape
2-12
MAINTENANCE
along and aft of the penciled line. Tape should be care- j. Brush on two (2) coats of undiluted DuPont clear
fully applied in order to keep solvent from entering lacquer No. P-1200-U-17060, at two (2) hour intervals.
under it. Allow to dry for six (6) hours after last coat. Remove
all tape and paper.
d. Cover the entire blade on both sides, with a good
grade of paper (Kraft or equivalent) secured with APPLICATION OF NARMCO RESIN 3133.
acetate fiber tape, from tape line established in step
b., to the trailing edge, for protection of finish against a. Materials.
deterioration by solvent.
1. Narmco Resin parts A and B.
e. Cut out separate strips of cheese cloth, approxi-
mately 36 inches long by 6 inches wide. Dip strips in 2. Acetate fiber tape 1.5 inch wide or equivalent
lacquer thinner. Wring out part of the excess solvent. smooth surface tape.
b. Cut a patch of fiberglas cloth of sufficient size
f. Place thinner soaked strips on compound to be
removed. Apply pressure
removed
pressure on strips,
Apply
on strips, either with aa
either with to provide a one-inch overlap around break. (To pre-
stripe of heavy rubber or a 2 x 4 inch piece of wood. vent cloth from unraveling, apply one coat of thinned
lacquer adhesive before cutting.) Place patchonbreak
and apply one coat of thinned sealer adhesive (one
g. Using a brush, apply lacquer thinner on cheese part sealer adhesive, five parts thinner).
cloth strips every five minutes to keep them saturated
for a period of thirty (30) minutes, while keeping c. Apply three coats of lacquer adhesive, thinned
strips under pressure as outlined in step f. approximately 25 per cent. Sand smooth and apply
three coats of aluminized lacquer (12 ounces aluminum
h. After thirty (30) minutes of soaking time, uncover pigment paste to one gallon clear lacquer). Balance
a small work area (approximately one foot at a time) blades. (Refer to paragraph 2-6.)
and very carefully remove compound with a putty
knife and carefully clean glass cloth with a piece of 2-32. COVERING INBOARD LEADING EDGE WITH
cheese cloth soaked with lacquer thinner. Allow the PLASTIC FILM. Leading edges of blades in the area
cleaned area to dry for two (2) hours. between inboard end of the stainless steel leading
edge and the outboard ends of the blade reinforcing
i. Brush on or rub in by hand until it feels dry, one plates, may be covered with plastic film, Scotchcal
coat of DuPont 5499 adhesive thinned with DuPont No. 455 (Minnesota Mining and Manufacturing Co.)
3412 thinner, in approximate proportion of 65 per or equivalent, to repair damaged fiberglas cover (or
cent thinner to 35 per cent of 5499. Allow to dry for to protect area originally left uncovered on blades of
two (2) hours. earlier manufacture). Repair as follows:
a. Smooth and clean area to be covered. Sand off

rough edges of existing cover or bare wood, with
grade 320 to 400 sandpaper, and wipe off any dust or
foreign material. Clean painted surfaces with a cloth
dampened with naptha, and wipe dry with clean cheese-
6" MAXIMUM cloth.
b. Cut plastic film to size and shape required. Re-

move paper backing and place plastic strip on a card-
board, or similar smooth backing, with adhesive side
up.
c. Apply adhesive activator to adhesive side of strip,

using a dampened felt squeegee or cheesecloth appli-
cator, with parallel strokes from end to end of strip.
(Adhesive activator and applicator are furnished with
plastic film by manufacturer.) Avoid excessive use of
activation solvent, which will result in puckering and
wrinkling of the film.
d. Fasten the center of the strip to leading edge of

blade, starting at one end and rubbing with hand to
PATTERN LEADINGEDGE insure positive contact and freedom from airbubbles.
47110-59 Using thumbs, press film into place, working from
leading edge toward trailing edges. Be sure all areas
Figure 2-11. Stainless Steel Leading Edge Repair of film are fastened. If air pockets are trapped, film
2-13
MAINTENANCE
may be lifted back to air pocket, reactivated if neces-

sary, and re-applied.
FOLD BACK LEADING EDGE
e. When film is securely inplace, seal and edges with 3/4" FOLD HERE
a bead of rubber cement, EC847 (Minnesota Mining
and Manufacturing Co.). Allow curing time, at room
temperature, of at least 24 hours before testing.
2-33. REPAIRING FIBERGLAS BY INSERTION. Any
damage to the fiberglas cloth, including all repairs
of a temporary nature accomplished by patching, will
be repaired by insertion, as follows:
a. Lay out a regular shape (square or rectangular) REMOVE DAMAGE CUT LINE
large enough to include the damaged area, and include AREA
approximately 3/4 inch at leading edge side to form
a flap to overlap leading edge side of patch. Mark with FLAP LEADING EDGE
a soft pencil. (See figure 2-12.) Carefully mask off
the marked area using three thicknesses of masking 3/4 1/8"
tape.
b. Using lacquer adhesive thinner, remove lacquer

adhesive in marked offarea. Carefully loosen damaged
area from blade, lift edges, and holding knife nearly
parallel to blade, cut away fiberglas on lay-out lines.
Lift, but DO NOT cut away, 3/4 inchwhich is intended
to overlap leading edge of patch, and do not permit
point of knife to contact wood. PATCH 1/8" TYPICAL EDGE
OVERLAP
c. Measure and lay out patch on patching material
(fiberglas). Make patch large enough to be inserted 47110-60
under flap at leading edge (within approximately 1/8
inch of butting), and to overlap sides and trailing Figure 2-12. Repair of Fiberglas by Insertion
edge by approximate 1/8 inch. Apply one coat of
lacquer adhesive to an area 1/4 inch wide around
outer edge of patch to prevent fraying, allow time
to dry, then cut patch on lay-out lines sandpaper, sand entire patch to prevent too great
a build-up of lacquer adhesive, and sand overlapped
d. Remove masking tape and sand exposed wood edges of patch to remove a small amount of patch
lightly to remove roughness. Apply a minimum of material. Do not attempt to feather-in patch in one
five coats of unthinned lacquer adhesive to area of sanding operation. Apply three additional coats to
blade to be patched. DO NOT apply lacquer adhesive dry thoroughly, and repeat sanding operation between
to flap. Allow each coat to dry thoroughly before coats.
applying next coat. When the final coat is thoroughly
dry, position patch (leading edge within 1/8 inch of
butting existing fiberglas under flap and overlapping CAUTION
1/8 inch at sides and trailing edge). (Seefigure 2-12.) .
Brush out all wrinkles with dry brush.
It is mandatory that each coat be thoroughly
e. Mix a small quantity (one part of lacquer adhesive dry before sanding, and thatdustbe cleaned
and nine parts of lacquer thinner) and apply a single off before applying the next coat. When the
coat to patch. Using the wet brush, brush this coat final sanding has been completed, the patch
into patch until all air has been expelled, and proper will be feathered into the contour.
adhesion assured. Allowto dry thoroughly.
g. Apply clear lacquer thinner to flap at leading edge
Note side of patch, and, using a putty knife, work flap into
place by sliding putty knife downward from the leading
On small patches, the brushing-out pro- edge side. Trim frayed edge (trailing edge) of flap
cedure can be accomplished by rubbing just prior to making the final strokes withputty knife.
lightly with fingers. Apply additional thinner, as necessary, while working
flap into place to assure proper adhesion. Allow
f. Apply one coat of unthinned lacquer adhesive, and sufficient time to dry thoroughly. Repeat preceding
allow to dry thoroughly. Using grade 240, wet or dry step f. and observe caution following step f.
2-14
MAINTENANCE
Note 2-35. REPAIRING LOOSE COVER ATTACHING

SPLINES.
A slight indentation in flap, across leading
edge of patch, is normal.
CAUTION
h. When thoroughly dry, apply one brush coat of
surfacer which has been thinned sufficiently with
lacquer thinner for good brushing technique. When Loose cover attaching splines must be re-
thoroughly dry, apply glazing putty to fill all irregu- paired immediately.
larities. After putty is thoroughly dry, remove excess
glazing putty with dampened, grade 240, wet or dry Note
sandpaper. Finish sanding with grade 320 sandpaper.
Apply one spray coat of surfacer to repaired area This repair is applicable on main rotor
and allow to dry thoroughly. Finish sanding with blades. Part No. 47-110-120-1, Serial
grade 320 sandpaper. Nos. 1 through 166 only. It is not appli-
cable on blades which have the letter "P"
i. Apply two spray coats of aluminized lacquer ad- preceding the serial number.
hesive made from 12 ounces of aluminum pigment
paste to one gallon of lacquer adhesive. Thin lacquer a. Remove tape covering from birch spline and re-
adhesive sufficiently to allow adequate incorporation move spline. Use thinner to loosen tape and spline
of aluminim pigment with lacquer adhesive thinner. if necessary. Thoroughly clean spline, spline groove,
Balance blades. (Refer to paragraph 2-6.) Check center and area of cover to which tape was adhered. Cut a
of gravity. (Refer to paragraph 2-21.) new piece of pinked tape to the proper dimensions.
Note b. Coat spline groove and strip approximately 1 1/2

inches wide on one side of tape (from straight edge)
If the repaired area is on the underside with wood cement, EC2002 (Minnesota Mining and
of the blade, complete the finishing by ap- Manufacturing Co.), or an equivalent urea base resin
plying one cross coat of dullblacklacquer. wood cement. Place tape into spline groove (coated
side down), with straight edge of tape butted against
2-34. RE PLACING FIBERGLAS. Replacement of trailing edge side of groove. (Figure 2-13.)
fiberglas is recommended when the damage is ex-
tensive, or when the condition of the fiberglas would
make repairs impractical. Replace fiberglas cloth, CAUTION
as follows:
a. Carefully loosen fiberglas cloth at the trailing Apply wood cement in accordance with the
methods and temperatures recommended
edge and peel forward to stainless steel leading edge,
using thinner to loosen. Cut fiberglas cloth one and by the manufacturer.
one-half inches aft of, and parallel to, stainless steel
leading edge. If reinforcing tape exists aft of leading c. Coat tape in spline groove (area which will con-
edge, loosen with thinner and peel forward with thinner tact spline) and spline with the same wood cement.
and remove. Sand blade lightly to eliminate any rough- Press spline into groove until top of spline is flush
with leading edge of fiberglas cover. Nail spline into
ness. place with flathead, brass wire nails, Specification
b. Apply five brush coats of lacquer adhesive, thinned 301B20-4, or commercial, flathead, brass wire nails
No. 20 diameter, 1/2 inch long. Clean excess cement
approximately 20 per cent, to blade, allowing each
coat to dry thoroughly. Wrap fiberglas cloth, cut to
fit, around blade and apply two brush coats of lacquer Note
adhesive, thinned approximately 66 2/3 per cent. Be
sure to work out any air bubbles that may appear. Work
the existing cloth, or reinforcing tape, aft of the End nails
leading edge down, and apply four brush coats of should be 1/2 inch from ends of spline.
lacquer adhesive, thinned approximately 20 per cent, (Figure 2-13.) Allow cement to dry in ac-
to the complete blade. Allow each coat to dry thor- cordance with manufacturer's instructions
oughly before applying the next coat. If spline was before proceeding with following step d.
installed, reinstall as described in paragraph 2-35.
d. Apply (brush) one coat of thinned lacquer adhesive
c. Sand blade lightly, and apply one spray coat of (one part lacquer adhesive C-1404, five parts thinner
lacquer thinned approximately 20 per cent. Apply two K5948, (Pierce and Stevens, Buffalo, N.Y.) to under-
spray coats of aluminized lacquer. If underside of side of tape and cleaned area of fiberglas cover.
blade was black, apply one cross coat of dull black Allow to dry, then draw tape over spline and leading
lacquer. Balance blades. (Refer to paragraph 2-6.) edge of fiberglas cover. Brush out all wrinkles.
2-15
MAINTENANCE
NAILS SPLINE
STEEL LEADING EDGE FIBERGLAS

COVERING
GROOVE 1/2"
FINISHED REPAIR-
Figure 2-13. Cut-Away View of Spline Installation
e. Apply (brush) one coat of lacquer adhesive C-1404, b. Pierce bubble with needle to create vents at two
thinned approximately 66 2/3 per cent with K5948, or three spots.
to tape and cleaned area of fibergals cover. Work out
all bubbles and allow to dry. c. Inject compound withhypodermic syringe No. 10YL
(Becton Dickinson or equivalent) and needle PD No.
f. Brush three coats of lacquer adhesive, C-1404, 181 (large) or equivalent.
thinned approximately 20 per cent with K5948, on tape
and cleaned area of fiberglas cover, allowing each d. Rub with finger for equal distribution and removal
coat to dry thoroughly. Sand area very lightly and of excess material.
spray a clear coat of lacquer C-1404, thinned ap-
proximately 20 per cent with K5948, on coated area. e. Cover repair with cellophane or paper and apply
pressure with buckshot or sand bag of 5 to 10 pounds.
g. Spray coated area with two coats of aluminized
lacquer adhesive C-1404 (12 ounces aluminum pig- f. Keep under pressure for a minimum of 12 hours.
ment paste, Specification No. AN-TT-A-461, to one
gallon of lacquer C-1404.). Thin with K5948 suffi- g. Allow 24 to 48 hours for curingtime, depending on
ciently to allow adequate incorporation of aluminum climate conditions.
pigment. Allow to dry thoroughly.
Note
Note
Use lacquer thinner to clean equipment.
If the repair was accomplished on under-
side of blade, spray with one coat of dull 2-37. REFINISHING MAIN ROTOR BLADES. Blades
black lacquer A3434 (Pierce and Stevens, which do not require replacement of fiberglas cloth
Buffalo, N.Y.). can be refinished as follows:
2-36. REPAIR OF FIBERGLAS BUBBLES. Fiberglas a. Thoroughly wash surface of blade first with warm
which has become detached from blades resulting in water and good grade of non-alkaline soap and then
bubbles may be repaired as follows: with carbon tetrachloride.
a. Mix (50-50) by weight. 3MEC1472 and 3M1473 b. Sand surface of blade lightly, and wipe clean with
adhesive sealer. a cloth moistened with carbon tetrachloride.
Note
c. Spray blade with one coat of lacquer adhesive,
Pot life - one hour for 100 gram batch at thinned approximately 20 per cent with lacquer
room temperature. thinner.
2-16
MAINTENANCE
d. Apply two spray coats of aluminized lacquer c. When glue is dry, shape insert to blade contour.
made from 21 ounces of aluminum pigment paste to Refinish repaired area. (Refer to paragraph 2-37.)
one gallon of lacquer adhesive. Thin lacquer with
lacquer thinner sufficiently to allow adequate in- 2-41. REPAIRING PINE TRAILING EDGE BY IN-
corporation of aluminum pigment. Apply one cross SERTION. Breaks which run into the pine trailing
coat of dull black lacquer to underside of blade, edge for one inch or less are repaired as follows:
(Figure 2-14.)
CAUTION a. Remove fiberglas cloth in damaged area. (Refer
to paragraph 2-31.) Prepare damaged area to re-
ceived new white pine insert. Prepare insert of white
pine. Make scarf joint with 15 to 1 ratio at either
Apply coats evenly in order that balance
of assembly will not be affected Check end. Grain must run spanwise. Be sure to leave
of assembly will not be affected. Check
of assembly
balance after willnotbe check
affected
refinishing blades. (Refer sufficient stock for finishing to contour.
to paragraph 2-6.) b. Glue insert into place, using resorcinol type glue.
2-38. WOOD REPAIRS. Clamp insert tightly into place using 100 to 150
pounds pressure.
2-39. REPAIRING BIRCH SECTION BY INSERTION. c. When glue is dry, shape insert to blade contour.
Gouges up to 1/16 inch deep, inboard from the stain- Refinish repaired area. (Refer to paragraph 2-37.)
less steel leading edge, are repaired by inserting Balance blades. (Refer to paragraph 2-6.) Check
birch dutchmen as follows: (See figure 2-14.) center of gravity.
a. Remove fiberglas cloth in damaged area, if 2-42. REPAIRING BALSA SECTION BY INSERTION.
necessary, and rout out wood, as shown, to receive Damaged balsa is repaired by inserting new pieces
insert. Prepare insert of birch with a 15 to 1 scarf of balsa wood as follows: (Figure 2-14.)
ratio on each end. Be sure to leave sufficient stock
for finishing contour. Grain must run spanwise. a. Remove fiberglas cloth in damaged area. (Refer
to paragraph 2-31.) Cut out broken or damaged area
b. Glue insert into place, using resorcinol type glue. to form a 60 degree V. If break or damage extends
Blade and glue must be at room temperature of over more thanone balsa remove
block, entire
23.89°C (75°F) minimum. Prepare glue inaccordance section. Prepare new piece of balsa to replace sec-
with manufacturer's instructions. Spread glue on both tion tion removed.
removed. Leave
Leave sufficient
sufficient stock
stock at
at trailing
trailing edge
edge
surfaces. Clamp insert tightly into place. Use pres- and on contours for finishing purposes.
sure of 200 to 250 psi for not less than five hours ,
Glue insert into place, using resorcinol type
glue. Clamp insert carefully into place using 15 to 25
Note pounds pressure and allow to dry for three hours.
Do not machine or handle blade roughly

for 24 hours after application of pressure. Refinish repaired area. (Refer to paragraph 2-37.)
2-43. DAMAGE NECESSITATING REPLACEMENT.
c. Shape insert to blade contour.
2-44. TRIM TABS. Cracks or breaks in the trimtabs
d. Refinish repaired area. (Refer to paragraph 2-37.) will necessitate replacement.
Balance blades. (Refer to paragraph 2-6.)
2-45. WOOD. If the damage to the wooden portion of
2-40. REPAIRING PINE SECTION BY INSERTION. a blade is greater than described in paragraphs 2-38
Gouges up to 1/8 inch in depth are repaired by in- through 2-42, it is recommended that both blades be
serting white pine dutchmen, as follows: (See figure returned to an approved repair station for repair or
2-14.) replacement.
a. Remove fiberglas cloth in damaged area. (Refer 2-46. STAINLESS STEEL LEADING EDGE. If the
to paragraph 2-31.) Rout out damaged wood to re- damage to the stainless steel leading edge is greater
ceive insert. Prepare insert of white pine with a than described in paragraphs 2-29 and 2-30, it is
15 to 1 scarf ratio on each end. Be sure to leave recommended that both blades be returned to an ap-
sufficient stock for finishing to contour. Grain must proved repair station for repair or replacement.
run spanwise.
2-47. INSTALLATION - MAIN ROTOR BLADES.
b. Glue insert into place, using resorcinol type glue.
Clamp insert tightly into place using 100 to 150 a. Apply a thin coat of corrosion preventive to blade
pounds pressure. reinforcing plates. Observe color code of blade tips
2-17
MAINTENANCE
WEB
BODY
TYPYPICAL REPAIR
BIRCH
TYPICAL 20°
BALSA REPAIR
BODY BLOCK
BODY WEB TYPICAL SPRUCE REPAIR
47100-58
Figure 2-14. WoodRepair

2-18
MAINTENANCE
and grips. Install blades in grips. Install blade with from yoke. Disconnect and remove equalizer links
lowest tip incidence in positive (high) grip. (4) from equalizer beams and blade grip horns.
b. Install blade drag brace. Torque blade attachment b. Remove cotter pin, nut and washer from inboard
bolts 1200 to 1400 inch-pounds. Torque drag brace end of bolt holding equalizer beam to yoke. Remove
bolts 160 to 190 inch-pounds. bolt and equalizer beam from yoke. Remove opposite
equalizer beam in same manner. Take note that
c. Check alignment of blades. (Refer to paragraph are thinner than those used under
2-7.) Check balance of blade washers (6) and
2-6.) Install main rotor. (Refer to paragraph 2-15.) snap-ring (7) from each beam.
2-48. MAIN ROTOR HUB. (Figure 2-15.) c. Cut lockwire, remove attaching bolts and washers,
and remove blade pitch horns (9) and equalizer horns
2-49. DESCRIPTION. The hub assembly consists of (10)
(10) from
from grips. Remove locking
grips. Remove locking plate
plate (11)
(11) from blade
fromblade
two main assemblies, a gimbal ring and yoke. The grip adapter, turn adapter counterclockwise with
gimbal ring (upper section of the assembly) provides
universal action for the azimuth position of the blades. Slide grip off yoke; remove opposite grip in same
trunnionof
The trunnion
The the ring
of the ring assembly provides the
assembly provides the mount-
mount- manner. Press outer race of roller bearings (12)
ing point of the hub assembly to the mast. The yoke and seals (13) from grips (14) using pressing plug
(lower section of the assembly, to which the blades T100394
are attached) is secured to the gimbal ring in such
a manner as to permit the hub assembly to pivot or d. Cut lockwire and remove lock-screw from yoke
seesaw in any direction. Pitch equalization is pro- bearing nut. Using spanner wrench, T100407, turn
vided by interconnecting linkage between the horns nut (16) counterclockwise. Nut will contact inner race
on the blade grips. The linkage consists of an equal- of bearing and push rollers and inner race (15) from
izer beam mounted on each side of the yoke and ad- spindle. Remove nuts (16) and slide spacer (17),
justable link-rods which connect the ends of each adapter assembly (24), shim (18), O-ring (19), and
equalizer beam to the pitch horns attached to the seal ring (20) from yoke (21). Disassemble opposite
blade grips. Due to this connection, when blade angles spindle of yoke in same manner.
are being changed the angle of both blades is changed
simultaneously and equally. The dynamic stops are e. Remove seal (22), and press bearings (23) from
cable assemblies connected between the gimbal ring adapter (24), using pressing plug 47-120-104-5-T212.
and stabilizer bar to prevent excessive flappingaction Disassemble opposite adapter assembly.
of the blades, while in flight. Counterweights are at-
tached to the assembly to aid in balancing collective securing upper andlower
forces. A dynamic flap restraint (procured as a kit) halves of gimbal ring (26) and separate halves. Lift
may be installed under the rotor retaining nut (in trunnion and pillow block assemblies from lower half
place of the static stop) to prevent excessive flapping of gimbal ring. Remove bearing caps (27), bearings
movement of the hub. (28) and shims (29) from outboard shoulders of trun-
nion. Keep shims separate so they can be reinstalled
in their original location. Remove Zerk fittings (30)
from caps (27). Remove bearings (31), rings (41) and
a. Remove main rotor assembly. (Refer to para-
graph 2-14.) seals (32) from inboard shoulders of trunnion.
b. Remove main rotor blades. (Refer to paragraph g. Remove bearing caps (34), bearings (35) and shims
2-18.) (36) from inboard shoulders of pillow blockpins. Keep
shims separated for use in their original location on
2-51. DISASSEMBLY - MAIN ROTOR HUB. (Figure reassembly. Remove bearings (37), rings (41) and
2-15.) seals (38) from pillow block pins.
Note 2-52. INSPECTION - MAIN ROTOR HUB.
Observe color coding of hub and attaching a. Inspect all parts for wear or damage. Visually
parts before proceeding with disassembly inspect splines for chipped, cracked, broken, or worn
so parts may be reinstalled in their origi- teeth and bearings for chips, cracks, and brinelling.
nal location. (Refer to paragraph 2-54.) Smoothness of operation will determine if bearings,
Part No. 7015, are satisfactory for re-use, end and
a. Remove cotter pins, nuts, and washers securing radial play is of no consequence and will vary con-
counterweight assemblies to equalizer horns, and siderably.
lift counterweight assemblies (1) from horns (10).
Remove drag braces (2). Remove pillow block bolts b. Inspect for evidence of fretting corrosion oninner
(3) and lift gimbal ring and pillow block assembly surface of blade grips, where grip and blade contact,
2-19
MAINTENANCE
?/'? O; X :.......
1. Counterweight Assemblies 23. Seal

22. Bearing
3. Pillow Block Bolts 24. Adapter
4. Equalizer Links 25. Capscrews
5.
6.
7.
3.
Bearing WasherBolts
SpacerRingaces
Snap
Pillow Block
26.
27.
2.
24. Bearing Ring
Gimbal
Bearing
Adapter Caps
8.
5. Equalizer
Bearing Links 2.
26. Capscrews
Gimbal Ring
6.
7. Spacer Washer
Snap Ring 27.
28. Bearing
Bearings Caps
8. Equalizer Beam 29. Shims
9. Pitch Horn 30. Fittings
10. Equalizer Horns 31. Bearings
11. Blade Grip Locking Plate 32. Seal
12. Blade Grip Bearing 33. Trunnion
13. Seal 34. Bearing Caps
14. Grip 35. Bearings
15. Bearing Inner Race 36. Shims
16. Yoke Bearing Nut 37. Roller Bearings
17. Spacer 38. Seals
18. Shim 39. Pillow Block Pins
19. 0-Ring Seal 40. Pillow Block
20. Seal Ring 41. Retainer Ring
21. Yoke 42. Dynamic Stop Cables
47120-30D
Figure 2-15. Disassembled View - Main Rotor Hub (Sheet 1 of 2)

2-20
MAINTENANCE
2 Grip - Blade Bolt Hole ID 1.0000 1.0010 1.0040

3 Grip - Outer Bearing Bore ID 3.5423 3.5433 3.5443 (mean)
4 Outer Bearing OD 3.5427 3.5433
5 Outer Bearing ID 2.1648 2.1654
6 Yoke - Outer Bearing Seat OD 2.1650 2.1655 2.1638
7 Yoke - Thrust Bearing Seat OD 2.9519 2.9525 2.9499
8 Thrust Bearings ID 2.9522 2.9528
9 Thrust Bearings OD 4.1331 4.1339
10 Adapter - Bearing Bore ID 4.1337 4.1347 4.1352
11 Pillow Block - Pin Bore ID 0.9995 1.0000
12 Pin OD 1.0000 1.0005
13 Pin - Gimbal Bearing Seat OD 0.9840 0.9844 0.9835
14 Bearings - Gimbal Ring ID 0.9839 0.9843
15 Bearings - Gimbal Ring OD 2.4404 2.4409
16 Gimbal Ring - Bearing Bore ID 2.4400 2.4410 2.4420
17 Pin or Trunnion - Thrust Bearing Seat OD 0.5840 0.5850 0.5800
18 Thrust Bearings ID 0.5903 0.5906
19 Trunnion - Gimbal Bearing Seat OD 0.9836 0.9840 0.9830
20 Bolt - Equalizer Beam OD 0.3125 0.3135
21 Bearing - Equalizer Beam ID 0.3120 0.3125
22 Bearing - Equalizer Beam OD 0.8120 0.8125
23 Equalizer Beam - Bearing Bore ID 0.8124 0.8129 0.8134
24 Trunnion Bearing Cap - End Play (each) in. 0.000 0.002 *
25 Pillow Block Bearing Cap - End Play (each) in. 0.002 0.004 **
26 Grip Adapter to Pillow Block - Clearance in. 0.064 0.160 **
27 Bolts - Pillow Block - Torque in/lb 300 350
28 Grip Adapter - Torque ft/lb 350 375
29 Nut - Yoke Bearing - Torque in/lb 1000 1500
30 Hole-Pitch Horn 0.250 0.251 0.255
31 Bolt 0.2487 0.2492 0.2465
*Maximum total for assembly 0.004, recommend 0.002. Slight drag when hand turned.
**Equal within 0.002. Total play for assembly 0.004 to 0.008, recommend 0.006.
***Equal both sides of hub within 0.030. 47120-59C
Figure 2-15. Disassembled View of Limits Chart - Main Rotor Hub (Sheet 2 of 2)
2-21
MAINTENANCE
& OVERHAUL INSIRUCIIONS
and on yoke spindle, where thrust bearings are mount- 8. Drag braces - Band.
ed. (Refer to paragraph 2-25 and figure 2-10 for re-
pairs.) Inspect blade bolt holes in grip for scored 9. Hub yoke - Dot 1/2 inch diameter, one side.
marks (possibly made during removal of bolt). Polish
out such marks to eliminate source of fatigue cracks. 2-55. ASSEMBLY-MAINROTORHUB.
(Figure 2-15.)
Maximum diameter of bolt hole must not exceed 1.004
inches. Note
c. Inspect static stop for permanent set or other Observe color coding of parts and install
indications of hard contact with gimble ring. them in relation to matching components.
d. Inspect 47-120-182-1 radius ring for wear where a. Press seal (22) into bore of adapter nut (24) with
71A1 seal rides. Wear up to 0.005inchis permissible. lip of seal extending inboard (towards center of yoke).
Replace ring if wear exceeds 0.005 inch. To shoulder of nut (if existing). If no should exist, press
seal flush with surface of nut. Turn adapter nut over
e. Inspect parts dimensionally. Refer to Section Ifor use pressing plug Part No. 47-120-104-5-T212 and
Magnaflux and Zyglo requirements, press thrust bearings (23) into adapter (with thrust
sides of bearings towards center of yoke whenadapter
2-53. REMOVING FRETTING CORROSION FROM nut is installed), using pressing plug Part No. 47-
HUB YOKE SPINDLE. 120-104-5-T212. Install seal ring (20) on yoke spindle
(21) with inside radius seated on shoulder at inboard
a. Clean thrust bearing surfaces of yoke spindles end of spindle. Install O-ring (19) in recess of ring.
thoroughly with dry cleaning solvent. Slide one shim (18) and adapter assembly in position
against ring.
b. Strap and polish area using crocus cloth.
b. Slide spacer (17) onto spindle and install yoke
Note bearing retaining nut (16). Torque nut 1000 to 1500
inch-pounds, using spanner wrench T100407. Do not
After cleaning, check diameter of thrust install lock-screw until adjustment of shims is com-
bearing area of hub yoke spindle. It shall plete. Press bearing and inner race (15) onto spindle,
not be reduced more than 0.002 inch below with chamfered edge of race inboard. Assemble
minimum diameter (2.9519inches). opposite spindle in same manner.
2-54. COLOR BANDING - MAIN ROTOR HUB PARTS. Note
Note If parts are being replaced, or if original

shims were lost or damaged, shim to ob-
Use 3M600 tape in red and white for color tain 0.064 to 1.160 inch clearance between
banding. pillow block and grip bearing adapter.
(See figure 2-15.) Clearance on each side
a. Replace blade tip identification markings if re- of hub must be alike within 0.030 inch.
quired. Replace markings with original color.
c. Position seal (13) in grip (14) with bevel face
b. Color band and mark the followingparts as indi- outboard. Position outer race (12) in grip with lip
cated. Make certain all parts are marked with the tip of race outboard. Using pressing plug, T100393,
color of the blade they control. (See figure 2-16.) press outer race into grip leaving sufficient clearance
between race and seal so seal may be rotated by hand.
1. Blade grip - Band. Slide assembled grip onto spindle, place small amount
of anti-seize compound on threads and start threads
2. Pitch horn link-rods (mixing levers to pitch on adapter into grip. Tighten adapter with spanner
horns) - Band. wrench, T100056, 350 to 375 foot-pounds. Assemble
and install opposite grip in same manner.
3. Pitch horns - Single stripe.
Note
4. Pitch horn to equalizer beam links - Single While tightening adapter, tap outboard end
band. of grip with a soft mallet to seat bearings.
5. Equalizer horns - Double stripe. Check to see that end of spindle is not
bottoming against seal. If spindle binds
6. Equalizer horn to equalizer beamlinks- Double against seal, remove grip and add another
band. shim (18) inboard of thrust bearing.
7. Equalizer beams - Single band one end; double d. Install pillow blocks (40) and torque nuts on bolts
band opposite end. 300 to 350 inch-pounds. Check clearance between
2-22
MAINTENANCE
Use 3M600 tape for red

and white color banding.
WHITE
RED
47120-21
Figure 2-16. Color Banding - Main Rotor
pillow blocks and adapter nuts. (Adjust amount of beam will be outboard. Place spacer (thin washer)
shims inboard of thrust bearing as necessary to onto bolt and insert bolt through hole in yoke. Install
obtain 0.064 to 0.160 inch clearance between pillow washer, nut and cotter pin. Assemble and install
block and adapter.) Remove pillow blocks after opposite equalizer beam in like manner. Turn beams
clearance check. so that slots in end of beams incline inboard and to
the top. Adjust equalizer links to equal length of
e. Remove grips. Install lock-screw through yoke 2 13/16 inches and install between beams and pitch
bearing nut and lockwire. Press bearing outer race horns. Check angular relationship of blade grips. (Re-
from grips using pressing plug T100393. Apply a fer to paragraph 2-56.)
light coat of rubber cement (EC847, Minnesota Mining
and Manufacturing Co.) to an area 1/4 inch wide on g. Install pillow block seals (38) on pins (39). Lubri-
both sides of seals. Assemble grips pack withgrease, cate bearings (37). Place lock-ring in groove of bear-
and install as outlined in step c. Install locking plate ing outer race, and press bearings onto pins with
with screws and form flange of plate into two wrench radius of inner race next to pillow block.
slots of adapter, using a square punch same width
as slot. Lockwire screws. Note
Note All helicopters using 47-120-190-1 gim-
bal ring bearings must have lock-ring in-
Pack grips with grease so when they are stalled in groove on outer race of each
installed they will be full of grease. bearing.
f. Install pitch and equalizer horns on grips. Torque h. Install pillow block on hub yoke and torque nuts
bolts 200 to 225 inch-pounds and lockwire. Insert 300 to 350 inch-pounds. Place shims (30) on inboard
snap-ring (7) in bearing bore of equalizer beam. Place shoulder of each pillow block pin. (0.030 inch for
spacer (6) into bore against snap-ring (inboard side) initial adjustment.) Lubricate thrust bearings (35)
and press bearings (5) into place. Insert mounting and install against shims, with thrust side of bearing
bolt through beam assembly so that offset ends of inboard.
2-23
MAINTENANCE
Note 1. Clean mating surfaces of gimbal ring. Hold as-

sembled trunnion in place, align matchmarks on halves
Two alternate procedures are provided of ring, and position upper and lower halves of ring
for checking and adjusting clearances together. Install Allen screws and tighten alternate
during assembly of gimbal ring. One pro- screws until a slight pressure is exerted. Tap ring
cedure is outlined in steps i. and 1. and with a soft mallet to insure exact alignment of the
the other in steps m. through r. halves of the ring and seat the outer races of the
bearings properly. Torque screws evenly 175 to 200
inch-pounds. Safety screws in pairs with 0.040 inch
i. Place pillow block bearing caps (34), with lugs lockwire. Install Zerk fittings in pillow block and
facing up over inboard bearings. Place lower half of trunnion bearing caps. Check pillow block caps for
gimbal ring (26) on pillow block pin bearings, bottom free turning. Check trunnion bearing caps for turning
side up, rotate gimbal ring half into proper position with a slight drag, indicating proper fit. Attach dynam-
and support securely. Place a suitable clamp over ic stop cables to lugs on pillow blocks caps. Install
each bearing cap and outboard end of pin, and lightly drag braces (2) and counterweights (1). Torque drag
tighten each clamp. Check for 0.002 to 0.004 inch end brace bolt 160 to 190 inch-pounds.
clearance at each pillow block assembly, measuring
between bearing cap and lip of gimbal ring bearing m. Place pillow block caps (34) (with lugs up) over
bore. Add or remove shims from the pillow block inboard bearings. Place lower half of gimbal ring
pins (36) in equal amounts so the two sets of shims (26) over pillow block pin bearings (bottom side up).
are equal within 0.002 inch. Total overall end play Rotate this half of ring into proper position. (Lugs
after assembly must be 0.004 to 0.008 inch. on caps should now be down.) Secure lower half of
ring in psotion by placing a wedge between hub yoke
j. Install seals (32) on inboard shoulders of trunnion and ring.
(33). Lubricate bearings (31) (place lock-ring on 47-
120-190-1 bearings) and install bearings on shoulders n. Install micarta seals (32) on inboard shoulder of
against seals, with chamfer of bearing inner race in- gimbal ring trunnion (33). Lubricate roller bearings
board against shoulder. (31) (place lock-ring (41) on each bearing if 47-120-
190-1 bearings are used) and install on each shoulder
k. Install shims (29) (0.030 inch for initial setting) of trunnion, with chamfer on inner race of bearing
on each trunnion shoulder, lubricate and installthrust inboard. Install shims (29) (0.030 inch for initial
bearings (28) on each shoulder against shim, with fitting) on each outboard shoulder of trunnion. Lubri-
thrust side of bearings outboard. Place bearing cap cate thrust bearings (28) and install, with thrust sides
(27) over each trunnion, and install trunnion assembly outboard, on trunnion next to shims. Place trunnion
in bore of upper half of gimbal ring (26). Place a caps (27) on each end of trunnion.
suitable clamp over each bearing cap and inside of
trunnion, lightly tighten each clamp. Check for 0.000 o. Clean mating surfaces of gimbal ring. Installupper
to 0.002 inch end play between flange of cap and lip half of gimbal ring (26), aligning match marks. Install
of gimbal ring bearing bore at end of trunnion. Total Allen screws and tighten alternate screws until each
overall end clearance at both ends should be 0.000 to screw exerts a light pressure. Tap ring with a soft
0.004 inch, with 0.002 inch recommended. Add to or mallet to insure exact alignment of the two halves,
substract from shims (29) in equal amounts on each and to properly seat the outer races of bearings.
side to obtain desired clearance. Torque screws 175 to 200 inch-pounds.
(Alternate method for shimming Main Rotor Gimbal Note

Ring for INITIAL assembly.) Hub should be ina static
position on work bench. Verification of 0.000 to 0.002 Check pillow block clearance with main
end clearance at Pillot Blocks and Spindle Ends of rotor blades removed from hub assembly
Core, 47-120-117, will be accomplished as follows: and preferably on bench with hub assem-
bly removed from helicopter.
(1) PILLOW BLOCKS-Hand pressure will be p. Remove Zerk fitting from pillow block pin, install
applied to clevis end of dynamic stop. Following ini- a 1/4 - 28 bolt, and mount a dial indicator on the
tial breakaway resistance 15 to 30 inch-pounds of bolt so that the indicator nib is against the flat ma-
applied force will overcome drag permitting CAP, 47- chined surface of the gimbal ring, adjacent to the
120-140, to be rocked back and forth. micarta seal. Using care to avoid scratching or
marring the gimbal ring, insert a screwdriver be-
(2) CORE SPINDLES-Apply 15 to 30 inch- tween the gimbal ring and the pillow block on op-
pounds pressure to a six inch end wrench on zerk posite side of hub. Exert pressure to move gimbal
fitting in CAP, 47-120-138, following initial break- ring toward dial indicator. Take hold of cap of pillow
away resistance this will overcome drag permitting block which is next to indicator, and release tension
rotation of CAP, 47-120-138. on screwdriver until cap can just be turned. Note dial
2-24
MAINTENANCE
indicator reading at this point (or set dial to zero).

Remove screwdriver and insert itbetween gimbal ring
and pillow block next to indicator, and exert pressure
to move ring away from dial indicator, thus loading
cap of pillow block at opposite side. Release pressure
on screwdriver until cap can just be turned, and again
note dial reading. Total end play, as indicated by dial
readings, must be 0.000 to 0.004 inch. Adjust lamin-
ated shims as necessary. Remove dial indicator when
adjustment is complete.
q. Check trunnion cap clearance by turning caps by
hand. Specified total overall end play is 0.000 to 0.004
inch, with 0.002 inch recommended. If caps can be
turned by hand, but have a slight drag, adjustment is
satisfactory. Adjust amount of shims if necessary.
r. Safety Allen screws in pairs with 0.040 inch lock-

wire. Install Zerk fittings in pillow block pins and
trunnion bearing caps. Remove wedges from between
yoke and gimbal ring. Check pillow block caps for
free oscillation. Attach dynamic stop cables to lugs
on pillow block caps. Install drag braces (2) and
counterweights (1). Torque drag brace bolt to 160 to
190 inch-pounds.
2-24A
MAINTENANCE
e. Remove aligning bar and rotate grips to check a. Heat pillow block, using a heat lamp or a suitable
that no binding occurs. Install gimbal ring assembly. heating method.
Torque pillow block bolts 450-500 inch-pounds.
b. Position pillow block on a press and press out
f. Install main rotor blades. Install main rotor. pin assembly. Use caution not to crack pillow block.
c. Place pin assembly in dry ice or a freezer com-
2-57. INSTALLATION - MAIN ROTOR HUB. partment, for approximately one hour, prior to in-
a. Install main rotor blades. (Refer to paragraph stallation
2-47.) d. Pillowblock may be heated as instructed in sub-
b. Install main rotor assembly.(Refer to paragraph paragraph a. Apply zinc chromate into hole in pillow
2-15.) block, position pin assembly squarely into hole in
pillow block and press in pin assembly. Use caution
2-58. REPLACING PIN ASSEMBLY IN PILLOW not to crack pillow block.
BLOCK.
2-26
Model 47G-2 BELL HELICOPTER COMPANY Section II (Part 2)
MAINTENANCE
Section II - Part 2
Main Rotor System
2-1. MAIN ROTOR INSTALLATION. and mechanic is recommended, since it is sometimes
difficult to distinguish between similar indications of
2-2. DESCRIPTION. Model 47G-2, Serial No. 2454 unlike conditions. Also recommend any adjustments
and subsequent are equipped with metal blades. The be made in small increments, and clearly recorded
main rotor installation consists of two main assemb- for reversal if effect is wrong.
blies, the hub and blades. The hub is mounted on the
mast by means of a splined universal type mounting
called agimbal ring and secured with lock-washer and Vibrations occurring once per revolution of the main
nut. rotor (slow enough to count) are termed 1:1 vibrations.
Direction, vertical or lateral, in which they are felt
The blades are mounted in the hub grips and secured by crew is significant in determining cause.
by attachment bolts. The attachment bolts are so
located that when the blades are properly installed
and aligned they will be 3/4 inch in front of the axis of
thegrip. Vibrations occurring twice per revolution of main
rotor (too fast to count) are termed 2:1 vibrations.
2-3. TROUBLE SHOOTING - MAIN ROTOR. The Direction is not significant.
following outline lists conditions which may be en-
countered in flight test after installation of main rotor. High frequency vibration, or buzz, does not originate
Before making adjustments, careful diagnosis by pilot from main rotor.
INDICATION OF TROUBLE PROBABLE CAUSE CORRECTIVE ACTION
1:1 Lateral vibration

(a) In hover or forward flight Spanwise out-of-balance Dynamically balance with tape
Chordwise out-of-balance Dynamically balance by sweeping

blade
"Hub rock" Adjust equalizer
(b) Bumping in abrupt maneuvers One dynamic stop cable too Rig dynamic stop cables. (Section
short. (2:1 if both cables short) VII.)
Sprag mount weak or one Readjust sprag mount system or

safety cable too short. (2:1 if replace parts. (Section V.)
both sides)
1:1 Vertical vibration (or

bounce)
(a) In hover and forward flight Rotor out-of-track Adjust trim tabs
(b) In forward flight but not Climbing blade Compare high and low speed track.
hover Adjust
2:1 Vibrations
(a) In hover or forward flight Mast misaligned Adjust sprag mounts. (Section V.)
Excessive play in sprag Replace worn parts. Preloadlateral

mounting sprag rods. (Section V.)
Elevator buffeting Adjust elevator cable tension. (Sec-

tion VII.)
Rev. 3 2-1
Section II (Part 2) BELL HELICOPTER COMPANY Model 47G-2
MAINTENANCE
(b) Bumping in maneuvers See (b) under 1:1 Lateral
Collective pitch control creep- Incorrect counterweights Adjust counterweights

ing in normal cruise
Rotor rpm high or low in auto- Minimum pitch blade angle in- Adjust both pitch control rods
rotation correct
Erratic nudging of cyclic con- Rotor unstable on longitudinal Sweep both blades aft
trol stick axis
2-4. TRACKING - MAIN ROTOR. Note

(Figure 2-7.)
Pitch change links have turnbuckle adjustment,
Note~1/4 turn roughly equivalent to 1/2 turn of
equalizer link adjustment. Observe this ratio
when rolling grips to correct an out-of-track
If tracking is being accomplished follow-
initial assembly of
initial assembly
inging main rotor,proceed
of main rotor,proceed condition. Safety wire pitch change links when
as follows: adjustment is complete. (Figure 2-19.)
e. Recheck track. If same blade is still identified
a. Check trim tab angles and adjust to "trail" as the low blade, shorten pitch link 1/4 turn on opposite
position. (Trim tab in line with blade lower contour.) blade and adjust equalizer linkage as requried to maintain
Check that pitch change links are set to equal lengths the hub yoke level. Repeat step d and this step until
(7 13/16 inches). satisfactory track is obtained.
b. Attach a piece of rubber to a small pole and Note

coat upper surface of rubber with a marking compound.
(Prussian blue or red lead mixed with oil.) Start and Alternate adjustment of pitch links as
warm up engine in accordance with instructions in Flight specified in steps d. and e. will retain
Manual. Operate engine at 3100 rpm an apply collective the minimum blade angle obtained by ad-
pitch to the maximum without the helicopter becoming justing pitch links step a. above to speci-
airborne. fied length and produce an autorotation rpm
within safe limits for test flight.
CAUTION
If run-up is being performed by other than

an experienced pilot, tie the helicopter down.
c. Slowly raise tracking pole into path of rotor

blades, near the tip, just far enough to mark the low
blade. Stop engine and allow rotor to stop.
d. Identify low or marked blade and lengthen pitch

change link one quarter turn. Check hub yoke to determine
if it is level with mast vertical and swashplate and
stabilizer bar level. (Use T101234 swashplate rigging i
fixture. (Figure 2-18.) If hub is not level, adjust equalizer
linkage as required to level hub yoke. Maximum adjustment
is limited to two full turns on any one equalizer link. 47749-3A
Check safety holes in rod-ends after each adjustment and
maintain as near equal lengths as possible. Figure 2-18. Swashplate Rigging Fixture
2-2 Rev. 3
MAINTENANCE
CORRECT INCORRECT
INSTALLATION INSTALLATION
PARALLEL
AN995-C32
LOCKWIRE
NOTE
SAFETY WIRE LINKS WITH I NOTE:
BARREL ADJUSTMENT AS - All pitch control links must be
SHOWN installed parallel as shown
47150-17
Figure 2-19. Pitch Change Link Adjustment
f. Test fly helicopter and check autorotation rpm b. Test fly helicopter. If the force is positive,
to be within limits. (333 rpm minimum to 370 rpm (collective lever tends to creep upward) remove
maximum.) At light gross weight and near sea level counterweights equal on both rods, if the force is
conditions the rotor speed should be near the minimum negative, (collective lever tends to creep downward)
operating limit as higher gross weights and altitudes add counterweights equal on both rods.
will produce higher rpm. If rotor underspeeds,
shorten pitch change links equally to reduce minimum c. Maximum of 18 washers, 61-103-120-1, on
pitch. If rotor overspeeds, lengthen pitch change each counterweight rod is allowed.
links equally to increase minimum pitch.
2-5. SPANWISE BALANCE CHECK - ROTOR
g. If rotor goes out-of-track in forward flight, INSTALLED.
it will be necessary to refine the track by adjusting
trim tabs. To find the low blade in forward flight,
accomplish the following procedure:
This procedure may be used as a field
1. Accomplish a tracking procedure at mini- check when pilot reports vibration
mum pitch at 1800 rpm and identify the low blade which appears to originate from spanwise
The low blade at 1800 rpm low pitch will be the high out-of-balance of main rotor.
blade in forward flight and therefore the trim tab of
the opposite blade should be bent up to correct the a. Park helicopter in a level area protectedfrom
condition. If the correction requires more than four circulating air. Disconnect pitch control links from
degrees of positive trim tab (above trail position) it pitch horns. If blades do not remain in the low pitch
is permissible to bend the opposite tab below trail position, secure them in low pitch by wrapping wire
the necessary amount to correct the condition. around counterweight shafts.
2-4A. ADJUSTING COUNTERWEIGHTS- MAIN b. Disconnect dynamic stop cables from stabilizer
ROTOR. bar center frame. Check rotor for freedom of move-
ment above spanwise axis by flapping blades slowly.
a. For initial flight, new or overhauled rotor, in-
stall seven counterweight washers, 61-103-120-1, and c. Position level spanwise on hub yoke. Pull one
one solidcounterweight47-110-239-9, on each counter- blade down slightly, release blade and allow it to
weight rod. This is the maximum each counterweight come to rest. Pull opposite blade down, release and
rod will accommodate. allow it to come to rest. Recheck the level.
2-3
Section II (Part 2) BELL HELICOPTER COMPANY Models 47G & 47G-2
MAINTENANCE
Note d. Adjust the drag brace on the light or high

side to sweep the blade aft until bubble movement
Main rotor hub gimbal bearings should is to the center.
not be pressure lubricated just prior to
balancing or balance checks. If rotor is 2-7. SWEEPING BLADES - ROTOR INSTALLED.
not in balance, balance in accordance with
paragraph 2-9.
Note
2-6. CHORDWISE BALANCE CHECK - ROTOR
INSTALLED. The following procedure can be used to
improve an unstable condition of the main
Note ~rotor. This condition may be recognized
This
may
procedure
be used as
This procedure may be used as a field
a in
control as
field flight an erratic nudging of the cyclic
stick. Do not use this procedure
check when pilot reports a vibration which control stick.
appears to originate from
appears from aa chordwise until initialbeen
fight have blade alignment and check
accomplished.
out-of-balance condition of main rotor. flight have been accomplished.
a. Park helicopter in a level area protectedfrom a. Place a scale along the drag brace assembly
circulating air. Disconnect pitch control links from parallel to it and aligned to the exact center of the
pitch horns. Position blades between zero and five wrench at on the drag brace. Place a crayon mark
degrees pitch angle. on the end fittings and on the wrench flat. On the
b. Disconnect the dynamic stop cables from sta- exact center of the next flat on the drag brace place
a crayon mark. (Figure 2-20.)
bilizer bar center frame. Place a cross test spirit
level on the hub yoke. Level hub spanwise.
c. Rock hub chordwise and note position of bubble

in level when hub comes to rest. If bubble is centered,
rotor is level chordwise.
Note Do not mark with scribe or punch.
Main rotor hub gimbal bearings should b. Loosen lock-nuts. Turn drag brace to shorten
not be pressure lubricated just prior to and sweep blades aft until second mark is in align-
balancing or balance checks. If the hub ment with marks on drag brace fitting. Tighten lock-
does not return to the same position each nuts and make certain marks are still in alignment.
time it is released, there is friction in the Sweep opposite blade in the same manner. Adjustdrag
gimbal bearings which must be corrected. braces with care as both blades must be swept aft
If reading indicates that hub is heavy on one exactly the same amount. Test fly helicopter after
side, observe step (d). each adjustment.
2-4
MARK REFERENCE LINES

WITH CRAYON
47110-34A
Figure 2-20. Marking Drag Brace
Note c. Remove droop from blades by placing a

47-976-002-1-T202 support under each blade. (See
If unstable condition has been eliminated figure 2-22.)
or reduced to an acceptable degree no
further adjustment is recommended. If d. Attach a linen thread to alignment pin at blade
condition
condition has
has not
not been
been corrected
corrected repeat
repeat tip, pull thread taut and attach to opposite blade in
preceding step (b) until blades have been
swept aft a total of five flats. Sweeping same p
blades aft will change collective pitch
forces which may require adjusting amount e. Place a square on each of the blade bolts so that
of counterweights. (Refer to paragraph the scales are directly in line with the scribe marks
2-4.) on the grips.
2-8. ALIGNMENT - MAIN ROTOR BLADES.

Note
a.Place rotor assembly on stand. Remove nuts
and washers from pillow block bolts and using a Two small mirrors may be used in place
dural drift, drive the pillow block bolts out. Care of the squares if desired. Place mirrors
should be taken that heads of bolts are positioned on each blade bolt head and under the
so they will not score the gimbal ring. Remove gimbal thread. By adjusting the drag brace so
ring. (See figure 2-21.) when sighting into the mirror the thread,
the scribe mark, and the reflection all
b. Insert pitch control attachment bolts in pitch lie in the same plane on both blades, the
horns. Raise pitch horns and place T 100747 aligning bar blades will be aligned.
chordwise on the hub yoke. Lower pitch horns until
pitch link attachment bolts contact upper surface of f. Align blades simultaneously using squares (or
the bar. Use C-clamps to hold bolts in contact with the mirrors) on the head of blade bolts. Adjust drag brace
bar. to position the thread over each outboard grip mark.
Rev. 3 2-5
MAINTENANCE OVERHAUL INSTRUCTIONS
COUNTERWEIGHTS
COUNTERWEIGHT
RODANDSPACER
Figure 2-21. Checking Alignment of Blades
g. Insert wire into inspection holes at end of drag

brace to make sure rod-end enters tube to cover in-
spection holes. Tighten lock-nuts and recheck align-
ment. Torque blade attachment bolts 1200 to 1400
inch-pounds.
h. Remove C-clamps and thread from hub and

blades. Remove aligning bar and pitch attachment
bolts. Install gimbal ring and pillow block bolts 450
to 500 inch-pounds. Check balance of main rotor
assembly.
2-9. BALANCING - MAIN ROTOR.
a. Place rotor on a suitable stand, and check

spanwise and chordwise balance.
b. Position blade pitch horns so that blades are
47110-2 between zero and five degrees pitch angle. Place a
spirit level on the upper surface of the yoke in a
Figure 2-22. Blades Supported to Remove Droop spanwise direction.
2-6 Rev. 3
c. Check spanwise level to determine if rotor

assembly is level. If bubble is not centered, screw
weight attachment bolt in the heavy blade to within
1/8 inch of bottoming.
d. Place any combination of AN960-616, AN970-6
washers, or 61-103-120-1 weights on weight attach-
ment bolt of light blade necessary for balance.
e. Screw weight attachment bolt, with weights,
into end of blade retention bolt. (See figure 2-23.)
Torque bolt 120 to 150 inch-pounds. Recheck span-
wise level.
f. Set blade grips to approximately plus five de-
grees and lockwire in position. Place a cross test
spirit level on the hub yoke. Rock the hub chordwise 1. Rotor Blade
and allow it to settle. Check position of chordwise 2. Rotor Attaching Bolt
level. If bubble is centered, blades are in chordwise 3. Rotor Grip
balance. 4. Weights
5. Washers
g. If bubble is not centered adjust drag brace of 6. Weight Attaching Bolt
light or high blade to sweep it aft until bubble move- 7. Nut
ment is toward center. Rotor assembly should be 47110-35
free enough to stop on center when rocked.
Figure 2-23. Balancing Weight On Blade

CAUTION Part No. 47-110-250-13
Do not change weights in tip of 47-110-

250-13 blades as they are factory bal- apply a light coat of lubricating grease to splines
anced for spanwise interchangeability. and a thin coat of anti-seize compound to mast
threads.
2-10. REMOVAL - MAIN ROTOR.
b. Position hoist over hub. Attach rotor sling
a. Straighten tangs on lock-washer that secures T100220 by wrapping each cable twice around each
the main rotor retaining nut. Using wrench, T101381, blade grip near the hub. Engage sling to hoist and
remove mast retaining nut. Lift off lock-washer and take up slack.
static stop. (Dynamic flap restraint, if installed.) Dis-
connect pitch control links from pitch horns. Discon- c. Position blades at approximately plus five
nect dynamic stop cables from stabilizer bar center degrees. Put tension on cables using care that grips
frame. do not twist enough to put tension on the equalizer
linkage. Station a man at each blade tip to guide the
b. Position hoist directly over mast. Attach rotor rotor and one at the hub to guide the hub on the mast.
sling T100220 by wrapping each end twice around the Raise the rotor above the mast with blades 90 de-
blade grip. Connect sling to hoist and take up slack grees to the stabilizer bar and the color bands
in cables. matched. Align the splines and lower the rotor until
it rests firmly on the split cone. Disconnect hoist
c. Position blade grips at approximately five and remove rotor sling.
degrees. Slowly raise main rotor from mast. Do not
allow grips to rotate -in journals enough to load Note
equalizer linkage.
It is permissible to increase the Core pin
d. Lower rotor and place on suitable stand. Re- holes to, 0.140 - 0.146" diameter, as shown
move split cones from mast. on figure 2-24.
2-11. INSTALLATION - MAIN ROTOR. d. Install static stop, (dynamic flap restraint,
if removed) lock-washer, and mast retaining nut on
a. Clean mast threads, splines, cone seat and mast. Using wrench T101381 torque main rotor re-
split cone with cleaning solvent. Examine splines for taining nut 125 to 175 foot-pounds. Bend two tangs
nicks, burrs or scratches and dress smooth with fine of lock-washer upward to lock retaining nut. Attach
stone if necessary. Position split cones on mast, pitch control links to pitch horns on blade grips.
2-7
2-15. REFINISHING - METAL MAIN ROTOR

BLADES.
Types of finish descrepancies and procedures neces-

sary to accomplish repair in the field or by a main-
tenance and overhaul facility are as follows:
a. Blades having thin or damaged lacquer top
coats or, to restore or change topcoat color.
0.140
DRILL 0.146DIA 0.25DEEP
(2 HOLES)COUNTERSINK 0.03x 45 (1) Degrease with aliphatic naphtha, TT-N-
95, Type 2. Do not use a solvent that will dissolve
or otherwise damage the lacquer finish.
(2) Scuff sand lightly, using No. 600 grit
sandpaper. Wet or dry sanding is permissible.
(3) Wash with cleaning compound, MIL-C-

18687A, mixed as follows: Four ounces of power per
gallon of water or one ounce of liquid detergent per
gallon of water. Throughly rinse the washed surfaces
to remove all traces of cleaning compound. Check for
47120-66 a clean surface that will be evident by a continuous
unbroken film of water on the surface. Allowthe blade
Figure 2-24. Rework or Core - Main Rotor Hub to dry thoroughly.
Note
e. Connect dynamic stop cables to stabilizer bar
center frame. Do not handle blade with bare hands from
this step through painting operations.
f. Adjust dynamic stop cables. (Refer to Sec-
tion VII.) (4) Apply three wet coats of P-95 acrylic
lacquer, gloss aircraft gray, F.S. Color No. 16473
to upper surfaces of blade.
2-12. MAIN ROTOR BLADES.
(5) Apply three wet coats of P-95 acrylic
2-13. DESCRIPTION. The main rotor blades are lacquer, camouflage black, F.S. Color No. 37-038
constructed of metal spars covered with aluminum to root end and the entire lower surface of the blade.
skin and a stainless steel leading edge. The end of
the blade that attaches to the grips is built up using Note
doublers, grip plates, and drag plates.
Allowthe lacquer to air dry a minimum of
45 minutes between coats.
2-14. REMOVAL - MAIN ROTOR BLADES.
b. Blades with organic finish defects such as
a. Remove main rotor assembly, place assembly
on suitable stand with supports under each blade small bare there
fects and areas, cracks, blisters or other such de-
is no evidence of corrosion on the
approximately 2/3 outboard of hub to remove droop, aluminum.
b. Observe color coding on blades and grips so (1) Solvent degrease with aliphatic naphtha
blades may be reinstalled in same grip. TT-N-95, Type 2. Donotusesolventsthatwould soften
or damage the organic finish.
Note
(2) Sand out defects in the organic finish
If color coding is not evident, color code using No. 320 grit or finer sandpaper. Wet or dry
all parts. (Refer to figure 2-16, and para- sanding is permissible. Smooth or bend sanded areas
graph 2-21.) to a feathering edge using No. 600grit sandpaper. Wet
or dry sanding is permissible. Remove sanding resi-
due with naphtha dampened cheesecloth.
c. Disconnect drag brace from blade. Remove
blade retention bolt. Lift blade tip slightly and slide (3) Wash with cleaning compound, MIL-C-
blade free of grip. Place blade on a suitable stand. 18687A, mixed as follows: Four ounces of powder
Remove opposite blade in same manner. detergent per gallon of water or one ounce liquid
2-8
MAINTENANCE
detergent per gallon of water. Thoroughly rinse the

washed surfaces to remove all traces of cleaning
compound. Check for a clean surface that will be
evident by a continuous unbroken film of water on the
surface. Allow the blade to dry thoroughly.
shall not be used to remove finish from the
adhesive squeeze out areas (bondlines).
Note (4) Check blade surfaces for possible corro-

sion, and any pitting that may have resulted from the
Do not handle blade with bare hands from corrosion. Any corrosion and/or pitting shall be re-
this step through painting operations. moved from the blade surfaces as follows:
(4) Where there is any bare aluminum ex- a. From butt end to station 140 corro-
posed, apply a brush touchup application of MIL-C- sion and pits if any, shall be polished out. Maximum
5541, Chemical Film Treatment. If the chemical polishing depth is 0.012 inch. Beginning at station
film is unavailable, use a 10% solution of chromic 140 and extending outboard, corrosion and pits if any,
acid. Allow the solution (keep wet) to react for ap- may be polished out to any depth required without
proximately two minutes. Rinse thoroughly. Allow penetrating through the outer skin. A flexible disc
the surfaces to dry. type air or mechanical driven sander may be used
to remove or burnish out the corrosion. Use fine
(5) Spray one wet coat of epoxy primer over aluminum wool or No. 600 grit sandpaper as the final
all reworked or epoxy primer exposed areas of the polish (rubbing spanwise) to remove burnishing tool
blade. Allow the epoxy primer to air dry a minimum or sanding scratches and all corrosion. Wet or dry
of 30 minutes, up to a maximum of four hours. sanding is permissible. Inspect adhesive squeeze out
and/or fairing. Remove any damaged adhesive squeeze
(6) Apply three wet coats of P-95 acrylic out or fairing. Use an edge sharpened piece of acry-
lacquer, gloss aircraft gray, F.S. Color No. 16473, lic (plexiglas etc.) to remove any damaged adhesive
to upper surfaces of blade. squeeze out. If no corrosion is evident under the
adhesive or fairing, sand lightly with No. 600 wet
(7) Apply three wet coats of P-95 acrylic or dry sandpaper.
lacquer, camouflage black, F.S. Color No. 37038 to
the root end, and entire lower surface of blade. Note
When corrosion cannot be removed within
the above tolerances, remove the blade
from service.
Allow the lacquer to air dry a minimum of When blades are found to have doubler
45 minutes between coats. separations or void in the doubler adhes-
ive that is in excess of the allowable in
c. Blades with severely deteriorated finishes such the inspection section of the maintenance
as surface cracks, blisters, bare spots, etc., with or and overhaul manual, they shall be with-
without evidence of corrosion of the aluminum. held from service until a disposition is
authorized by the Bell Helicopter Company
(1) Degrease with aliphatic naphtha, TT-N- Service Department.
95, Type 2, or other degreasing solvent.
When there are indications of corrosion
(2) Mask adhesive squeeze out (bond line), extending under the stainless leading edge,
so as to prevent softening of the adhesive. With the the blade shall be withheld from service
adhesive squeeze out and/or bond lines masked, use pending disposition by Bell Helicopter
cheesecloth, or Scotchbrite pads, Type A, fine, wetted Company Service Department.
with methyl-ethyl-ketone and then scrubbing until
finish is removed. Repeat applications until finish is (5) Apply chemical film treatment, MIL-C-
removed. Usage of Scotchbrite pads or sandpaper will 5541 to bare aluminum exposed by removal of bond-
usually remove the alodine or anodize chemicaltreat- adhesive (fairing) squeeze out.
ment. This is permissible.
(6) Apply fairing compound RP 1257-2 (mixed
(3) Finish shall be removed from the adhesive 10 parts to one part hardener) to areas requiring fair-
squeeze out (bond line) by sanding, using No. 600 grit ing due to adhesive squeeze out removal. Remove
sandpaper, wet or dry, and/or Scotchbrite. Avoid sand- excess fairing compound by sanding. Use No. 600 grit,
ing through the adhesive squeeze out except when wet or dry sandpaper as a final sanding operation
corrosion is evident. of the fairing compound.
2-9
(7) Sand stainless steel leading edge employ- Note

ing a circular motion. Use 180 grit, wet or dry
sandpaper. Air dry the corrosion and abrasion re-
sistant coating a minimum of 30 minutes
between coats (the coating does not dry
tack-free in 30 minutes).
CAUTION
(14) Allow the corrosion and abrasion resis-

Do not allow the sandpaper to overlay onto tant coating to air dry for 16to 24 hours at room tem-
the aluminum surfaces while sanding the perature, or dry 30 minutes at room temperature
stainless steel leading edge. and heat cure approximately two hours at 150° to
160°F. If heat cure is used, allow the metal to return
to room temperature prior to topcoating.
(8) Wash blade areas with cleaning compound
MIL-C-18687A, mixed as follows: Four ounces of (15) Apply one thin wetcoatingofepoxyprimer
powder detergent to one gallon of water or one ounce to all blade surfaces. Allow to air dry 30 minutes to
liquid detergent to one gallon of water. Thoroughly two hours.
rinse the washed surfaces to remove all traces of
cleaning compound. Check for a clean surface that (16) Apply three wet coats of P-95 lacquer,
will be evident by a continuous unbroken film of gloss aircraft gray, F.S. Color No. 16473, to upper
water on the surface. Allow the blade to dry thro- surfaces of blade.
oughly.
(17) Apply three wet coats of P-95 lacquer,
camouflage black, F.S. Color No. 37038, to root end
Note and the entire lower surface of the blade.
Do not handle blade with bare hands from

this step through painting operations. Note
Allow the lacquer to air dry a minimum of

(9) Apply by brushing, flowing, or spraying, 45 minutes between coats.
chemical film treatment, MIL-C-5541, to all exterior
surfaces of the blade. Keep the surfaces wet with Allow the finish to air dry a minimum of
the solution for one to three minutes. Thoroughly 48 hours prior to installing blades on the
rinse with water. Insure that all solution is removed. helicopters.
Air-dry.
d. Corrosion and abrasion resistant coating.
(10) Apply one wet coat or epoxy primer to
entire blade. Allow the epoxy primer to air dry a (1) Mixing This material is a two part
minimum of 30 minutes and a maximum of four hours. of EC-2216 epoxy paste.
(11) Mask off surfaces of grip plates and drag The "B" material (base) is off
brace plates. Apply two wet coats of corrosion and white in color.
abrasion resistant coating. (EC 2216 plus epoxy primer
mixed and thinned as specified below) from the butt The "A" material (hardener)
end of blade to a distance of approximately 3/4 inch is medium gray.
outboard (follow contour) of outermost doubler tip.
Continue along butting surface (bondline) of stainless Mix the two materials to-
steel leading edge to aluminum skins with a two inch gether until the mixture is
wide coating, overlapping the stainless leading edge a uniform gray in color.
1/4 inch and the balance 1-3/4 inches onthe aluminum
surface, for the entire length of the blade. Mixing Ratio By Weight
(12) Using the same procedure apply two wet Base "B" 100 parts
coats over all surfaces of the trim tab and over- Hardener "A" 140 parts
lapping trim tab squeeze out (bondline), and extending
a minimum of 1/2 inch onto the aluminum surfaces. .------
(13) Following the above, apply one full wet

coat over all epoxy primer blade surfaces, including
the blade areas receiving the prior applied corrosion Pot life of this material as mixed is ap-
and abrasion resistant coating. proximately two hours.
2-10
MAINTENANCE
(2) Thinning The mixed EC-2216 shall be MANUFACTURER'S MANUFACTURER'S

of EC-2216 thinned for spraying as fol- DESIGNATION NAME AND ADDRESS
lows:
Methyl-Ethyl- Solvent or Chemical Distri-
a. Add 13% to 15% (by weight) of Super Ketone butor
Koropon epoxy primer (513-003) mixed 1:1 with cur-
ing solution (910-014), to the mixed EC-2216. Mix RP-1257-2 Wren Plastics
thoroughly. (paste & hardener) Lansing 9, Michigan
b. Thin to a sprayable consistency by 2-16. INSTALLATION - MAIN ROTOR BLADES.

adding methyl-ethyl-keton in an amount not to ex-
ceed 50% by volume of the mixed EC-2216. Add the a. Observe color coding of blade tips and grips.
methyl-ethyl-ketone in small amounts, with constant Install blades in grips, install blade attachment bolts
stirring (usually a 35% by volume of methyl-theyl- and torque bolts 1200 to 1400 inch-pounds.
ketone will produce a sprayable consistency).
b. Connect drag braces to blade retention plates.
CAUTION pounds.
2-17. MAIN ROTOR HUB.

Spray pot life of the thinned corrosion and
abrasion resistant material is approxi-
materly three hours 2-18. DESCRIPTION. The hub assembly consists
of two main assemblies, the gimbal ring andthe yoke.
e. List of material and source of supply. The gimbal ring which is the upper portion of the as-
sembly provides universal action for the azimuth
position of the blades. The trunnion of the ring pro-
MANUFACTURER'S MANUFACTURER'S vides the mounting point of the hub assembly to the
DESIGNATION NAME AND ADDRESS rotor mast. The yoke (lower section of the assembly
to which the grips are mounted) is secured to the
Super Koropon DeSoto Chemical Coatings, gimbal ring in such a manner as to permit the hub
Epoxy Primer Inc. assembly to pivot or seesaw in any direction. Pitch
(513-003) P.O. Box 10, Garland, Texas equalization is provided by interconnecting linkage
between the horns and blade grips. The linkage con-
Curing Solution or DeSoto Chemical Coatings, sists of an equalizer arm mounted on each side of
Converter Inc. the yoke and adjustable link-rods which connect the
(910-014) P.O. Box 10, Garland, Texas ends of each equalizer beam and the horn on each
blade grip. Due to this connection, when blade angles
P-95 Acrylic Lac- DeSoto Chemical Coatings, are being changed the angle of both blades is changed
quer (BPS 299- Inc. simultaneously and equally. The dynamic stops are
947-069) P.O. Box, Garland, Texas cable assemblies connected between the gimbal ring
and stabilizer bar to prevent excessive flapping of the
EC-2216 (2 part Minnesota Mining & Mfg. Co. blades, while in flight. Counterweights attached to
material) Scotch- 900 Bush Avenue blade grips aid in balancing collective forces.
brite Type "A" St. Paul 6, Minn.
Grade: very fine 2-19. REMOVAL - MAIN ROTOR HUB.
(nylon web)
Cleaning Compound Atlantic Refining Co. a. Remove main rotor. (Refer to paragraph
(MIL-C-18687, 260 S. Broad St. 2-10.)
Type I, Power) Philadelphia, P. 19105
b. Remove main rotor blades. (Refer to para-
Type 2 (Liquid) Rohm & Haas, Co. graph 2-14.)
Washington Square
Philadelphia, P. 19105 2-20. DISASSEMBLY - MAIN ROTOR HUB.
Regal Beads Armour and Company Note

(Laundry Deter-
gent Powder) Observe color coding before disassembly
of hub so parts may be reinstalled inorig-
Aliphatic Naphtha Any solvent or Petroleum inal location. (Refer to paragraph 2-26
TT-N-95, Type 2 Company Distributor for color coding.)
Rev. 3 2-11
Section II (Part 2) BELL HELICOPTER COMPANY Model47G-2
MAINTENANCE
a. Remove cotter pins, nuts, and washers that secure c. Inspect blade bolt holes in grip for scored
counterweight assemblies to equalizer horns. Lift marks possibly made during removal of bolt. Polish
counterweight assemblies (1, figure 2-15) from horns and out such marks to eliminate source of fatigue cracks.
remove drag braces (2). Remove pillow block bolts (3) Maximum diameter of bolt hole must not exceed
and lift gimbal ring and pillow blocks from yoke. 1.004 inches.
Disconnect and remove equalizer links (4) from equalizer
beams and blade grip horns. d. Inspect static stop for permanent set or other
indications of hard contact with gimbal ring.
b. Remove cotter pins, nuts, and washers from
inboard ends of bolts securing equalizer beams to yoke. e. Refer to Section I for magnetic particle and
Remove equalizer beam bolts and remove beams (8) fluorescent penetrant requirements.
from yoke as an assembly. Remove bearings (5), spacer
washer (6), and snap-ring (7) from beam. f. Inspect parts dimensionally. (See figure 2-10.)
c. Cut lockwire, remove attaching bolts and washers g. Inspect seal ring (20, figure 2-15). Replace seal
and lift blade pitch horns (9) and equalizer horns (10) ring if wear exceeds 0.005 inch.
from grips. Remove locking plate (11) from blade grip
adapter and turn adapter counterclockwise with T100056 2-22. REPAIR OR REPLACEMENT - MAIN ROTOR
spanner wrench until threads are disengaged. Slide grip off HUB.
yoke.
a. Replace all seals on assembly.
d. Press outer race of blade grip bearing (12) and
seal (13) from grip (14) using T100394 pressing plug. b. Clean thrust bearing surfaces of yoke spindles
thoroughly with cleaning solvent and polish with crocus
e. Cut lockwire and remove lock-screw from yoke cloth. Replace yoke if diameter of thrust bearing area
bearing nut. Using T100407 spanner wrench turn nut (16) is less than 2.9499 inches.
counterclockwise. Nut will contact inner race of bearing
and push rollers and inner race (15) from yoke spindle. 2-23. LUBRICATION - MAIN ROTOR HUB. Lubricate
Remove yoke bearing nut (16) and slide spacer (17) bearings with MIL-G-25537 grease during assembly.
adapter assembly, shim (18), O-ring seal (19) and seal
ring (20) from yoke (21). 2-24. REASSEMBLY - MAIN ROTOR HUB.
f. Remove seal (22) and press bearings (23) from Note

adapter (24). Use T101385 pressing plug.
Observe match marks on individual parts and
g. Remove cap screws (25) securing upper and reinstall in their original location.
lower halves of gimbal ring (26) and separate halves.
Lift trunnion and pillow block assemblies from lower a. Press seal (22, figure 2-15) into bore of adapter nut
half of gimbal ring. Remove bearing caps (27), bear- (24). (Lip of seal must be faced to center of yoke when
ings (28), and shims (29) from outboard shoulder of adapter nut is installed.) Use T101385 pressing plug
trunnion. Tag shims for reassembly in samelocation. and press thrust bearing (23) into adapter nut (opposite
Remove zerk fittings (30) from caps. Remove bear- seal) with thrust side of bearing to center of yoke when
ings (31) and seal (32) from inboard shoulder of adapter nut is installed. Install seal ring (20) on yoke
trunnions (33). spindle (21) with radius inside of ring seated on shoulder
(35) and near yoke end of spindle. Install O-ring seal (19) in recess
h.
h. Remove
Remove caps (34)
bearing caps
bearing (34) bearings
bearings (35) and
shims (36) from inner shoulders of pillow block pins. of ring Slide one shim (18) and adapter nut assembly
Tag shims for reassembly in same location. Remove in position against seal ring.
roller bearings (37) and seals (38) from pillow block
pins. b. Slide spacer (17) on spindle and install yoke
bearing retaining nut (16). Torque nut to 1000 to 1500
2-21. INSPECTION - MAIN ROTOR HUB. inch-pounds using T100407 spanner wrench.
a. Inspect all parts for wear or damage. Visually

inspect splines for chipped, cracked, broken or worn
teeth. Inspect bearings for chips, cracks and/or Accomplish steps a. and b. on each yoke
brinelling.
b. Inspect for evidence of fretting corrosion on c. Install pillow blocks (40) temporarily and torque
inner surface of blade grips (where grip and blade nuts on attaching bolts 300 to 350 inch-pounds. Check
contact, see figure 2-10.) and on yoke spindle where clearance between pillow blocks and adapter, adjusting
thrust bearings are mounted. the amount of shims inboard of thrust bearing (as
2-12 Rev. 3
necessary) to obtain clearance of 0.064 to 0.160 inch i. Check angular relationship of blade grips.
at both sides of hub. Clearance at this point on each (Refer to paragraph 2-25.)
side of the hub must be alike within 0.030 inch. (See
figure 2-25.) Install lock-screw through yoke bearing j. Install pillow block seals (38). Lubricate roller
retaining nut. Safety wire lock-screw. Press roller bearing bearings (37). Place retainer ring (41) in groove in
and inner race (15, figure 2-15) on end of spindle each bearing outer race and press bearings on pins
with chamfered edge of race inboard. (39) with chamfer of inner race next to pillow block.
d. Apply a light coat of rubber cement EC1300 k. Install pillow blocks (40) on hub yoke with
to an area approximately 1/4 inch wide around the bolts (3) nuts and washers. Torque nuts 300 to 350
outer edge (both sides) of the outboard bearing seal. inch-pounds. Place shims (36) (0.030 inch for initial
Position seal (13) in grip (14) with beveled face inboard adjustment) on inboard shoulder of each pillow block
when grip is installed. Position outer race (12) in grip pin. Lubricate thrust bearing (35) and install against
with lip on race outboard when grip is installed. Use shim with thrust side of bearing next to pillow block
T100393 pressing plug press outer race into grip. cap. Place pillow block bearing caps (34) (with lugs
up) over inboard bearings.
e. Hand fill assembled grip with grease. Move all the
rollers in bearing (15) toward axis of spindle until they 1. Install shims (29) (0.030inch for initial setting)
touch the inner race. Stand yoke on end with spindle Lubricate andinital setting
facing upward and start blade grip with bearing outer on each shoulder against shims with
race over rollers. If the bearing outer race tends to hang bearing each shoulder
(28) ofonbearings against shims with
thrust side next to cap. Place bearing
on rollers, lift off grip and push rollers inward again thrust side of bearings next to cap. Place bearing
until all touch inner race. Slide grip on yoke. Start threads
cap (27) over each trunnion and install trunnion as-
of adapter plate (24) into grip. Tighten adapter with
sembly in bearing bore in upper half of gimbal ring
(26).Place a suitable C-clamp over each bearing
T100056 spanner wrench. While tightening grip adapter,
use a soft mallet against outboard end of blade grip cap
each and the inside of the trunnion. Lightly tighten
clamp. Check for 0.000 to 0.002 inch end play,
to seat bearing. Check seat to see that end of yoke measuring between flange of bearing cap and lip of
spindle is not bottomed against seal. If seal binds against gimbal ring bearing bore at each end of the trunnion.
yoke, remove grip assembly and add another shim (18) Total overall end clearance at both ends should be 0.000
inboard of thrust bearings. Torque 350 to 375 foot- to 0.004 inch with 0.002 recommended. Add or sub-
pounds. tract from trunnion shims (29) in equal amounts at
each side of trunnion to obtain desired clearance.
f. Install locking plate (11) with screws and form Remove C-clamp. (Alternate method for shimming
flange of plate into at least two wrench slots in adapter Main Rotor Gimbal Ring for initial assembly.) Hub
using a square punch of same width as slot. Lockwire should be in a static position on work bench. Vertification
screws. of 0.000 to 0.002 end clearance at Pillow Blocks and
Spindle Ends of Core will be accomplished as follows:
g. Remove pillow blocks and install blade pitch
horns (9). Torque mounting bolts 200 to 225 inch- (1) PILLOW BLOCKS-Hand pressure will be
pounds. Install equalizer horns (10). Torque mounting applied to clevis end of dynamic stop. Following initial
bolts 50 to 70 inch-pounds. Lockwire all mounting bolts. breakaway resistance 15 to 30 inch-pounds of applied
force will overcome drag permitting 47-120-140 cap to be
rocked back and forth.
h. Insert snap-ring (7)in bearing bore of equalizer
beam (8). Place spacer washer (6) into bore against (2) CORE SPINDLES-Apply 15 to 30 inch-
snap-ring (inboard side) and press bearing (5) into pounds pressure to a six inch end wrench on zerk
place. Insert mounting bolt through equalizer beam fitting in 47-120-138 cap following initial break-away
so that off-set ends of beam will be outboard. Slide resistance this will overcome drag permitting rotation
thin washer on bolt and insert bolt through hole in of 47-120-138 cap.
yoke. Install washer, nut and cotter pin. Install slant
of the slot outboard at the top. Adjustlinks to 2 13/16 m. Clean mating surfaces of gimbal ring. Hold
inches and install equalizer beam links (4) between assembled trunnion in place, align match marks on
beams and blade pitch and equalizer horns with bolts, halves of gimbal ring and install upper half of gim-
washers and nuts with inspection hole in link down. bal. Install cap screws (25) and tighten alternate
Rev. 3 2-13
MAINTENANCE
ADJUST TO CLEARANCE OF .064 TO .160

EQUAL AT BOTH SIDES OF HUB WITHIN .030
BY SHIMMING HERE.
1. Thrust Bearings
2. Adapter
3. Adapter Bearing Seal INBOARD
4. Seal Ring
5. O-Ring Seal
6. Shim
7. Pillow Block
8. Grease Fitting
9. Blade Grip
Spacer
10. Spacer SEE DETAIL A
11. Hub Yoke Spindle
12. Bearing Retaining Nut
13. Lock Screw
14. Bearing Outer Race
15. Bearing Inner Race
16. Seal (Disc)
ROUND OFF ANY SHARP EDGE OF

SEAL RING IN CONTACT WITH YOKE SPINDLE.
DETAIL A
47120-10A
Figure 2-25. CutawayView- Blade Grip Installation
screws until a slight pressure is exerted. Tap ring lower half of gimbal ring in place with wedges be-
with a soft mallet to insure exact alignment of the tween hub yoke and gimbal ring.
ring halves and to seat the outer races of the bearings
properly. Torque cap screws 175 to 200 inch-pounds. o. Install seals (32) on inboard shoulder of gimbal
Safety screws in pairs. Install Zerk fitting (30) in trunnion (33). Lubricate roller bearings (31), place
pillow block pins and trunnion bearing caps. Check lock-ring (41) in groove in each bearing outer race
pillow block caps for free turning. Check trunnion and install on shoulder of trunnion against seals with
bearing caps for turning with a slight drag indicating chamfer on inner race of bearing inboard against
proper fit. Install drag braces (2) and counterweights shoulder. Install shims (29) (0.030 inch for initial
(1). setting) on each trunnion shoulder. Lubricate and in-
stall thrust bearings (28) on each shoulder against
Note shims with thrust side of bearings outboard. Place
bearing caps (27) over each trunnion and install
Observe following steps (p) through (t) trunnion and install trunnion assembly in bearing
for checking adjusting clearance during bore of lower half of gimbal.
assembly of gimbal ring.
n. Place pillow block caps (34) (with lugs up) p. Clean mating surfaces of gimbal ring. Install
over inboard bearings. Place lower half of gimbal upper half of gimbal ring (26) aligning match marks.
ring (26) over pillow block pin bearings (bottom side Install Allen screws and tighten alternate screws
up). Rotate this half of gimbal ring into proper posi- until each screw exerts a light pressure. Tap ring
tion. (Lugs on bearing caps should be down.) Prop with a soft mallet to insure exact alignment of the
2-14
MAINTENANCE
two halves and to properly seat the outer races of pitch control link attachment bolts in main rotor
the bearings. Torque screws 175 to 200 inch-pounds blade pitch horns. Position aligning bar, T100747,
and safety in pairs. chordwise on hub yoke with undercuts at top and
bottom and with pitch link bolts located above the
Note upper surface of the bar.
Check pillow block clearance with main c. Press downward on blade pitch horns, gently
rotor blades removed from hub assembly and evenly until one or both pitch link attachment
and preferably on bench with hub assem- bolts contact upper surface of aligning bar. Make sure
removed from helicopter. that both ends of bar remain in contact with yoke.
If both bolts contact bar or if clearance on free bolt
is less than 0.010 inch relationship between pitch
q. Install a 1/4 x 28 bolt in Zerk fitting opening link bolt holes is satisfactory. Remove bar and
in the pillow block pin. Mount a dial indicator on the proceed with following step (e). If relationship is not
bolt so that the indicator nib is against the flat satisfactory, proceed with step (d).
machined surface of the gimbal ring, adjacent to the
micarta seal. Using care to avoid scratching or d. Disconnect equalizer link from high pitch
marring the gimbal ring, insert a screw driver be- horn
horn and
and shorten
shorten link
link one-half
one-half turn.
turn. Disconnecteither
Disconnect either
tween the gimbal ring and the pillow block on the equalizer link at opposite side of hub and lengthen
opposite side of the hub. Exert pressure to move
opposite side of the hub. Exert pressure to move this link one-half turn. Connect both links and tighten
gimbal ring toward dial indicator. Hold cap of the lock-nuts. Make certain aligning bar is in position
pillow block which is next to the indicator and release on yoke press downward on pitch horns and recheck
on yoke, press downward on pitch horns and recheck
tension on screw driver until the cap can just be
turned. Note dial indicator reading at thii point (or clearance between bolt through high horn and bar.
set dial at zero). Remove screw driver and insert
it between gimbal ring and pillow block next to indi- Note
cator. Exert pressure to move gimbal ring away from
indicator thus loading cap of pillow block at opposite When preceding step (d) is accomplished
side. Release tension on screw driver until cap can the original high horn may move down-
just be turned and again note dial reading. Total end ward (within tolerance) or the bolt through
play as indicated by dial readings must be 0.000 to this horn may touch the bar and the op-
0.004 inch. Adjust laminated shims as necessary. Re- posite horn may move upward. This is
move dial indicator and bolt when adjustment is normal and satisfactory if the clearance
complete. does not exceed 0.010 inch.
r. Check trunnion cap clearance by turning caps e. Remove aligning bar and rotate grips to check
by hand. Specified total overall end play is 0.000 to that no binding occurs. Grip must have free travel,
0.004 inch, with 0.002 inch recommended. If caps can minus two degrees to plus twelve degrees with no
be turned by hand but have a slight drag, adjustment binding of equalizer linkage. Replace gimbal ring
is satisfactory. Adjust amount of shims if necessary. and pillow blocks. Torque bolts 450 to 500 inch-
Shims on both pillow blocks and trunnion must be pounds.
equal on both sides within 0.002 inch.
f. Install rotor blades. (Refer to paragraph 2-16.)
s. Install Zerk fitting (30) in pillow block pins Install main rotor. (Refer to paragraph 2-11.)
and trunnion bearing caps. Remove wedges from be-
tween yoke and gimbal ring. Check pillow block caps
for free oscillation. Install drag braces (2) and 2-26. COLOR BANDING - MAIN ROTOR HUB.
counterweights (1). Torque drag brace to 160 to 190 (Figure 2-16.)
inch-pounds.
2-25. ADJUSTING ANGULARRELATIONSHIP - Note

BLADE GRIPS.
(Figure 2-17.) Match mark parts prior to disassembly
so parts will be reassembled in original
a. Remove main rotor. (Refer to paragraph 2- location. Do not use punch or scribe.
10.) Remove main rotor blades. (Refer to paragraph
2-14.) Remove gimbal ring assembly and pillow
blocks from yoke as an assembly. (Keep pillowblocks a. Replace blade tip markings, if required, with
and gimbal ring together and match mark grip and original color.
pillow block for reinstallation in same location.)
b. Color band and mark the following parts as
b. Position hub assembly so that yoke is resting indicated. Make certain all parts are marked with
on a block with blade grips free to rotate. Insert the tip color of the blade they control.
2-15
MAINTENANCE
1. Blade grip - Band. 6. Equalizer horn to equalizer beam links -

2. Pitch horn link-rods -Band(Mixinglevers Double band.
to pitch horns). 7. Equalizer beams - Single band one end;
3. Pitch horns - Single strip. Double band opposite end.
4. Pitch horns to equalizer beam links - 8. Drag braces - Band.
Single band. 9. Hub yoke - Dot 1/2 inch diameter, one
5. Equalizer horns - Double strip. side.
2-16
Models 47D-1, 47G & 47G-2 BELL HELICOPTER COMPANY Section III
MAINTENANCE
Section III
Mast and Controls
3-1. MAST CONTROLS. (Part No. 47-150-209.) Indication Probable

(Figure 3-1.) of Trouble Cause Remedy
Note
For mastPart
For mast controls No. 47-150-259
controls
Part No. 47-150-259 ontrol stick Gimbal ring Replace or clean
see paragraph 3-48.) binds bearings of bearings
swashplate
3-2. DESCRIPTION.The mast controls are mounted brinelling or
in, and driven by, the transmission. The installation dirty
consists of the following: Mast assembly, stabilizer
bar assembly, damper assembly, and swashplate as- Control stick Incorrect Adjust position
sembly. The mast which is driven by the transmis- centers to positioning of swashplate
sion has five sets of splines, which are an intergal right or left of swashplate
part of the mast, that provide mounting points for of neutral
the component parts and to drive the assembly.
Pitch control Insufficient Clean and lubri-
The stabilizer bar assembly is mounted on the mast
below, and 90 degrees to, the main rotor assembly. Its stick binds lubrication cate splines
inertia effect tends to stabilize the helicopter, and to on swashplate
provide an absolute horizon in reference to which the sleeve spline
rotor is controlled independently of the body. Sleeve
Sleeve yoke
yoke Clean
Clean or
or replace
replace
The damper assembly which is bolted to a frame and bearings dirty bearings
secured to the mast by a split-splined clamp is con- or loose
nected to the stabilizer bar limiting the independence
of the bar for the purpose of maneuvering. Vibration in Improper ad- Adjust dynamic
cyclic con- justment of stop cables
The swashplate assembly encircles the mast near its dynamic stop
base, and is mounted on a support so that it may tilt in all maneu- cables
any direction. Movement of the control stick results in
a corresponding tilt of the swashplate, and through a
system of linkage and levers, the inclination of the rotor Excessive Hydraulic Repair or replace
is changed. A vertical movement of the sleeve within feed-back in boost inop- malfunctioning
the swashplate support is transmitted through a system control stick erative unit or units
of linkage and levers to the blade grip pitch horns.
3-3. TROUBLE SHOOTING. 3-4. REMOVAL - MAST CONTROLS.
Indication Probable
of Trouble Cause Remedy a. Remove main rotor. (Refer to Section II.) Reinstall
main rotor retaining nut. Disconnect control tubes
Sluggish re- Dampers ad- Adjust dapers from fore and aft and lateral control levers on
control stick Malfunctioning

Malfunctioning Refill
Refill or
or replace pitch lever on swashplate. Position a hoist directly
or leaking dampers over mast, and connect to main rotor retaining
dampers
Over-sensi-
Over-sensi- Dampers
Dampers ad-
ad- Adjust
Adjust dampers
dampers b. Remove nuts and washers from studs at base of
of aircraft to swashplate support. Remove nuts, bolts and shims
control, most which attach collective pitch disc support to adapter
noticeable when plate (if installed). Remove support and note position
hovering of shims so they may be reinstalled in same location.
One to one Worn or bind- Replace pivot
lateral vibra- ing pivot bear- bearings c. Operate hoist and lift mast control assemblyfrom
tion of air- ings in center- helicopter. Place assembly on stand Part No. 47-150-
craft frame of 001-T210. Disconnect hoist. Remove main rotor re-
stabilizer bar taining nut. Cover top of transmission.
3-1
Section III BELL HELICOPTER COMPANY Models 47D-1, 47G & 47G-2
MAINTENANCE
1. Control Links
3. Control Rods
4. Retaining Ring - Upper
5. Stabilizer Bar
6. Retaining Ring - Lower
7. Dampers (Houde)
8. Damper Frame
9. Clamp
10. Dust Boot
11. Swashplate
12. Mast
47150-91
Figure 3-1. Mast Controls Installation

3-2
MAINTENANCE
3-5. INSTALLATION - MAST CONTROLS. b. Remove mixing levers (6) by removingpivotbolts.
a. Install main rotor retaining nut and connect hoist. c. Cut lockwire and remove retaining nuts (7) which
Remove cover from top of transmission. Lift assembly secure tubes to frame. Remove bolts at ends and
over helicopter and carefully lower assembly into center of frame to separate frame halves (8), spacers
transmission. Hold collective lever so that pivot shaft (9), core (10), and tube assemblies. Remove thrust
eccentric is up, and control levers are aligned with washers (11) from core trunnions. Trunnions that have
control tubes. inner race of needle bearing remove inner race and
thurst washer.
b. Secure assembly to transmission studswithwash-
ers and nuts. Install adapter plate for collective pitch d. Disassemble each frame half as follows: Remove
control support, securing with two shear nuts. Tighten grease fitting (14) from plug. Remove plate (15) and
nuts 100 to 140 inch-pounds, torque shear nuts 60 to attaching bolts. Use 47-140-012-1-T210 plug to press
85 inch-pounds. Lockwire nuts and stop-screws. bearing (16) from frame. If frame has BR128 bearings
use T101255 tool. Remove set screw (17).
c. Install collective pitch control support with origi-
nal shims (if removed). Connect control tubes to e. Disassemble each tube assembly as follows: Pull
swashplate levers. Tighten bolts carefully. tube (18) off tie rod (19). Remove nut (20), rod end
(21) and lock-nut (22), stud (23) and lock-nut (24).
CAUTION 3-9. CLEANING - STABILIZER BAR. Clean all

parts (except bearings) in dry cleaning solvent. Dry
Design provides a small clearance (up to 0.009
inch) between transmission cap and case. Do 3-10. INSPECTION - STABILIZER BAR.
not close this gap by over torqueing nuts.
a. Visually inspect all parts for wear or damage.
Tighten bolts in swashplate levers finger tight b. Inspect parts dimensionally. (Figure 3-2.)
plus one castellation. Over torqueing of these
bolts will result in damage to the ears of
swashplate levers. 3-11. REPAIR OR REPLACEMENT - STABILIZER BAR.
If stabilizer bar tube is bent in excess of 0.070 inch over
d. Disconnect hoist and remove main rotor retaining its entire length, it must be replaced. Any kink or distortion
nut. Install main rotor. (Refer to Section II.) Check of the tube is cause for replacement.
main rotor and swashplate rigging. (Refer to Sec-
tion VII.)
3-12. REASSEMBLY - STABILIZER BAR.
3-6. STABILIZER BAR.
3-7. REMOVAL - STABILIZER BAR.
a. Remove main rotor. (Refer to Section II.) Dis-

Reinstall all serviceable parts in original location
connect damper links at damper levers and dis-
connect control rods from mixing levers. Remove
upper retaining ring from mast.
b. Raise stabilizer bar and remove from mast,being a. Assemble stud (23, figure 3-2) and rod end fitting (21),
careful not to burr stabilizer bar or main rotor mast with stud extending 1.34 inches from untapered end of
splines. Remove lower retaining ring. fitting and secured by lock-nut (24). Check that stud
is clear of taper pin hole.
3-8. DISASSEMBLY - STABILIZER BAR.
b. Assemble lock-nut (22) and rod-end assembly on

Note left-hand threads of tie-rod (19). Adjust so that taper
To facilitate reassembly, adjustment, and pin hole center is 38.062 inches from inboard end of
balancing parts should be match-marked rod. Tighten lock-nut. (See figure 3-2.)
before disassembly. c. Position tie-rod assembly in tube (18). Aligntaper
a. Remove nut (1, figure 3-2), washer, cap (2), ballast pin holes and temporarily insert pintoholdalignment.
washers (if installed), and spring (3), from stud in outboard Install nut (20) on inboard end of tie-rod, adjusted to
side of each weight. Remove taper pins (4) and pull weights obtain 0.010 inch clearance between nut flange and end
(5) from end of tubes. of tube and secure with cotter pin. Remove taper pin.
Rev. 3 3-3
MAINTENANCE
1. Nut - Balance Assembly 13. Plug - Core Adjusting

2. Cap 14. Grease Fitting
3. Spring 15. Plate
4. Taper Pin 16. Bearing
5. Weight 17. Set Screw
6. Mixing Lever 18. Tube
7. Retaining Nut - Tube Assy. 19. Tie Rod
8. Frame 20. Nut
9. Spacers 21. Rod-End
10. Core 22. Lock-Nut
11. Thrust Washer 23. Stud
12. Dynamic Stops 24. Lock-Nut
47140-5B
Figure 3-2. Disassembled View and Limits Chart - Stabilizer Bar (Sheet 1 of 2)
3-4
MAINTENANCE
ITEM NOMENCLATURE MIN. MAX. REPLACE
25 Core- Spline- Trunnion OD .7500 .7505 .7495

26 Frame- Bearing- Core ID .9985 .9995 1.0000
27 Hub- Bearing ID .7488 .7493 .7498
28 Bearing-Hub-Mixing-Lever OD .7495L .7500L
29 Bearing-Hub-Mixing-Lever ID .2495 .2500
30 Lever-Mixing-Bearing-Center ID .7489 .7495 .7500
31 Bearing-Center-Lever-Mixing OD .7495T .7500T
32 Bearing-Center-Lever-Mixing ID .2495 .2500
33 Lever-Mixing-Bearing-End ID .7489 .7495 .7500
34 Bearing-End-Lever-Mixing OD .7495T .7500T
35 Bearing-End-Lever-Mixing ID .2495 .2500
L Loose Fit T Tight Fit

47150-42A-2
Figure 3-2. Disassembled View and Limits Chart - Stabilizer Bar (Sheet 2 of 2)
d. Slide retaining nut (7) on tube from outboard end. Note
Place weight (5) on end of tube. Align holes and install
taper pin (4). Whenever possible, avoid reaming of origi-
nal parts by careful reassembly to align
e. Observe the followingpoints of reassembly, espe- existing holes.
cially when installing new parts.
f. Assemble each half of frame: Install set screw
1. With large end of taper pin up, large end of (17, figure 5-19) in machined groove at leading end
weight and slot at inboard end of tube must face of frame. Press bearing (16) into frame (8) from
direction of rotation. inboard side, using 47-140-012-1-T210 plug against
numbered end of bearing. (If BR128 bearings use
2. Taper pin should fit snugly in weight, tube and T101255.) Avoid damaging bearing by pressure after
rod end, secured by cup washer and fiber self- end of bearing is in contact with shoulder of frame
locking nut. If small end of taper shank extends more bore. Install plate (15) secured by bolts with heads
than 1/16 inch through weight, a standard steel washer inboard. Install grease fitting (14) in plug (13) and
may be used between cup washer and weight to allow screw plug loosely into plate. Install dynamic stop
proper tightening. lug (12).
3. Line ream with No. 2 Brown and Sharpe taper g. Place a phenolic washer (11) on each trunnion of
reamer to fit pins through new parts, or as neces- core (10). (If BR128bearings used press inner races
sary when using original parts. Maintain dimensions on trunnion shaft.) Assemble frame halves with tube
as shown, equal for both assemblies. Maximumtaper assemblies and core, with core trunnions inserted in
pin size is AN386-3-16. bearings and set screws at each end of frame engaged
Rev. 3 3-5
Section BELL HELICOPTER COMPANY Models 47D-1, 47G & 47G-2
MAINTENANCE
in slot of tube flange. Install and tighten bolts through

ends of frame, with heads of bolts in direction of WARNING
rotation.
h. Screw retaining nut (7) on threads of each tube, Heads of bolts, connecting control rods to
torque 100 to 150 foot-pounds until inside taper of inboard ends of mixing levers, must face
nut is seated firmly over beveled shoulder of frame. lugs to obtain adequate clearance.
Align a hole in skirt of nut with the slot at juncture
of frame halves on upper side of bar. Secure with a 3-14. BALANCING - STABILIZER BAR.
loop of 0.041 diameter lockwire through nut, with twisted
end laid in slot. a. Disconnect damper control links from stabilizer
bar. Disconnect pitch change rod and push-pull tubes
i. Install spacer (9) and bolt at each side of core (10), with from mixing levers. Make certain mixing levers hang
head toward rotation. Tighten bolt. Use two feeler gages downward at same level. Disconnect dynamic stop
to measure equal gap of 0.022 to 0.030 inch (each side) cable if installed.
between the inboard side of the frame and washer.
If gap is not within limits; install AN960-516L or b. Place spirit level spanwise at trunnion on upper
AN960-516 washer, as required, between spacer (9) and surface of center frame. If bubbleis centered, balance
inside of frame (8). Tighten bolts. is satisfactory. If bubble is not centered accomplish
steps c. and d.
Note
c. Remove fiber nuts and ballast container cap from
This measurement may be taken between the light side. Add a sufficient number of AN960-10 or
washer and the core face adjacent to the bearing AN960-10L washers on stud to balance stabilizer bar.
journals.
Note
j. Adjust free movement of core (10) as follows:
A maximum of seven washers on one end
1. With feeler gages in place (core centered) turn is permissible.
is permissible.
each plug (13) in finger tight until it contacts the core d Reinstall cap and check balance of bar.
journals.
e. Reinstall control rods after final adjustments
2. Index mark (pencil) the plug (13) position in have been made.
relation to the retaining plate (15).
3-15. DYNAMIC STOP CABLES.
3. Back out 1/4 to 3/8 of one turn, each side.
3-16. DESCRIPTION. The dynamic stop cables are
4. Lockwire each plug (13) to plate (15) bolts, as attached to the stabilizer bar and pillow blockbearing
shown in figure 34. caps of the main rotor hub. Their purpose is to limit
the flapping angle of the rotor while the rotor is
k. Install mixing levers (6) in original locations, secured turning. If the rotor tends to flap excessively, the
by pivot bolts. Tie inboard ends of levers with lockwire dynamic stop cables come intoactioninsucha manner
to sides of frame in approximately level position, to as to depress the stabilizer bar to control rotor away
protect from damage and for accurate balancing. from static stop. This action precludes the possibility
of the rotor striking the tail boom or static stop while
1. Install spring (3), cap (2), washer and nut (1) on the helicopter is airborne. If dynamic stop cables
stud in outboard side of each weight. are improperly adjusted, in that one cable is shorter
than the other the pilot will experience a one/rev.
vibration during rolling maneuvers. If both cables
3-13. INSTALLATION- STABILIZERBAR. are adjusted evenly, but too short, excessive two/rev.
vibration will be experienced during rolling maneu-
a. Clean mast splines with dry cleaning solvent. Examine vers.
splines for nicks and burrs, dress with fine India stone,
if necessary. Lubricate splines with MIL-G-25537 grease. 3-17. REMOVAL - DYNAMIC STOP CABLES.
b. Install lower lock-ring in groove of mast. Lower a. Disconnect cables at stabilizer bar by removing
stabilizer bar onto mast (aligning bar with damper lock-nut, nut, washer, spring, spacer, and brass
frame) against lower lock-ring. Install upper lock- grommet.
ring. Check balance of stabilizer bar. (Refer to para-
graph 3-14.) Install main rotor. (Refer to Section II.) b. Remove cotter pins, clevis pins andwashers which
Connect control links and rods to mixing levers. secure cables to pillow block caps. Remove cables.
3-6 Rev. 3
Model 47D-1,47G, & 47G-2 BELL HELICOPTER COMPANY Section III
3-18. INSPECTION - DYNAMIC STOP CABLES. In- b. Insert end of each cable through its respective
spect dynamic stop cables for wear or broken wires. fitting on stabilizer bar. Secure by installing brass
Replace cable that has more than six broken wires grommet, spacer, spring, washer, nut and lock-nut.
in any one inch length.
3-20. ADJUSTMENT - DYNAMICSTOP CABLES.
Note
3-19. INSTALLATION - DYNAMIC STOP CABLES.
1. Disengage restraint bumper springs
a. Position cables to lugs on pillow block caps and and position flap restraint arms outboard.
secure with pins, washers, and cotter pins. (If installed.)
Rev. 3 3-6A/3-6B
MAINTENANCE
2. Place 20-pound sack of shot on one

blade about four feet outboard from hub.
3. With gimbal ring against the static

stop, take a reading with a protractor on!
the top of the gimbal ring. Repeat proce-
dure on opposite blade and note the total
reading for both blades.
4. Result is degree of flapping. Refer to

following chart to determine stabilizer
bar setting.
Flapping Stabilizer Bar Setting 47 140-2
16 2 1/2
Note (following the weighted blade) is inclined upward at

angle as indicated on the preceding chart. Tighten
If rigging gage, T101391, is not available, locknut. Move shot bag and weight to opposite blade
follow instructions in steps a., d. and e. and bar. Adjust opposite cable in same manner. Lock-
wire cables and remove rigging gage and weights.
a. Position helicopter reasonable level. Rotate the
main rotor until blades are fore and aft. Disengage d. Place the head of a square or a two-way level
bumper springs and position arms outboard (if in- against the mast directly below the stabilizer bar
stalled), place a 20-pound sack of shot on the aft (if necessary, turn the mast until bubble indicates
blade about four feet from hub. Allowblade to settle vertical). Do not turn rotor blades after this position
until gimbal ring rests on static stop, then place a has been obtained until adjustment of dynamic stop
weight (sufficient to keep cable taut) on the outer end
of the stabilizer bar which follows the weighted blade
(figure 3-3). e. Adjust a bubble protractor to read the degrees
as indicated on preceding chart and place it on the
outer frame of the stabilizer bar at the weighted
side. Loosen the locknut and adjust the cable until
the bar is pulled up and the bubble centers. Tighten
locknut. Move shot bag and weight to opposite blade
and bar. Adjust opposite cable in same manner. Lock-
wire cables and remove protractor and weights.
Note
If dynamic stop cables nudge the stabilizer
bar stops during changeof attitude, backoff
the locknut on each cable in 1/2 turn in-
47110-36
crements until the nudging condition is
eliminated. Flight test after each adjust-
ment.
Figure 3-3. Shot Bag on Rotor Blade and Weight on
Stabilizer Bar 3-21. STABILIZER BAR DAMPERS.
b. Clamp rigging gage, T101391, on the mast so that 3-22. DESCRIPTION. The double action dampers are
the base of the pointer rests against the lower surface bolted to a frame which is secured to the mast by
of the stabilizer bar center frame directly beneath a split-splined clamp. Adjustment of dampers de-
the trunnion bearing (figure 3-4). termines the following time of the stabilizer bar in
relation to the mast inclination for purposes of
c. Loosen locknut and adjust dynamic stop cable until maneuvering.
3-7
MAINTENANCE
In order for the pilot to experience maneuverability 3-28. ADJUSTING STABILIZER DAMPERS.
of the helicopter, such as rolling from one turn to
another, the stabilizer bar must follow and become Note
perpendicular to the mast within a reasonable period
of time. Should the dampers become maladjusted and The initial set position of the adjustment
give inadequate damping to the stabilizer bar, the valve has a great deal to dowiththe damp-
control response is slow. Shouldthe dampers become er's performance at elevated tempera-
maladjusted to give excessivedampingtothe stabilizer tures. If set too near the closed position
bar, the control response would be rapid and the the temperature compensating device can-
stability of the helicopter would be jeopardized. not reduce the size of the damping orifice
and this cannot adjust for decrease in the
3-23. REMOVAL - STABILIZER BAR DAMPERS. fluid viscosity which causes a drop in the
damper strength. When the adjustment
a. Remove damper links from damper arms. valve has to be adjusted too near the closed
position, it indicates the internal damper
b. Loosen four fiber nuts on damper clamp bolts parts have become worn. Itis recommend-
(attaching damper frame to clamp on mast) to permit ed that when adjusting the dampers, that
damper frame to open slightly. if the adjustment valve is within one six-
teenth inch of the stop in the closed posi-
c. Remove four fiber nuts, washers, and bolts at- tion the damper must be replaced with a
taching each damper to frame, and separate dampers new or factory reconditioned damper to
from frame. insure proper performance of the dampers.
3-24. INSPECTION - STABILIZER BAR DAMPERS.

Visually inspect all parts for wear or damage. In- Note
spect splines for wear. Check dampers for leaks.
Swashplate must be approximately level
when dampers are timed.
3-25. REPAIR OR REPLACEMENT - STABILIZER
BAR DAMPERS. a. Loosen dynamic stop cables to give the stabilizer
bar full range of travel without interference.
a. Replace dampers if leaks are evident. Replace
damper link rod-ends having over 0.005 inch radial
play.
CAUTION
b. If holes in damper arms have become elongated,
they may be repaired by reaming hole 0.3745 to
0.3755 and installing bushing. (Bell Standard 85B6- CSC870 damper adjusting screw is an
15-20-16.) Ream bushing 0.250 - 0.2505. Allen head type, Houdaille A13965 damper
adjusting screw requires using an open
3-26. LUBRICATION - STABILIZER BARDAMPERS. end wrench. The adjusting screw is
locked when lever is clamped to shaft.
a. Disconnect link rods from damper levers. LOOSEN LEVER CLAMP BOLT when
making adjustments.
b. Remove filler plug in damper housing. Fill damper Note
to inside edge of filler hole with petroleum base
hydraulic fluid, Specification No. MIL-0-5606. Subparagraphs b, c, and sub-paragraphs
1 through 10 are applicable to adjusting
c. Move damper arm up and down slowly through damper CSC870 "ONLY".
its full travel while filling to expel air from working
chamber. Reinstall filler plug. b. Adjust damper to approximate setting by checking
stabilizer bar movement by hand.
3-27. INSTALLATION - STABILIZER BAR DAMPERS.
c. Check stabilizer bar dampers as follows: (See
a. Position dampers between sides of frame, and figure 3-5.)
install four bolts, washers and nuts throughframe and
mounting lugs on each damper. Tighten nuts on damper (1) Disconnect the connecting link from damper to
frame clamp bolts. stabilizer bar at the stabilizer bar.
b. Check adjustment of stabilizer bar dampers. (Re- (2) Hang a one pound weight on stabilizer bar
fer to paragraph 3-28.) Connect damper links to next to weight on stabilizer bar where damper is
damper arms. connected.
3-8
MAINTENANCE
(3) Move stabilizer bar full travel two or three (8) Reinstall link assembly and repeat timing
times check for freedom throughout range. procedure on opposite damper in same manner.
(4) Hold stabilizer bar in UP position where one (9) Remove weight and extension. Check clamp
pound weight is attached, release stabilizer bar and bolts for security when satisfactory timing has been
check for full travel in four seconds plus or minus obtained.
1/2 second. This operation checks the damper in
DOWN stroke. 3-28A. SEAL REPLACEMENT - STABILIZER
DAMPER. (Figure 3-7.)
(5) Remove the one pound weight from stabilizer
bar and hang weight on opposite bar where link is Note
disconnected.
It is recommended that damper repairs
(6) Move stabilizer bar full travel two or three be limited to seal replacement. Return
times checking for freedom throughout range. dampers for overhaul or other repairs
to Sargent Brother, Tulsa, Oklahoma who
(7) Hold stabilizer bar in UP position where also is the source for the kit.
weight is attached, release stabilizer bar and check
for full travel in four seconds plus or minus 1/2 se- a. Cut safetywire and remove filler plug (1). Fill
cond. This operation checks the damper in the UP reservoir with hydraulic fluid (MIL-H-5606) and re-
stroke. place filler plug (1) finger-tight.
(8) Attach link to stabilizer bar. b. Remove lever from damper.
(9) Repeat procedure outlined in the above step 1 c. Position damper assembly vertically on bench
through 8 for checking the other damper for the UP up
and DOWNstroke.
d. Remove spirolox retainer ring (3) and lockplate
(10) Check stabilizer bar rigging. (4)
e. Remove teflon kapseal (5) and packing (6) from
Note damper.
Sub-paragraph d. and sub-paragraphs 1 f.Install packing (6) and Kapseal (5).
through 9 are applicable to adjusting Hou-
daille damper A13965"ONLY".
CAUTION
d. When timing damper with extension, 7 pound
weight, and stop watch method, proceed as follows Be careful kapseal is not scratched when
(figure 3-6): installing over serrated end of shaft.
(1) Fabricate a damper timing extension lever g. Install lock-plate (4) and spirolox retainer (3).
as shown in figure 3-6.
h. Check for air in the damper as follows:
(2) Disconnect stabilizer bar attaching link as-
sembly from damper arm. (1) Turn adjustment screw (7), in until screw
bottoms out.
(3) Attach extension of damper arm.
(4) Move extension through complete (2) Install damper lever and work lever through
(4) Move extension through complete range ofrange of full travel in both directions. Any lost motion when
damper
damper travel
travel three
three of
of four
four times.
times. If
If soft
soft or
or hard
hard changing direction indicates air in the damper, which
spotsreplace
are detected
damper. must be removed before installing on helicopter.
(5) If no soft or hard spots are detected sus- i. Remove air from damper as follows:
pend the seven pounds weight on extension and raise
to upper limit. Release and check for travel time of (1) Position damper vertically on bench.
four seconds (plus or minus one-half second) to lower
limit. (Repeat three times.) (2) Remove adjusting screw (7), compensator (8)
(6) Loosen lever clamp and adjust damper by and spool (9) from the wing shaft of damper.
turning adjusting screw. (Clockwiseto decrease travel
time or counterclockwise to increase traveltime.) Note
(7) Replace damper if proper timing cannot be Remove compensator and spool using a
obtained and time new damper. hooked wire to lift out.
3-8A
MAINTENANCE
(3) Fill shaft with hydraulic fluid (MIL-H-5606) (6) Position damper horizontally on bench and
and operate wing shaft through full stroke a number of loosen filler plugs (1), to allow air to escape and pre-
times to force air out of damper. vent internal pressure buildings, and screw adjust-
ment screw in.
(4) Use a paper towel to remove air bubbles
floating on top of hydraulic fluid. (7) Tighten filler plug (1), and recheck for air in
damper.
(5) When no more air bubbles are visible install
the spool (9), the compensator (8), with the hole 3/4
inch from end into spool (9) and adjusting screw (7), (8) If damper is satisfactory, torque fillerplugto
in shaft. 20-30 inch-pounds and safetywire filler plug.
1. One Pound Weight

2. Stabilizer Bar Weight
3. Stabilizer Bar Assembly
Note 4. Link
5. Damper
Exhibit for checking damper in "UP"
stroke only. Refer to text for checking
damper in "DOWN" stroke.
47140-40
Figure 3-5. Adjusting CSC870 Stabilizer Bar Dampers

3-8B
MAINTENANCE
DAMPER
FABRICATECLAMP PLATE
FROM0.125ALUM. SHEET
AN525-10SCREW
13° (REF)
FABRICATEANGLEBLOCK
MATERIAL-ALUM. 0.375
DRILL ANDTAP
NO. 10-32 HOLE
IN LEVER 47-140-158LEVER
16.00
FABRICATELEVER EXTENSION
FROM0.125 ALUM.SHEET
HOLESIZE TO
ACCOMODATE METHOD
OF WEIGHTATTACH 0.75
1.00
SUITABLEMATERIAL 2.25
6.00 TO SUPPORTWEIGHT
DRILL TWO1/4(0.250 INCHDIA.)
HOLE
AN525-416SCREW 2 REQD
NAS679A4NUT2 REQD
-7 POUNDWEIGHT
47150-88B
Figure 3-6. Damper (Houdalle A13965) Timing Tool - 7 Pound Method

3-8 C
& OVERHAUL INSTRUCTIONS -
MAINTENANCE
1. Plug - AN814-2DL 7. Adjustment Screw -

(Torque 20-30 inch-pounds) CSC866-1
2. Packing - MS28778-2 8. Compensator - CSC867-1
3. Spirolox Retainer - RR 156C 9. Spool Assembly - CSC875-3
4. Lockplate - CSC881-2 10. Packing (2 pc) - MS28775-023
5. Kapseal - KIN-5213 11. Packing - MS28775-222
6. Packing - AN6227-18
47150-92
Figure 3-7. Seal Replacement - Damper CSC870
3-29. SWASHPLATE ASSEMBLY. support so that it may tilt in any direction. Move-
ment of the control stick results in a corresponding
3-30. DESCRIPTION. The swashplate assembly en- tilt of the swashplate, and through a system of link-
circles the mast near its base, and is mounted on a ages and levers, the inclination of the rotor is changed.
3-9
MAINTENANCE
A vertical movement of the sleeve within the swash- (17) and yoke assembly from sleeve. Turn assembly
plate support is transmitted through a system of up-right and pull collective pitch sleeve (18) from
linkages and levers to the blade grip pitch horns. swashplate support.
3-31. REMOVAL - SWASHPLATE. e. Place yoke assembly in holding fixture, 47-150-
003-5-T211, and clamp fixture in a vise. Cut lock-
a. Remove main rotor. (Refer to Section II.) Re- wire, and using wrench, 47-150-023-1-T215, turn
move stabilizer bar. (Refer to paragraph 3-7.) Re- clockwise to remove yoke bearing retaining nut (19)
move stabilizer bar dampers and frame. (Refer to and lift seal (20) from yoke. Press yoke bearing (21)
paragraph 3-23.) Disconnect and remove push-pull and spacer (22) from yoke (23) using pressing plug,
tubes from scissor levers on swashplate. 47-150-103-5-T210.
b. Disconnect push-pull tubes from control levers on f. Cut lockwire and remove screws which secure
swashplate. Remove nuts and washers from studs at halves of gimbal ring together. Thread four of these
base of swashplate support. Lift swashplate off mast, screws into jacking holes in upper half of gimba
being careful not to burr collective pitch sleeve splines ring. Tighten screws evenly until halves of gimba]
or splines on mast. ring separate. Lift upper half of gimbal ring (24)
from assembly. Remove control plate assembly, and
3-32. DISASSEMBLY
- SWASHPLATE.(Figure 3-8.) pull pivot pins (25) from control plate. Push lower
half of gimbal ring downward. Pull gimbal pivot pins
a. Remove cotter pins, nuts, washers, and bolts (26) from swashplate support, and lift lower half of
which attach outboard end of scissor levers to upper gimbal ring (27) from support.
end of swivel links. Remove cotter pins, nuts, washers
and bolts holding scissor levers to brackets on col- Note
lective pitch sleeve. Pull scissor levers (1) and
spacer washer (2) from brackets. Do not remove swivel studs from outer
ring unless it is necessary to replace them.
Note If necessary to remove studs, drill out
locking rivet, and remove stud from outer
Do not remove scissor lever bearings, ring.
(3, 4 and 5) from scissor levers unless
replacement is necessary or scissor levers g. Remove lock-rings (28) andoutboardbearing seals
are to be Zyglo inspected. (29), and pull pivot shaft (30) from support. Remove
bearings (31) and inboard bearing seals (32) from
b. Remove cotter pins and nuts from outer ring swashplate support. Remove snap-ring (33), seal (34)
trunnions, and pull swivel link assemblies from trun- and needle bearings (35) from swashplate support (36).
nions. Remove nuts, washers and bolts and separate
link bar (6) from swivel fork assembly. Pull swivel h. Remove shields (37 and 38) and cap rings (39
assembly from swivel fork. Press bearings (7) from and 40) from control plate by removing bolts and
swivel fork (8) and link bar (6), using pressing plug screws. Pull outer ring assembly (46) from swash-
47-150-028-1-T210. Remove lock-ring (9) from plate (44). Use 47-150-103-6-T210 plug to press
swivel, and press bearing (10) from swivel (11) using bearing (45) from outer ring. When replacement of
pressing plug, 30-729-456-1-T210. needle bearings is necessary remove lock-ring (41),
seal (42), and press out bearing (43) using a suitable
c. Remove nuts and bolts which hold halves of pressing plug.
collective pitch levers together. Remove collective
pitch stop assembly (12) from lever arms. Separate 3-33. INSPECTION- SWASHPLATE.
halves of lever and remove from pivot and yoke trun-
nions. Press bearings (13 and 14) from levers (15) a. Visually inspect all parts for wear or damage.
using pressing plug, 47-150-036-2-T210. Inspect bearings for chips, cracks, and brinelling,
and splines for chipped, cracked, broken or worn
d. Invert assembly, and place in a vise with vise teeth.
jaws about welded brackets of collective pitch sleeve.
Use extreme caution not to distort sleeve. Straighten b. Check swivel studs in outer ring for damaged
tang of lock-washer, and using wrench, 47-150-019- threads or looseness in outer ring.
1-T215, loosen collective pitch sleeve lock-nut by
turning wrench clockwise until a few nut threads c. Inspect bolt holes in scissor levers and swivel
are still engaged. Remove assembly from vise, and links for wear if diameter of hole exceeds 0.2555 inch,
position upper edge of support mounting flange on repair in accordance with paragraph 3-34.
bench so that sleeve can move up and down. With
yoke trunnions resting in support cut-outs, tap lightly d. Inspect pivot bolts and link bolts for wear. If
on retaining nut with non-metallic hammer to free dimension in any area of bolt is less than 0.2465,
yoke assembly. Remove lock-nut (16), lock-washer replace bolt.
3-10
& OVERHAUL INSTRUCTIONS-
MAINTENANCE
e. Inspect parts dimensionally. (Figure 3-8.) head of bolt. If sufficient clearance does not exist
an AN960-416L washer must be used.
3-34. REPAIR OR REPLACEMENT - SWASHPLATE
d. Repair holes in swivel links as follows: Lineream
a. Replace seals at reassembly. hole to 5/16 inch diameter. (The thickness of metal
around hole after reaming must not be under 0.160
b. Replace studs in outer ring if threads are damaged. inch.) Install a flush type steel bushing for 0.0003
Replace outer ring if studs are loose. to 0.0005 inch interference fit. (Dip bushing in zinc
chromate before installation.) Line ream bushing
c. Repair bolt holes in collective sleeve bracket as 0.2495 to 0.2505 inch.
follows: (See figure 3-9.) 3-35. LUBRICATION - SWASHPLATE. Lubricate
carrier, pivot shaft and needle bearings.
1. Line ream holes in bracket to 3/8 inch (0.375)
diameter, chamfer outside edge of hole inthinner (1/8 3-36. REASSEMBLY- SWASHPLATE.(Figure 3-8.)
inch) side of bracket to accommodate fillet (0.010
inch radius) of collared bushing. a. Insert snap-ring (41) seal (42) andneedle bearings
(43) into control plate (44). Lubricate swashplate
2. Make bushings from steel bar stick, Specifi- bearings (45). Position swashplate lower bearing (as
cation 4140 to obtain a 0.0005 to 0.001 inch inter- shown in figure 3-8) and start into swashplate outer-
ference fit. ring (46), by tapping on outer race with a leather
mallet. Press bearing into place using plug, 47-150-
3. Make bushing "A" with a collar 0.060 inch 103-6-T210. Install upper bearing. Attach outer cap-
thick by 0.562 inch diameter. Install in thinner (1/8 ring (40) and outer shield (38) with bolts. Lockwire
inch) side of bracket to fit flush at inside surface bolts in pairs. Install outer ring assembly onto the
with collar tight against outside surface. Collar elim- control plate assembly. Install inner cap-ring (39)
inates use of washer under nut. and inner shield (37) with bolts. Lockwire bolt in
pairs.
4. Install straight bushing "B" in thicker (3/16 Note
inch) side of bracket, flush at both sides. Stake bush-
ing both sides by indenting bushing. If swashplate outer ring has been reworked
per 251 SI to provide lubrication fitting
5. Line ream bushings to 0.249 inch, plus or minus and Y96-PW1-2-CR-DB bearings are be-
0.0005 inch, to accommodate AN174-31 bolt. Repair ing installed, align index marks on bear-
opposite bracket in same manner. ings and position bearings with slots ap-
proximately 45 degrees from grease
6. When this repair has been accomplished, install fittings for better distribution of grease.
a new bolt and place an AN960-416 washer under Do not over lubricate bearings.
3-11
MAINTENANCE
27
aft
47150-42
Figure 3-8. Disassembled View and Limits Chart - Swashplate (Sheet 1 of 4)

3-12
MAINTENANCE
1. Scissor Levers 24. Gimbal Ring Upper Half

2. Spacer Washers 25. Pivot Pins
3. Scissor Lever Bearings 26. Pivot Pins
4. Scissor Lever Bearings 27. Gimbal Ring Lower Half
5. Scissor Lever Bearings 28. Lock Rings
6. Link Bar 29. Outboard Bearing Seals
7. Swivel Link Bearings 30. Pivot Shaft
8. Swivel Fork 31. Bearings
9. Lock Ring 32. Inboard Bearing Seals
10. Bearing 33. Snap-ring
11. Swivel 34. Seal
12. Collective Pitch Stop 35. Needle Bearings
13. Collective Pitch Lever Bearing 36. Swashplate Support
14. Collective Pitch Lever Bearing 37. Inner Shield
15. Collective Pitch Lever 38. Outer Shield
16. Lock-nut 39. Inner Cap Ring
17. Lock-washer 40. Outer Cap Ring
18. Collective Pitch Sleeve 41. Snap-ring
19. Retaining Nut 42. Seal
20. Seal 43. Needle Bearings
21. Yoke Bearing 44. Control Plate
22. Spacer 45. Swashplate Bearings
23. Yoke 46. Outer Ring
. b. Insert inboard seals (32) into swashplate support

(36). Lubricate pivot shaft bearings (31) and insert
bearings into swashplate support. Insert pivot shaft
(23). Lubricate yoke bearing (21) with grease, Speci-
fication No. MIL-G-25537, and place on bearing plug,
47-150-103-5-T210, so that shielded side of bearing
(30) through swashplate support, and place outboard will be against spacer when pressed into yoke. Press
seals (29) against bearings. Install snap-ring (33), seal bearing into yoke. Position yoke assembly into holding
(34) and needle bearings (35) into holes in upper end fixture, 47-150-003-5-T211, and clamp fixture invise.
of swashplate support. Apply a light coat of white lead base anti-seize com-
c. Place lower half of gimbal ring (27) onto support pound to threads of lock-nut (19). Place seal (20) into
assembly. Insert two pivot pins (26) into needle bear- yoke (groovedside and start threads of
down)
ings of support assembly. Invert support assembly yoke assembly (nut has left-hand thread). Torque nut
and press lower half of gimbal ringontopins extending to 400-800 inch-pounds with spanner wrench, 47-
from support. 150-023-1-T215, and install lockwire.
f. Insert collective pitch sleeve (18) through swash-
Note plate support. Slide yoke and bearing assembly on
shoulder of sleeve with trunnions extending through
It may be necessary to tap gimbal ring cut-outs in support and nut of yoke assembly facing
onto the pins. If so, use a soft mallet, and up. Tap with plastic mallet, if necessary, to properly
tap evenly around ring to assure an even seat yoke assembly. Apply a light coat of anti-seize
fit. compound (white lead base) onthreads of sleeve. Place
lock-washer (17) on sleeve, and screw lock-nut (16)
d. Insert two pins (25) into needle bearings of swash- into place. (Nut has a left-hand thread.) Torque nut
plate assembly. Hold upward on lower half of gimbal 150 to 200 foot-pounds using spanner wrench, 47-150-
ring, and lower control plate assembly onto support, 019-1-T215, and secure locknut by bending tang to
engaging pins in lower half of gimbal ring. Place top lock-washer into castellation.
half of gimbal ring (24) onto lower half observing g. Lubricate collective pitch lever bearings (13 and
match-marks. Install screws, and draw two halves 14) and press into lever (15)using pressing tool, 47-
together. When screws are installed, check ring for 150-036-2-T210. Rotate pivot shaft trunnion inupper-
an even fit. Check end play at gimbal and control most position. Block collective pitch sleeve in upper-
plate pins; 0.002 minimum and 0.012 maximum is most position. Assemble halves of collective pitch
permissible. Lockwire screws in pairs. lever on yoke and pivot shaft trunnions. Install col-
lective pitch stop (12) between halves of lever, and
e. Install spacer (22) in collective pitch sleeve yoke install bolts and nuts.
3-13
MAINTENANCE
U
0
K O O OOCOS-
O,.0CD 3.5 4 O5O~t~' hO
41O
Models 47D-1, 47G & 47G-2 BELL HELICOPER COMPANY Section III
MAINTENANCE
47150-3A
3-15
MAINTENANCE
Note
Be sure pivot shaft trunnions are inupper-

most position when installing pitch lever
to assure proper cam action of pivot shaft.
h. Lubricate swivel bearings (10). Place bearings

on bearing pressing plug, 30-729-456-1-T210, and
press into swivels (11). Install lock-rings (9). Press
swivel link bearings (7) into swivel fork (8) using
plug, 47-150-028-1-T210. Insert swivels into forks,
and position link bars (6) on opposite trunnion. Install
bolts and nuts. Position swivel link assemblies on
studs of swashplate outer ring with snap-rings out-
board. Install washers, nut and cotter pins.
i. Install scissor lever bearings (3, 4 and 5) if re-
moved. Position scissor levers (1) in bracket so that
bearing race on inboard side of lever contacts bracket.
Place spacer washers (2) between bearing race on 47150-7
outboard side of lever and bracket to remove all side
play. Install bolt (with head inboard), washer (thick
or thin washer under head of bolt as dictated by Figure 3-10. Checking Clearance Between Scissor
clearance see paragraph j.) nut and cotter. Torque Lever and Bolt Heads
nut 50 to 70 inch-pounds. Perfer high side. If cotter
pin slot does not line up, tighten nut to next castal-
lation. Connect upper end of swivel links and out-
board end of scissor levers with bolts, washers and
If pivot bolt holes are worn to 0.2550 inch nuts. Tighten nut just enough to remove clearance
maximum dimension install bushings to re- between lugs and swivel link and washers, and between
store holes to originalblueprint dimension washers and nut or head of bolt.
0.2490" + or - 0.0005".
COLLECTIVE PITCH SLEEVE Note
(REF.)
Do not tighten nut enough to deflect lugs

BUSHING "A" of swivel link, or install washers between
lugs of swivel link and scissor lever as
proper clearance (0.040 to 0.070 inch) be-
tween these two items must be maintained.
j. Check each scissor lever for 1/32 inch clearance

between head of bolt (through scissor lever bracket)
and opposite scissor lever. (Figure 3-10.)If clearance
is less than 1/32 inch, place a thin washer between
inboard bearing of scissor lever and welded bracket.
3-37. INSTALLATION - SWASHPLATE.
LINE REAM TO
3/8 INCH(0.375) a. Clean, then lubricate mast splines with grease,
Specification MIL-G-25537. Make sure pivot shaft
trunnions are in uppermost position. Slide swashplate
AN960-416 WASHER BUSHING "B" assembly over mast, and when swashplate is almost
bottomed, align cut-outs in swashplate support with
LINE REAM BUSHINGS collective pitch stops, and align control levers on
AFTER INSTALLATION swashplate with their respective controls. Align
0.2490" + OR - 0.0005" 47150-33 mounting bolt holes in swashplate support with studs
of transmission. Lower assembly over studs, and
install washers and nuts. Torque nut 100 to 140
Figure 3-9. Rework of Collective Sleeve Bracket inch-pounds.
3-16
MAINTENANCE
b. Connect push-pull tubes in swashplate levers. 3-42. INSPECTION - MAST.
a. Visually inspect all parts for wear and damage.

CAUTION Inspect splines for chipped, cracked, broken or worn
............. teeth. Inspect bearings for chips, cracks and brinell-
ing.
Shim swashplate arm, as required, to
limit end play of tube assembly to a maxi- b. Check mast for run-out, as follows:
mum of 0.005 inch. Tighten nut finger tight
plus one castellation. 1. Place disassembled mast in two V-blocks; one
block at machined surface at upper end of mast, and
c. Slide dust boot on mast and install damper frame, one block at mast bearing surface.
campers and stabilizer bar. (Refer to paragraph 3-13.)
Check rigging of cyclic and collective pitch control 2. Check run-out with dial indicator at needle
systems. (Refer to Section VII.) bearing inner race (lower end of mast). Maximum
permissible run-out is 0.006 inch T.I.R.
3-38. MAST ASSEMBLY.
Note
3-39. DESCRIPTION. The main rotor mast assembly
is mounted in and driven by the transmission. The If run-out exceeds 0.006 inch T.I.R., re-
mast control units and the main rotor assembly are turn mast to factory for inspection repair
mounted on the mast. Five sets of splines, integral and/or replacement.
with the mast, provide mounting points for the com-
ponent parts, and the means of driving the assembly. c. Refer to Section I for magnetic particle inspection
requirements.
3-40. REMOVAL - MAST.
d. Inspect parts dimensionally. (Figure 3-11.)
a. Remove main rotor. (Refer to Section II.) Re-
move stabilizer bar. (Refer to paragraph 3-7.) Re-
move stabilizer bar dampers and frame. (Refer to e. Inspect mast for scratches as follows.
paragraph 3-23.) Remove swashplate. (Refer to para-
graph 3-31.) Reinstall main rotor hub retaining nut.
Note
b. Position a hoist directly over the mast and attach
to main rotor hub retaining nut. Operate hoist, and Longitudinal length of scratch immaterial
withdraw mast assembly from transmission. Place mast provided scratch does not extend over
assembly in 47-150-001-T210 holding stand. Remove hoist three-fourth around circumference. For
and retaining nut from mast. Cover opening in transmission depth refer to steps 2, 3, and 4.
to prevent entrance of foreign matter.
1. No cracks are allowed and are cause for im-
mediate rejection.
3-41. DISASSEMBLY- MAST.
2. Scratches or nicks in upper 15 1/2 inches
a. Remove transmission cap assembly from mast. Remove (top of mast to damper frame spline) may be polished
out if depth or nick or scratch
depth or nick or
snap-ring (1, figure 3-11) from cap. Press seal (2) from cap outif scratch does
does not
not exceed
exceed 0.030
0.030
inch and circumferential length does not exceed 3/4
(3) using T100224 plug.(3) using T100224 plug. or depth not exceeding 0.010 inch and no limit on
circumferential length.
b. Place mast T100221 holding fixture in a vise, and
engage splines at lower end of mast with splines of fixture. 3. Scratches or nicks from damper from spline
Straighten tang on lockwasher and remove bearing to bottom of mast except that covered in step (2)
retaining nut (4) using T100880 spanner wrench. Remove may be polished out if depth of scratch or nick does
lock-washer (5) from mast. Position T100364 sleeve on not exceed 0.010 inch and circumferential length of
mast bearing, and tap bearing (6) from mast (7). 3/4 or a depth of 0.005 inch and no limitation on
circumferential length.
Note
4. Scratches or nicks within 1/2 inch of scissors
Do not remove inner race of needle bear- spline and within 1/2 inch from end of thread where
ing from lower section of mast unless re- nut secures thrust bearing may be polished out if
placement is necessary. depth of scratch or nick does not exceed 0.002 inch.
Rev. 3 3-17
MAINTENANCE
2. Seal
3. Cap
4. Retaining Nut
5. Lock-Washer
6. Mast-Bearing
7. Mast
8 Mast-Splines- Lower (Use a 0.2065 Diam Pin) 2.9641 2.9671 2.9603

9 Mast-Bearing OD 2.7548 2.7554 2.7528
10 Bearing-Mast ID 2.7553L 2.7559L
11 Bearing-Mast OD 4.3301 4.3307
12 Plug-Race-Bearing-Inner OD 0.7494 0.7497 0.74933
13 Race-Bearing-Inner ID 0.7495 0.7500
14* Race-Bearing-Inner OD 0.9995 1.0000
15+ Race-Bearing-Inner 0.9998 1.0001
16 Cap-Transmission-Bearing 4.3305 4.3315 4.3325
17 Spline - Stabilizer Bar - Tooth Width 0.256 0.258 0.226
18 Spline - Collective Sleeve Tooth Width 0.256 0.236 0.226
* Before Assembly + After Assembly
47150-43E
Figure 3-11. Disassembled Viewand Limits Chart - Mast

3-18 Rev. 3
MAINTENANCE
f. Measure OD of needle bearing inner race. (See c. Apply a light coat of grease to seal lip in cap
figure 3-11.) Check race for taper or out-of-round assembly, and to seal surface of bearing nut. Lower
or combination of these conditions is 0.0003. cap assembly into position, being careful not to dam-
age seal. Lower swashplate into position.
d. Connect push-pull tubes to swashplate and scissor
levers of swashplate.
3-44. REPAIR OR REPLACEMENT - MAST.

SURFACE "A" (REF.)
0.156" a. Dress splines with a fine India stone (if neces-
SURFACE"B" sary) to remove burrs or scratches.
b. Replace mast bearing seal at installation. Replace
0.125"
0.125" all unserviceable parts.
MIN.
c. Inspect mast nut, Part No. 47-130-116-1, for in-
Surface "B" must be dication of bottoming at shoulder of mast bearing
square to Surface "A" seat before inner race of bearing, Part No. 47-130-
within 0.001" TIR 110-1 is clamped tight. If this condition exists, inner
(Total Indicated Runout) race of bearing will turn and wear surface of flange.
Inspect flange for wear, if wear exists rework as
47150-19 follows:
Note
Figure 3-12. Rework of Mast Flange
If nut was loose, and no wear indicated on
flange, rework nut only or install shim.
3-43. CHECKING CONCENTRICITY OF MAST
BEARING NUT SEAL SURFACE - MAST IN- 1. Machine surface "B" (figure 3-12) asnecessary
STALLED. to obtain a clean surface to position bearing. After
machining, minimum thickness of flange must be
Note 0.125 inch and surface "B" must be concentric with
surface "A" within 0.001 inch.
The following procedure may be used to
check concentricity of mast bearing nut 2. Rework nut (figure 3-13) to increase undercut
seal surface with mast installed. dimension to 0.330 inch maximum. This will insure
positive clamping of bearing inner race. Be careful
not to mark or damage surface of nut where seal is
a. Disconnect push-pull tubes from swashplate. Dis- located.
connect push-pull tubes from scissor levers of swash-
plate. Remove nuts and washers from studs at base 3. An alternate method to insure clamping is to
of swashplate support. Lift swashplate assembly upon install a shim between bearing inner race and lock-
mast far enough for access to the mast bearing locknut washer, Part No. 47-130-134-1. Makeshim from sheet
and support swashplate in this position. Lift trans- steel 0.060 inch thick x 3.100 inch, outside diameter,
mission cap assembly off transmission studs, and x 2.780 inch, inside diameter, plus or minus 0.010
secure to the bottom of the swashplate. inch.
b. Mount a dial indicator to top of upper trans- d. Replacing needle bearing inner race. Replace
mission case so that pawl of indicator rests on seal needle bearing inner race on lower end of mast, only
surface of mast bearing nut. Adjust indicator and when necessary because of wear, damage, or dimen-
rotate mast. Concentricity of bearing nut seal sur- sions beyond tolerance. (Refer to paragraph 3-42.)
face must be within 0.008 inch T.I.R.
1. Place mast holding block, T100221, in vise and
engage mast splines in block. Remove cotter key, nut
Note and cup washer from lower end of mast. Remove
bearing inner race.
If 0.008 inch T.I.R. is exceeded, the nut
must be replaced. If concentricity of nut 2. Check condition of spacer, replace if necessary.
is satisfactory, check for proper seating Check dimension of new bearing inner race. Deter-
of nut on lock-washer with feeler gage. mine thickness of shim required between spacer and
Also visually inspect condition of seal in bearing inner race to position lower end of race
cap assembly. 0.030 to 0.040 inch above lower end of mast plug.
3-19
Section III BELL HELICOTER COMPANY Models 47D-1, 47G & 47G-2
MAINTENANCE
SEE DETAIL "A" (See figure 3-23.) Install shim against spacer.
Tap or press race onto mast plug. Check OD
MAX.
0.330" of race after installation. (See figure 3-11.) Check
for taper and out of round. (Refer to para-
graph 3-42.) Install cup washer and nut. Tighten
0.010" MAX. nut to 160 to 190 inch-pounds torque and install
UNDER CUT cotter pin. Check mast run-out. (Refer to para-
0.010" R graph 342.)
MIN.
DETAIL "A"
DETAIL
"A" 344A. REPAIR LIMITS-MAST. Corrosion on
mast may be removed per data contained on fig-
Rework nut maximum. ure 3-13A.
Depth of undercut must
not exceed 0.330" 47150-18
3-45. LUBRICATION - MAST. Lubricate bearings with
Figure 3-13. Rework of Retainer Nut MIL-0-6082 oil during reassembly.
ALLOWABLES:
A. 0.005 Inch Local C.U.

B. 0.010 Inch Local C.U.
C. 0.015 Inch Local C.U.
D. See Chart Below
E. 2.034 Max. I.D.
F. Surface Corrosion - Brush Removable Only.
STATIONS MEASURED FROM TOP OF MAST

O.D. 2.370 2.375 2.380
MAX. ID 0-10 2.020 2.027 2.034
MAX. ID 10-24 2.015 2.022 2.029
MAX. ID 24-37 2.010 2.017 2.024
NOTES:
1. Material removal from the I.D. must be

uniform around the diameter
2. Pitting must be completely removed
within allowable clean up depth.
3. Finish reworked areas to 32 RMS.
4. A, B & C are on outside diameter
47130-13
Figure 3-13A. Repair Limits - Mast

3-20 Rev. 3
Model 47D-1,47G, & 47G2 BELL HELICOPTER COMPANY Section III
3-46. REASSEMBLY- MAST. ing with a dial indicator. The two surfaces must be
concentric within 0.008 inch T.I.R. Bend tang of lock-
Note washer into slot of retaining nut if concentricity is
within limits.
Any bearing having the word "THRUST"
etched on both inner and outer races should be Note
installed with "THRUST" marked side of
outer race up and "THRUST" marked side of If concentricity exceeds 0.008 inch T.I.R.
inner race downward. replace mast bearing retaining nut and
recheck. If the limit is still exceeded, re-
a. Place mast bearing (6, figure 3-11) on mast (7). Position check mast run out. (Refer to paragraph
T100364 sleeve onto mast and tap bearing into place. 3-43.)
Note
d. Apply a light coat of plastic lead sealing com-
When using mast bearing Part No. 47-620- pound to seal bore to transmission cap. Place cap
973-1, the following procedure is recom- in water and heat gradually to a temperature of 100°C
mended to be used: (212°F). Press seal (2) into cap (3) using pressing
plug, T100224, and install snap-ring (1). Wrap mast
The mast bearing can be installed or re- splines with paper to protect cap oil seal from being
moved by utilizing a locally procured or damaged. Lower cap onto mast. Be careful upper
modified gear puller incorporating legs of edge of mast bearing retaining nut does not cut seal.
sufficient length. An alternate method is Remove protective paper from mast.
to heat the bearing by means of hot oil or47. INSTALLATION - MAST.
heat lamp to maximum 190°F. and slip the
bearing in place. Bearing can be removed
by tapping evenly on the inner race with a a. Screw main rotor retaining nut onto mast. At-
brass or aluminum drift. tach hoist, raise mast assembly and lower into trans-
mission. Locate cap seal assembly properly on top
In installing the bearing care should be case of transmission so stops are in correct position.
taken to align the "0" marks on the inner
race within plus or minus 5 degrees of each b. Install swashplate. (Refer to paragraph 3-37.)
other. Adherence will insure that high and Install dampers and frame. (Refer to paragraph
low points in the split inner race groove 3-23.) Install stabilizer bar. (Refer to paragraph
have been mated. This will provide a 3-13.) Install main rotor. (Refer to Section II.) Check
smoother operating bearing and hence pro- rigging of cyclic and collective pitch control systems.
vide longer bearing life. (Refer to Section VII.)
b. Place mast holding block, T100221, in a vise
and engage splines at lower end of mast with splines 3-48. MAST CONTROLS. (Part No. 47-150-259)
of holding block. Install lock-washer (5). Coat mast (See figure 3-14.)
threads with white lead anti-seize compound, and
start bearing retaining nut (4) onto threads. 3-49. DESCRIPTION.
(Refer to paragraph 3-2.)
CAUTION i 3-50. TROUBLE SHOOTING.

----
-- w--------------- (Refer to paragraph 3-3.)
Tape seal bearing surface of retaining 3-51. REMOVAL - MASTCONTROLS.
nut or jaws of wrench, to protect seal (Refer to paragraph 3-4.)
bearing surface from damage while tighten-
ing nut. 3-52. INSTALLATION - MASTCONTROLS.
Torque nut 3000-3300 inch-pounds with spanner
wrench, T100880. 3-53. STABILIZER BAR. (Figure 3-15.)
c. Remove mast assemblyfromholdingfixture. Place 3-54. REMOVAL - STABILIZER BAR.
the upper end of the mast (machined surface) in a
V-block and let the lower end of the mast rest on a. Remove main rotor. (Refer to Section II.) Dis-
the inner race of the mast needle bearing in a V- connect damper links at damper levers and discon-
block. Check concentricity of the lock-nut seal bear- nect control rods from mixing levers. Remove upper
ing surface, and the outer surface of the mast bear- retaining ring from mast.
Rev. 3 3-20A
MAINTENANCE
b. Raise stabilizer bar and remove from mast, outboard side of each weight. Remove taper pins (4)
being careful not to burr stabilizer bar or main and pull weights (5) from end of tubes.
rotor mast splines. Remove lower retaining ring.
b. Remove mixing levers (6) by removing pivot
3-55. DISASSEMBLY - STABILIZER BAR. bolts.
(Figure 3-14.)
c. Cut lockwire and remove retaining nuts (7)
Note which secure tubes to frame. Remove bolts at ends
and center of frame to separate frame halves (8),
spacers (9), core (10) and tube assemblies. Remove
To facilitate reassembly, adjustment and thrust washers (11) from core trunnions. Remove
balancing, parts should be match-marked inner race of needle bearing, remove inner race and
before disassembly. thrust washer.
a. Remove nut (1), washer, cap (2), ballast d. Disassemble each frame half as follows: Remove
washers (if installed) and spring (3), from stud in grease fitting (14) from plug. Remove plate (15)
3-20B Rev. 3
Models 47D-1, 47G & 47G-2 BELL HELICOPTER COMPANY Section m
1. Nut
2. Control Rods
3. Control Links
4. Lock-Ring - Upper
5. Stabilizer Bar Assembly
6. Lock-Ring - Lower
7. Damper Frame Assembly
8. Dust Boot
9. Swashplate Assembly
10. Mast Assembly
11. Transmission Cap Assembly
1
47150-78
Figure 3-14. Mast Control Installation

3-21
Section II BELL HELICOPTER COMPANY Models 47D-1, 47G & 47G-2
MAINTENANCE
1. Nut - Balance Assembly 13. Plug - Core Adjusting

2. Cap 14. Grease Fitting
3. Spring 15. Plate
4. Taper Pin 16. Bearing
5. Weight 17. Set Screw
6. Mixing Lever 18. Tube
7. Retaining Nut - Tube Assy 19. Tie Rod
8. Frame 20. Nut
9. Spacers 21. Rod-End
10. Core 22. Lock-Nut
11. Thrust Washer 23. Stud
12. Dynamic Stops 24. Lock-Nut 47140-34
Figure 3-15. Disassembled View - Stabilizer Bar (Sheet 1 of 2)

3-22
3-22
MAINTENANCE
DETAIL
120-046-31-20 SHIMAR
TO EQUALONE HALF
THE SPACE BETWEEN
THE MIXINGLEVER AND
THE SIDE FRAMES,
WITHINONELAMINATE 12
120-046-31-20 SHIMAR
TO EQUALONE HALF
THE SPACEBETWEEN
THE MIXINGLEVER
AND THE SIDE FRAME
MINUSTHE AMOUNTOF DETAIL C
120-046-31-12 SHIMSUSED,
WITHINONE LAMINATE
120-045-31-12 SHIMAR
TO EQUALTHE SPACE
BETWEENTHE INNER
RACE ANDTHE
FRAME,WITHINONE
DETAI L A LAMINATE
DETAIL B
ITEM
NO. NOMENCLATURE MIN. MAX. REPLACE
1 Trunnion Core OD 0.7500 0.7505 0.7495

2 Frame - Bearing Seat ID 1.2485 1.2495 1.2500
3 Core Spline - Spacer Width 0.2580 0.2610 0.2660
4 Mating Spline on Mast 0.2560 0.2580 0.2510
5 Lever - Bearing Seat Inboard ID 0.9002 0.9007 0.9012
6 Bearing - Lever End Inboard OD 0.9009 0.9014
7 Lever - Bearing Seat Center ID 0.9002 0.9007 0.9012
8 Bearing - Lever Center OD 0.9009 0.9014
9 Lever - Bearing Seat Outboard ID 0.8120 0.8130
10 Bearing - Lever Outboard
11 Bushing ID 0.2490 0.2500
12 Thrust Washer
13 Bearing Assembly Race ID 0.7495 0.7500 0.7505
14 Bearing Frame
47140-33-1B
Figure 3-15. Limits Chart - Stabilizer Bar (Sheet2 of 2)

3-23
MAINTENANCE
38.062
Adjust for 0.010 inch clearance.
Slot in tube flange must

be aligned with weight as shown.
VIEW LOOKING OUTBOARD

47140-26
Figure 3-16. Assembly Details - Stabilizer Bar
and attaching bolts. Use T101255 plug to press bear- in area of dynamic stop lugs on frame assembly may
ing (16) from frame. Remove set screw (17). be burnished out.
e. Disassemble each tube assembly as follows:
Pull tube (18) off tie rod (19). Remove nut (20), rod
end (21) and lock-nut (22), stud (23) and lock-nut (24).
MIL-G-25537,during reassembly.
3-56. CLEANING - STABILIZER BAR. Clean all
parts (except bearings) in dry cleaning solvent. Dry
Note
3-57. INSPECTION - STABILIZER BAR.
Reinstall all serviceable parts in original
a. Visually inspect all parts for wear ordamage. location by observing match-marks.
b. Inspect parts dimensionally. (Figure 3-15.) a. Assembly stud (23) and rod-end fitting (21),
with stud extending 1.34 inches from untapered end
3-58. REPAIR OR REPLACEMENT - STABILIZER of fitting and secured by lock-nut (24). Check that
BAR. If stabilizer bar tube is bent in excess of 0.025 stud is clear of taper pin hole.
inch in any foot of its length or in excess of 0.070
inch over its entire length, it may be straightened b. Assemble lock-nut (22) and rod-end assembly
to within these tolerances except that no bend or on left-hand threads of tie-rod (19). Adjust so that
straightening of bend is allowed within the inboard taper pin hole center is 38.062 inches from inboard
sleeve area. Any kink or distortion of tubing is cause end of rod. Tighten lock-nut. (See figure 3-16.)
for replacement. This translated into total indicated
run-out is 0.050 inch per 12 inches and 0.140 over c. Position tie-rod assembly in tube (18). Align
entire length. Scratches not in excess of 0.035 inch taper pin holes and temporarily insert pin to hold
3-24
MAINTENANCE
alignment. Install nut (20) on inboard end of tie-rod, feeler gages to measure equal gap of 0.022 to 0.030
adjusted to obtain 0.010 inch clearance between nut inch (each side) between the inboard side of the frame and
flange and end of tube and secure with cotter pin. washer. If gap is not within limits; install AN960-516L or
(See figure 3-16.) Remove taper pin. AN960-516 washer, as required, between spacer (9) and
inside of frame (8). Tighten bolts.
d. Slide retaining nut (7) on tube from outboard
end. Place weight (5) on end of tube. Align holes and Note
install taper pin (4).
This measurement may be taken between the
e. Observe the following points of reassembly, washer and the core face adjacent to the
especially when installing new parts bearing journals.
1. With large end of taper pin up, large end j. Adjust free movement of core (10) as follows:
of weight and slot at inboard end of tube must face
direction of rotation.
1. With feeler gages in place (core centered) turn
2. Taper pin should fit snugly in weight, each plug (13) in finger tight until it contacts the core
tube and rod-end, secured by cup washer and journals.
self locking nut. If small end of taper shank extends
more than 1/16 inch through weight, a standard steel 2. Index mark (pencil) the plug (13) position
washer may be used between cup washer and weight in relation to the retaining plate (15).
to allow proper tightening.
3. Back out 1/4 to 3/8 of one turn, each side.
3. Line ream with No. 2 Brown and Sharpe
taper reamer to fit pins through new parts or as 4. Lockwire each plug (13) to plate (15) bolts,
necessary when using original parts. Maintain di- as shown in figure 34.
mensions as shown, equal for both assemblies. Maxi-
mum taper pin size is AN386-3-16. k. Install mixing levers (6) in original locations
and secure with pivot bolts. Tie inboard ends of levers
Note with lockwire to sides of frame in approximately level
position, to protect from damage and for accurate
Whenever possible, avoid reaming of origi- balancing.
nal parts by careful reassembly to align
existing holes. 1. Install spring (3), cap (2), washer and nut (1)
on stud in outboard side of each weight.
f. Assemble each half of frame: Install set
screw (17), figure 3-15, in machined groove at lead-
ing end of frame. Press bearing (16) into frame (8) 3-61. INSTALLATION -STABILIZER BAR.
from inboard side using T101255, plug against num-
bered side of bearing. Install bearing flush with a. Clean mast splines with dry cleaning solvent.
frame, avoid damaging bearing by excessive pres- Examine splines for nicks and burrs and dress with
sure. Install plate (15) with bolt heads inboard. Install fine India stone if necessary. Lubricate splines with
grease fitting (14) in plug (13) and screw plug loosely MIL-G-25537 grease.
into plate. Install dynamic stop lug (12).
g. Place a phenolic washer (11) on each trunnion b. Install lower lock-ring in groove of mast.
of core (10). Install inner race of bearing on trunnion. b. Install lower lock-ring in groove of mast.
Lower stabilizer bar onto mast (aligning bar with
Lower stabilizer bar onto mast (aligning bar with
Assemble frame halves withtube assemblies andcore, damper frame) against lower lock-ring. Install upper
with core trunnions inserted in bearings and set screws lock-ring. Check balance of stabilizer bar. (Refer to
at each end of frame engaged in in slot of tube flange. lock-ring. Check balance of stabilizer bar. (Refer to
paragraph 3-62.) Install main rotor. (Refer to Section
Install bolts through ends of frame, with heads of bolts II.) Connect control links and rods to mixing levers.
of rotation.
direction of
in direction
in rotation. II.) Connect control links and rods to mixing levers.
h. Screw retaining nut (7) on threads of each

tube, tightening 100 to 150 foot-pounds until inside
taper of nut is seated firmly over beveled shoulder CAUTION
of frame. Align hole in skirt of nut with the slot at .............
junction of frame halves on upper side of bar.
Secure with a loop of 0.072 inch diameter lockwire
through nut with twisted end laid in slot. Heads of bolts, connecting control rods to
inboard ends of mixing levers, must face
i. Install spacer (9) and bolt at each side of core dynamic stop cable lugs to obtain adequate
(10), with head toward rotation. Tighten bolt. Use two clearance.
Rev. 3 3-25
MAINTENANCE
SURFACESTO
3E PARALLEL
WITHIN.020"
BOTHENDS
BREAK SHARP EDGES

.015" - .025" RADIUS
30TH ENDS
TORQUE BOLTS
47140-32
Figure 3-17. Damper Installation

3-62. BALANCING - STABILIZER BAR. 3-65. REMOVAL - DYNAMIC STOP CABLES.
a. Disconnect damper control links from stabi-
lizer bar. Disconnect pitch change rod and push-pull 3-66. INSPECTION - DYNAMIC STOP CABLES.
tubes from mixing levers. Make certain mixinglevers (Refer to paragraph 3-18.)
hang downward at same level. Disconnect dynamic
stop cable if installed. 3-67. INSTALLATION - DYNAMIC STOP CABLES.
b. Place spirit level spanwise attrunniononupper
surface of center frame. If bubble is centered, balance 3-68. ADJUSTMENT - DYNAMIC STOP CABLES.
is satisfactory. If bubble is not centered accomplish (Refer to paragraph 3-20.)
steps c. and d.
3-69. SWASHPLATE ASSEMBLY.
c. Remove nuts and ballast container cap from (Figure 3-18.)
light side. Add a sufficient number of AN960-10 or
AN960-10L washers on stud to balance stabilizer bar. 3-70. DESCRIPTION. The swashplateassemblyen-
circles the mast near its base, and is mounted on
Note a support so that it may tilt in any direction. Move-
ment of the control stick results in a corresponding
A maximum of seven washers on one end tilt of the swashplate and through a system of link-
is permissible. ages and levers the inclination of the rotor is changed.
A vertical movement of the sleeve within the swash-
d. Reinstall cap and check balance of bar. plate support is transmitted through a system of
linkages and levers to the blade grip pitch horns.
e. Reinstall control rods after final adjustments
have been made. 3-71. REMOVAL - SWASHPLATE.
3-63. DYNAMICSTOP CABLES. a. Remove main rotor. (Refer to Section II.)

(Refer to paragraph 3-15.) Remove stabilizer bar. (Refer to paragraph 3-54.)
Remove stabilizer bar dampers and frame. Discon-
3-64. DESCRIPTION. nect and remove push-pull tubes from scissor levers
(Refer to paragraph 3-16.) on swashplate.
3-26 Rev. 3
Model47D-1,47G, & 47G2 BELL HELICOPTER COMPANY Section III
b. Disconnect push-pull tubes from control levers end of swivel links. Remove cotter pins, nuts, wash-
on swashplate. Remove nuts and washers from studs ers and bolts holding scissor levers to brackets on
at base of swashplate support. Lift swashplate off collective pitch sleeve. Pull scissor levers (1) and
mast, being careful not burr collective pitch sleeve spacer washer (2) from brackets.
splines or splines on mast.
3-72. DISASSEMBLY - SWASHPLATE. Note
(Figure 3-18.) Do not remove scissor lever bearings,
(3, 4 and 5) from scissor levers unless
a. Remove cotter pins, nuts, washers and bolts replacement is necessary or scissor levers
which attach outboard end of scissor levers to upper are to be Zyglo inspected.
Rev. 3 3-26A/3-26B
MAINTENANCE
3-27
Figure 3-18. Disassembly View - Swashplate (Sheet 1 of 4)

BELL HELICOPTER COMPANY
Section III MAINTENANCE & OVERHAUL INSTRUCTIONS Models 47D-1, 47G & 47G-2
1. Scissor Levers 24. Gimbal Ring Upper Half
2. Spacer Washers 25. Pivot Pins
3. Scissor Lever Bearings 26. Pivot Pins

4. Scissor Lever Bearings 27. Gimbal Ring Lower Half
5. Scissor Lever Bearings 28. Lock-rings

6. Link Bar 29. Outboard Bearing Seals
7. Swivel Link Bearings 30. Pivot Shaft
8. Swivel Fork 31. Bearings
9. Lock-ring 32. Inboard Bearing Seals
10. Bearing 33. Snap-ring
11. Swivel 34. Seal
12. Collective Pitch Stop 35. Needle Bearings
13. Collective Pitch Lever Bearing 36. Swashplate Support
14. Collective Pitch Lever Bearing 37. Inner Shield
15. Collective Pitch Lever 38. Outer Shield
16. Lock-nut 39. Inner Cap Ring
17. Lock-washer 40. Outer Cap Ring
18. Collective Pitch Sleeve 41. Snap-ring
19. Retaining Nut 42. Seal
20. Seal 43. Needle Bearings
21. Yoke Bearing 44. Swashplate
22. Spacer 45. Swashplate Bearings
23. Yoke 46. Outer Ring

3-28
MAINTENANCE
U 3 YA 3-29
)
MAINTENANCE
1 BoiL OD 0.3112 0.3117 0.3090

2 Bushing ID 0.3120 0.3125 0.3175
3 Bearing - Scissor Link OD 0.9009 0.9014
4 Scissor Link - Bearing Seat ID 0.9002 0.9007 0.9012
5 Scissor Lever - Bearing Seat ID 0.8120 0.8130
6 Scissors Lever - Bearing Seat Trail Side ID 0.8745 0.8755
7 Link Bearing Seat ID 0.8113 0.8118 0.8123
8 Link Bearing OD 0.8120 0.8125
9 Trunnion Swivel OD 0.3123 0.3127
10 Trunnion Bearing Seat ID 0.8740 0.8745 0.8750
11 Trunnion Bearing OD 0.8745 0.8750
12 Bearing Swivel OD 0.3745 0.3750
13 Pin - Swivel Bearing Seat OD 0.3742 0.3747 0.3737
14 Pin - Outer Ring Trunnion OD 0.5000 0.5005 *
15 Outer Ring Trunnion - Pin Seat ID 0.4995 0.5000 *
16 Outer Ring - Bearing Seat ID 7.1240 7.1260 7.1280
17 Bearings - Swashplate OD 7.124 7.125
18 Bearings - Swashplate ID 5.999 6.000
19 Swashplate - Bearing Seat OD 5.998 5.999 5.996
20 Gimbal Ring - Pin Bores ID 0.4995 0.5000 *
21 Pin - Gimbal Ring Seat OD 0.5000 0.5005 0.4995
22 Pin - Needle Bearing Seat OD 0.6250 0.6253 0.6258****
23 Insert - Needle Bearing Bore ID 0.8075 0.8078 **
24 Insert OD 0.9385 0.9390 ***
25 Swashplate or Support - Insert Seat ID 0.9370 0.9375
26 Sleeve - Yoke Bearing Seat OD 2.9355 2.9365 2.9340
27 Bearing - Collective Pitch Yoke ID 2.9370 2.9380
28 Bearing - Collective Pitch Yoke OD 3.8740 3.8750
29 Yoke - Bearing Seat ID 3.8740 3.8745 3.8760
30 Support - Pivot Shaft Bearing Seat ID 1.3125 1.3135 1.3140
31 Bearing - Pitch Control Pivot Shaft OD 1.3115 1.3125
32 Bearing - Pitch Control Pivot Shaft ID 0.8740 0.8760
33 Shaft - Pitch Control Pivot OD 0.8730 0.8740 0.8725
34 Trunnions - Pivot Shaft and Yoke OD 0.3932 0.3935 0.3915
35 Bearing - Collective Pitch Lever ID 0.3934 0.3937
36 Bearings - Collective Pitch Lever OD 1.1807 1.1811
37 Lever - Pitch-Bearing Bores ID 1.1800 1.1810 1.1820
38 Levers - Pitch and Swashplate Bushing Seats ID 0.3745 0.3755 *
39 Bushing - Pitch and Swashplate Levers OD 0.3760 0.3765 *
40 Bushings - Pitch and Swashplate Levers ID 0.2490 0.2500 0.2510
41 Link Assembly - Swivel ID 0.3120 0.3125 0.3130
42 Collective Sleeve - Spline Space Width 0.2580 0.2610 0.2910
* Replace bushing or pin if loose.
** Line bored after installation.
*** Insert to be 0.001 to 0.002 inch interference fit in mating part (25).
****Replace if brinelled or if less than replacement dimension.

3-30
MAINTENANCE
& OVERHAUL INSTRUCTIONS --
b. Remove cotter pins and nuts from outer ring h. Remove shields (37 and 38) and cap rings (39
trunnions and pull swivel link assemblies from and 40) from control plate by removing bolts and
trunnions. Remove nuts, washers and bolts and screws. Pull outer ring assembly (46) from control
separate link-bar (6) from swivel fork assembly. plate (44). Use 47-150-103-6-T210 plugtopressbear-
Pull swivel assembly from swivel fork. Press bearing (45) from outer ring. Whenreplacement of needle
ings (7) from swivel fork (8) and link-bar (6), using bearings is necessary remove snap-ring (41), seal
pressing plug 47-150-028-1-T210. Remove lock-ring (42) and press out bearing (43) using a suitable
(9) from swivel, and press bearing (10) from swivel pressing plug.
(11) using pressing plug, 30-729-456-1-T210.
3-73. CLEANING - SWASHPLATE. Clean all parts
c. Remove nuts and bolts which hole halves of with dry cleaning solvent, Federal Specification P-
collective pitch levers together. Remove collective S-661. Dry with filtered compressed air. Do not
pitch stop assembly (12) from lever arms. Separate allow bearings to rotate while drying.
halves of lever and remove from pivot and yoke
trunnions. Press bearings (13 and 14) from levers 3-74. INSPECTION - SWASHPLATE.
(15) using pressing plug, 47-150-036-2-T210.
d. Invert assembly, and place in a vise with vise Inspect bearings for chips, cracks and brinelling.
jaws about welded brackets of collective pitch sleeve. Check splines for chipped, cracked, broken or worn
Use extreme caution not to distort sleeve. Straighten teeth.
tang of lock-washer and using wrench, 47-150-019-
1-T215, loosen collective pitch sleeve lock-nut by b. Check swivel studs in outer ring for damaged
turning wrench clockwise until a few nuts threads threads or looseness in outer ring.
are still engaged. Remove assembly from vise and
position upper edge of support mounting flange on c. Inspect pivot bolts and link-bolts for wear. If
bench so that sleeve can move up and down. With yoke dimension in any area of bolt is less than 0.3090
trunnions resting in support cut-outs tap lightly on replace bolt.
retaining nut with non-metallic hammer to free yoke
assembly. Remove lock-nut (16), lock-washer (17) d. Inspect parts dimensionally. (Figure 3-18.)
and yoke assembly from sleeve. Turn assembly up-
right and pull collective pitch sleeve (18)from swash- 3-75. REPAIR OR REPLACEMENT-
plate support. SWASHPLATE.
e. Place yoke assembly in holding fixture, 47-
150-003-5-T211 and clamp fixture in a vise. Cut a. Replace seals at reassembly.
lockwire and using wrench, 47-150-023-1-T215, turn
clockwise to remove yoke bearing retaining nut (19) outer ring if
and lift seal (20) from yoke. Press yoke bearing (21) damaged. Replace outer ring if studs are loose.
and spacer (22) from yoke (23) using pressing plug,
47-150-103-5-T210. c. Replace bushings in collective sleeve bracket
f. Cut lockwire and remove screws which secure if bolt hole exceeds 0.3175 inch.
halves of gimbal ring together. Thread four of these 1.
screws into jacking holes in upper half of gimbal inch to accommodate AN175-33
bolt. Repair opposite
ring. Tighten screws evenly until halves of gimbal bracket ammate t eai site
ring separate. Lift upper half of gimbal ring (24) from
assembly. Remove control plate assembly and pull
pivot pins (25) from control plate. Push lower half of 2. When this repair has been accomplished
gimbal ring downward. Pull gimbal pivot pins (26) from install a new bolt and place an AN960-516 washer
swashplate support and lift lower half of gimbal ring under head of bolt. If sufficient clearance does not
(27) from support. exist(1/32 inch minimum between headof bolt through
scissor lever bracket and opposite scissor lever) an
Note AN960-516Lwasher must be used.
Do not remove swivel studs from outer
ring unless it is necessary to replace
them. If necessary to remove studs drill CAUTION
out locking rivet and remove stud from
outer ring.
Do not repair swivel links, by installing
g. Remove lock-rings (28) and outboard bearing bushings, when metal main rotor blades
seals (29) and pull pivot shaft (30) from support. Re- are installed.
move bearing (31) and inboard bearing seals (32) from
swashplate support. Remove snap-ring (33), seal (34) 3-76. LUBRICATION - SWASHPLATE. Lubricate
and needle bearings (35) from swashplate support (36). carrier, pivot shaft and needle bearings.
3-31
MAINTENANCE
3-77. REASSEMBLY - SWASHPLATE.

(Figures 3-18 and 3-30.)
a. Insert snap-ring (41) seal (42)andneedle bear-

ings (43) swashplate (44). Lubricate swashplate bear-
ings (45). Position swashplate lower bearing (as shown
in figure 3-21) and start into swashplate outer-ring
(46) by tapping on outer race with a leather mallet. 1. Swashplate
Install duplex bearings in swashplate outer ring with 2. Inner Cap Ring
lubrication slots on upper bearings facing down and 3. Inner Shield
slots on lower bearing facing up. Position slots ap- 4. Outer Shield
proximately 90° apart and install bearings with slots 5. Outer Cap Ring
45° each side of lubrication fitting. Press bearing into 6. Outer Ring
outer-ring with plug, 47-150-103-6-T210. Position 7. Lubrication Fitting
upper bearing. (See figure 3-19.) Start bearing into 8. Bearings
outer-ring with leather mallet. Press bearing into 9. Seal and Retainer
place using plug, 47-150-103-6-T210. Attach outer
cap-ring (40) and outer shield (38) with bolts. Lockwire Seal and retainer installed in upper bearing.
bolts in pairs. Install outer-ring assembly onto the 47150-163
control plate assembly. Install inner cap-ring (39)
and inner shield (37) with bolts. Lockwire bolts in
pairs. Figure 3-19. Bearing Installation - Swashplate
gimbal ring and lower control plate assembly onto
Note support engaging pins in lower half of gimbal ring.
Place top half of gimbal ring (24) onto lower half
When bearing 47-150-240-1 is installed in observing match-marks. Install screws and draw two
assembly with grease provisions inthe 47- halves together. When screws are installed check ring
150-207-1 shield assembly only, remove for an even fit. Check end play at gimbal and control
seal and retainer from upper bearing. To plate pins; 0.002 minimum to 0.012 maximum is
provide grease reservoir when bearing is permissible. Lockwire screws in pairs. Maximum
installed in assembly with grease provi- vertical play allowed is 0.012 inch.
sions in each side of outer ring assembly
install bearing as received. e. Install spacer (22) in collective pitch sleeve
yoke (23). Lubricate yoke bearing (21) with grease
Note Specification MIL-G-25537 and place on bearing plug,
47-150-103-5-T210, so that shielded side of bearing
Lubrication of top fitting not requiredwhen will be against spacer when pressed into yoke. Press
side fittings are installed. bearing into yoke. Position yoke assembly into holding
fixture, 47-150-003-5-T211, and clampfixtureinvise.
b. Insert inboard seals (32) into swashplate sup- Apply a light coat of white lead base anti-seize com-
port (36). Lubricate pivot shaft bearings (31) and in- pound to threads of retaining nut (19). Place seal (20)
sert bearings into swashplate support. Insert pivot into yoke (grooved side down) and start threads of
shaft (30) through swashplate support and place out- nut onto yoke assembly (nut has left-hand thread).
board seals (29) against bearings. Install snap-ring Torque nut to 400-800 inch-pounds with spanner
(33), seal (34) and needle bearings (35) into holes in wrench, 47-150-023-1-T215, and install lockwire.
upper end of swashplate support.
f. Insert collective pitch sleeve (18) through
c. Place lower half of gimbal ring (27) onto swashplate support. Slide yoke and bearing assembly
support assembly. Insert two pivot pins (26) into on shoulder of sleeve with trunnions extendingthrough
needle bearings of support assembly. Invert support cut-outs in support and nut of yoke assembly facing
assembly and press lower half of gimbal ring onto up. Tap with plastic mallet if necessary to properly
pins extending from support. seat yoke assembly. Apply a light coat of anti-seize
compound (white lead base) on threads of sleeve. Place
Note lock-washer (17) on sleeve and screw lock-nut (16)
into place. (Nut has a left-hand thread.) Torque nut
It may be necessary to tap gimbal ring to 150 - 200 foot-pounds using spanner wrench,
onto the pins. If so use a soft mallet and 47-150-019-1-T215, and secure lock-nut by bending
tap evenly around ring to assure an even of lock-washer into nut slots.
fit.
g. Lubricate collective pitch lever bearings (13
d. Insert two pins (25) into needle bearings of and 14) and press into lever (15) using pressing tool,
swashplate assembly. Hold upward on lower half of 47-150-036-2-T210. Rotate pivot shaft trunnion in
3-32
IT IS PERMISSIBLE TO FILE THIS AREA

TO OBTAIN CLEARANCES BELOW.
0.060 MIN. CLEARANCE IN THIS AREA
WITH CONTROLS RIGGED.
0.040 MIN AT FULL SWASHPLATE
ANGLE WITH CONTROLS DISCONNECTED.
PAINT WITH TWO COATS ZINC CHROMATE PRIMER.
DETAIL B
MINIMUMCLEARANCE 0.040 INCH
MAXIMUM CLEARANCE 0.080 INCH
IS PERMISSIBLE
2. Pitch Control Sleeve

FWD 9. Washer
MAXIMUM 0.070 INCH
IS PERMISSIBLE
4. Bearing
Scissor Arm11. PithTorque SEE finger
DETAIL A tight plus
one castellation.
A
DETAIL
A* Torque bolts 100-140
inch-pounds and lockwire.
1. Scissor Arm Assembly 8. Inner Race

2. Pitch Control Sleeve 9. Washer
3. Scissor Arm Bearing 10. Washer
4. Scissor Arm Bearing 11. Pitch Control Sleeve Bracket
5. Scissor Arm Bearing 12. Link Assembly
6. Washer 13. Thrust Washer
7. Seal 14. Shim
47150-1000
Figure 3-20. Scissors and Link Installation
Rev. 3 3-33
MAINTENANCE
uppermost position. Block collective pitch sleeve in 5. Attach scissor assembly to pitch control sleeve
uppermost position. Assemble halves of collective with bolt, washers (under nut) and nut. Torque 100 to
pitch lever on yoke and pivot shaft trunnions. Install 140 inch-pounds and lockwire per detail B, figure 3-20.
collective pitch stop (12) between halves of lever and
install bolts and nuts. 6. Install other scissor assembly on oppo-
site sides of pitch control sleeve using same procedure
Note (step i, 1 through 5.)
Be sure pivot shaft trunnions areinupper- j. Install two link assemblies on scissor assem-
most position when installing pitch lever blies as follows: (See figure 3-18.)
to assure proper cam action of pivot shaft.
1. Insert inner race, into outboard hole in
scissor assembly.
h. Lubricate swivel bearings (10). Place bearings scissor assembly.
on 30-729456-1-T210 bearing pressing plug and press 2. Position link assembly on scissor as-
into swivels (11). Install lock-rings (9). Press swivel link sembly.
bearings (7) into swivel fork (8) using 47-150-028-1-T210
plug. Insert swivels into forks and position link bars 3. Insert thrust washer, between link as-
(6) on opposite trunnion. Install bolts and nuts. Position sembly and scissor assembly (leading edge side) with
swivel link assemblies on studs of swashplate outer ring chamfered side of thrust washer against link assembly.
with snap-rings outboard. Install washers, nuts and cotter
pins. 4. Insert 35Z1-32-10-H62 shim between link
assembly and inner race of needle bearing in scissor
Note assembly on trailing edge side (maximum clearance of
0.002 inch).
Torque bolts attaching scissor levers to
collective sleeve bracket 100 to 140 inch- 5. Attach link assembly to scissor assembly with
pounds. When torque value of bolts has bolt, two washers (one under head and one under nut) and
been attained and cotter pins slots are not nut. Torque nut finger tight, plus one castellation and
aligned, tighten nut to next castellation. install cotter pin.
Do not loosen.
i. Install two scissor assemblies, on pitch control

sleeve, as follows: (See figure 3-18.)
Note
A maximum of 0.070 inch side play in
scissor assembly bearings is permissible
when mounted in pitch control sleeve
bracket.
Side play of link assembly (when attached

to scissor lever) is 0.040 inch to 0.080
inch maximum.
0.030" TO 0.040"
1. Install scissor levers bearings (3, 4 and5) PEEL SHIMAS
if removed. REQUIRED
2. Position scissor assembly on pitch con-

trol sleeve. 1. Mast Plug
2. Spacer
3. Insert thrust washers, between scissor 3. Shim
assembly and pitch control sleeve bracket (near cen- 4. Bearing Inner Race
ter line of pitch control sleeve) with the chamfered 5. Cup Washer
side of thrust washer against bracket.
47130-5
4. Insert washer (1), a combinationof washers
(2), sufficient to fill space on opposite side, between
scissor assembly and control sleeve bracket. (fig- Figure 3-21. Mast Needle Bearing Inner Race
ure 3-18.) Installation
3-34 Rev. 3
Model 47D-1,47G, & 47G2 BELL HELICOPTER COMPANY Section III
6. Attach link assembly to other scissor as- controls. Align mounting bolt holes in swashplate support
sembly in accordance with step j. 1.through 5. with studs of transmission. Lower assembly over studs and
install washers and nuts. Torque nut 100 to 140 inch-
Note pounds.
Maintain a minimum clearance of 0.060
inch between swivel link and fore and aft b. Connect push-pull tubes in swashplate levers.
swashplate horn with controls properly
rigged or 0.040 inch minimum at full
swashplate angle with controls discon-
nected. Filing limited to amount neces- CAUTION
sary to obtain minimum clearance. (fig-
ure 3-18.)
Shim swashplate arm, as required to limit
3-78. INSTALLATION - SWASHPLATE. end play of tube assembly to a maximum
of 0.005 inch. Tighten nut finger tight plus
a. Clean, then lubricate mast splines with one castellation.
MIL-G-25537 grease. Make sure pivot shaft trunnions
are in uppermost position. Slide swashplate assembly c. Slide dust boot on mast and install damper
over mast and when swashplate is almost bottomed align frame, dampers and stabilizer bar. Check rigging of
cutouts in swashplate support with collective pitch stops cyclic and collective pitch control systems. (Refer
and align control levers on swashplate with their respective to Section VII.)
Rev. 3 3-35/3-36
Models 47D-1, 47G & 47G-2 BELL HELICOPTER COMPANY Section IV
MAINTENANCE
& OVERHAUL INSIRUCTIONS
Section IV
Transmission Assembly
4-1. TRANSMISSIONASSEMBLY. (Figure 4-1.) 4-3. TROUBLE SHOOTING- TRANSMISSION.
4-2. DESCRIPTION. The transmission assembly, Indication Probable

which is mounted on an adapter plate at the upper of Trouble Cause Remedy
end of the engine, is a speed-reducing mechanism
for driving the main rotor, cooling fan, generator,
tail rotor, and rotor tachometer generator. The cyl- Rotor and Centrifugal Remove clutch and
indrical case is composed of a series of castings engine clutch replace worn or
and rings held together by through bolts. The main tachometer slipping damaged parts. If
rotor mast support bearing is mounted in the top of needles not shoes are glazed,
the upper section. Four drive assemblies, whichdrive synchronized wire brush to re-
the tail rotor drive shaft, cooling fan, generator, and at engine speed move glaze
rotor tachometer generator are mounted to the lower greater than
section of the case. 2000 rpm
Excessive Oil seals Replace damaged

Internally, the assembly consists of a centrifugal engine oil on damaged or or worn seals
clutch, freewheeling unit, a two-stage planetary re- transmission worn
duction gear train, spiral bevel gear to drive the
tail rotor drive assembly, and a bevel gear to drive
the cooling fan. Excessive oil Cork plug Replace cork plug
at accessory missing from
drive assem- drive shaft
blies affected
The centrifugal clutch relieves the starter of the
rotor load during starts, and permits rotation of the
rotor manually for inspection without turning the Damaged Replace O-rings
engine. The freewheeling unit makes possible auto- O-rings
rotation landings with an idling or dead engine. The
generator, tail rotor drive, and rotor tachometer
generator are driven whenever the main rotor is in 4-4. REMOVAL- TRANSMISSION.
motion, power on or power off. This makes it possible
for the pilot to have complete control of the helicopter
during autorotation landings. Note
On Models 47G and 47G-2 the fuel tanks
and supports may be removed to facilitate
RATIO CHARTS removal of the transmission.
Engine Crankshaft 1.0 a. Remove main rotor installation. (Refer to Section

II.) Remove mast and controls. (Refer to Section II.)
Cover top of transmission to prevent entry of foreign
Main Rotor Mast 0.111 matter. Remove fan belts. (Refer to Section V.) Mark
fan belts so they may be reinstalled on same pulleys.
Tail Rotor Drive 1.2
b. Disconnect and remove cyclic and collective pitch
control linkage and supports from transmission, keep
all spacers for reinstallation in same location.
Fan Drive 1.5 c. Disconnect wiring and remove generator, rotor
tachometer generator, and transmission oil tempera-
Tachometer Drive 0.5 ture bulb. Disconnect flexible oil feed line fromtrans-
mission and cover ends to prevent entry of foreign
Generator Drive 1.2 particles.
4-1
Section IV BELL HELICOPTER COMPANY Models 47D-1, 47G & 47G-2
MAINTENANCE
3. Upper Mast Bearing 23. Fan Drive Gear 33. Mast Lower Bearing
4. Oil Seal 24. Fan Drive Gear Shim 34. Generator Drive Assembly
5. Swashplate Support 25. Clutch Drum 35. Pinion Gear Bearing Roller
6. Mast 26. Clutch Shoe 36. Pinion Gear Bearing Gage
7. Lock Nut 27. Clutch Shoe Pivot Pin 37. Freewheeling Inner Race
8. Upper Sun Gear 28. Clutch Lock Nut 38. Freewheeling Outer Race
9. Shear Bolt 29. Fan Drive Gear Bearings 39. Freewheeling Roller
10. SunGear Bearing 30. Clutch Bearing 40. Pinion Gear Washer
11. Upper Spider 31. Fan Drive Gear Bearing Retainer 41. Pinion Gear Pin
12. Upper Spider Ring Gear 32. Fan Drive Assembly 42. Support Plate
13. Upper Spider Pinion Gear NOTE: RPM OF TRANSMISSION DRIVES ARE BASED ON
14. Oil Slinger GEAR RATIO OF DRIVE RELATIVE TO ENGINE RPM.
RPM OF DRIVE RPMOF DRIVE
15. Lower Spider Pinion Gear ITEM GEAR FRANKLIN EN- LYCOMINGEN-
16. Lower Sun Gear NO. DRIVE RATIO GINE 3000 RPM GINE 3100 RPM
17. Drive Gear Bearing to Case Lock Nut 21 TAILROTOR 1.2 3600 3720
18. Drive Gear Bearing to Gear Lock Nut DRIVE
19. Drive Gear Bearings 34 GENERATOR 3600 3720
20. Accessory
21. Tail Rotor Drive
Drive Gear
Assembly 22 DRIVE
TACHOMETER 0.5 1500 1550
32 FANDRIVE 1.5 450 4650
22. Tachometer Generator Drive Assembly 6 MAST 0.111 333 344.1
Figure 4-1. Cutaway View of Transmission Assembly

4-2
MAINTENANCE
Note d. Position holding fixture, T100090, so that its

outboard dowel pins engage through-bolt holes, and
On Models 47G and 47G-2, if fuel tanks inboard dowel pins engage teeth of lower sun gear.
and support assembly are not removed,
generator may be removed by the follow- Note
ing procedure. Disconnect electrical cord-
age and remove nuts and washers from Fixture must rest firmly on top of trans-
studs and drive shaft, turn it so as to be mission case.
clear of transmission and suspend securely
with safety wire in outer part of engine
mount structure until transmission has e. Invert transmission assembly, and clamp fixture
been removed. in a vise. Cut lockwire from clutch drum lock-nut
screws, remove screws (14) and using specialwrench
d. Remove rotor brake (if installed). Remove for- T100230, remove clutch drum lock-nut (15). Slide
ward section of tail rotor drive shaft. (Refer to centrifugal clutch assembly (16) from splines of sun
Section VI.) gear.
e. Remove tail rotor and cooling fan drive assem- Note

blies. (Refer to paragraphs 4-57 and 4-65.) Remove
shims from studs and secure to respective drive If clutch drum sticks on spline of lower
assembly. Do not lose or mix shims. sun gear, drill two holes in metal plate
to index with puller holes in clutch drum.
Place plate over end of lower sun gear,
f. Remove nuts, washers, and bolts which attach puller holes, and pull assembly from
transmission to adapter plate. Install hoisting ring lower sun gear.
T100089 on top of transmission, attach a suitable
hoist and lift transmission from helicopter. Place
transmission on a suitable stand. Remove gasket f. Lift lower transmission case assembly fromvise,
from adapter plate. and place upright on a bench. Remove holding fixture
T100090, and lift lower sun gear (17) from trans-
mission.
4-5. DISASSEMBLY - TRANSMISSION - MAJOR AS-
SEMBLIES.(Figure 4-2.)
Note
Note Position lower case assembly on work
bench. Using transmission mounting holes
Match-mark outer surfaces of transmis- as guides, drill four equally spaced holes
sion with quick-drying paint before dis- in bench. Insert bolts through transmis-
assembling major assemblies. sion mountingholes and bench to hold case
in place.
a. Remove rotor tachometer generator drive (para-
graph 4-49.) Remove generator drive (paragraph 4-41). g. Straighten tang of lock-washer and remove ac-
Remove nuts, washers and through-bolts (1) from cessory drive gear retaining nut (19), using spanner
transmission. Remove oil strainer (2) from upper wrench T100311. Lift lock-washer (20) from trans-
and lower cases. Tap lightly on upper section of case mission case. Pass legs of puller, T100414over gear,
with a non-metallic hammer to loosen. Pull upward, and engage ends of puller legs with inner race of
and lift upper case (3) from transmission assembly. bearings. Place ring in position to hold legs from
Remove O-ring seal (4) from upper ring gear. spreading, tighten puller and pull accessory drive
gear (21) from transmission lower case assembly (22).
b. Lift upper spider and drive flange assembly (5)
from transmission. Remove upper ring gear (6) and Note
O-ring seal (7) from center section of transmission.
Tap lightly on center section of case with a non- The cooling fan drive gear and shim will
metallic hammer to loosen, and lift center case (8) be removed in the disassembly of lower
and O-ring (9) from top of freewheeling unit. case assembly.
c. Remove bronze thrust bearing (10), upper sun 4-6. CLEANING - TRANSMISSION - MAJOR AS-
gear (11), freewheeling assembly (12), and lower SEMBLIES. Clean all metal parts, except clutch
spider assembly (18) from transmission. Remove shoes, in dry cleaning solvent. Dry with filtered
O-ring seal (13) from lower case assembly. compressed air.
4-3
MAINTENANCE
1. Transmission Through-Bolts 14. Retaining Screws

2. Oil Strainers 15. Clutch Drum Lock-nut
3. Upper Case Assembly 16. Centrifugal Clutch
4. 0-ring Seal 17. Lower Sun Gear
5. Upper Spider Assembly 18. Lower Spider Assembly
6. Upper Ring Gear 19. Retaining Nut
7. 0-ring Seal 20. Lock-washer
8. Center Case 21. Accessory Drive Gear
9. 0-ring Seal 22. Lower Case Assembly
10. Bronze Thrust Bearing 23. Fan Drive Assembly
11. Upper Sun Gear 24. Rotor Tachometer Generator Drive
12. Freewheeling Unit Assembly
13. O-ring Seal 25. Tail Rotor Drive Assembly
26. Generator Drive Assembly
47620-129
Figure 4-2. Disassembled Viewand Limits Chart - Transmission (Sheet 1 of 2)

4-4
MAINTENANCE
TORQUE 100-140
INCH-POUNDS
28
TORQUE 50
INCH-POUND
TORQUE1500-1800----
INCH-POUNDS 35
ITEM
27 Upper Case - Mast Bearing Seat ID 4.3305 4.3315 4.3317

28 Upper Case - Ring Gear Seat ID 9.9985 10.0000
29 Ring Gear - Upper Case Seat OD 10.0000 10.0015
30 Ring Gear - Teeth (Use 0.1440 Dia. Pins) 9.0811 9.0870 9.090
31 Thrust Bearing OD 3.9350 3.9370
32 Upper Sun Gear ID 3.9390 3.9410 3.9420
33 Upper Sun Gear - Teeth and Lower Spline 4.8223 4.8281 4.8194
(Use 0.1728 Dia. Pins)
34 Fan Drive Gear - Spline Width 0.1250 0.1270 0.1240
35 Crankshaft Ring - Spline (Use 0.288 Dia. Pins) 5.0672 5.0712 5.0522
* Replace if any looseness is found.
Figure 4-2. Disassembled View and Limits Chart - Transmission (Sheet 2 of 2)

4-5
MAINTENANCE
4-7. INSPECTION TRANSMISSION - MAJOR 3. The distance, measured from the top of the
ASSEMBLIES. flange to the base of the groove (Dimension B, figure 4-3A),
must not be less than a minimum of 2.295 inches.
a. Visually inspect sections of case (upper and center)
for cracks and damage, and gears for chips, cracks, wear b. Rework the flange because of a deep or rough groove
and damage. as follows: (figure 4-3B).
b. Inspect parts dimensionally. (Figure 4-2.) 1. Machine the flange only to the depth necessary
to remove the groove. The diameter cleaned up is to be a
c. Refer to Section I for magnetic particle or fluorescent minimum of 4.450 inches (flat area) (Dimension C,
penetrant inspection requirements. figure 4-3B) plus a 0.030 inch minimum corner radius.
The rework surface must be flat and parallel with outboard
4-8. DISASSEMBLY - UPPER SPIDER. lower surface of flange within 0.004 inch TIR and the
finish must be 20 RMS or better.
a. Cut lockwire and remove shear bolts (1, figure 4-3),
which attach drive flange to upper spider. Separate drive 2. The thickness of the flange after rework
flange (2) from spider assembly. (Dimension D, figure 4-3B) must not be less than a
minimum of 0.105 inch.
b. Support spider assembly on blocks and using
47-620-001-1-T291 pressing plug push pinion pins (3) 3. The distance, measured from the top of the
and small steel balls (4) out of spider assembly. Lift flange to the reworked surface (Dimension E, figure 4-3B),
thrust washers (5) and pinion assembly from spider (6). must not be less than a minimum of 2.300 inches.
Remove cage (7), rollers (8) and inner race (9) from each
pinion gear (10). 4-11. REASSEMBLY - UPPER SPIDER.
4-9. CLEANING - UPPER SPIDER. Clean parts in cleaning a. Slide cage (7, figure 4-3) and inner race (9) into pinion
solvent and dry with compressed air. gear (10), and insert T100234 pin, into inner race. Install
rollers (8) in one side of cage, and place thrust washer (5)
in position. Carefully invert gear, install rollers in opposite
4-10. INSPECTION - UPPER SPIDER. side of cage and place thrust washer in position. Hold thrust
washers against inner race, and check for 0.0006 to 0.0024
a. Visually inspect all parts for wear and damage. inch clearance between thrust washers and end of rollers.
Inspect splines for chipped, cracked, broken, or worn Leave T100234 pin in place to maintain alignment, and
teeth, and rollers for chips, cracks, brinelling. slide assembly into position in spider (6). Check for
interference fit of 0.001 to 0.004 inch between thrust
b. Inspect parts dimensionally. (Figure 4-3.) washers and spider.
Note
c. Refer to Section I for magnetic particle or fluorescent
penetrant requirements. Three thicknesses of washers are provided
to permit making a selection which will insure
4-10A. INSPECTION AND REWORK OF MAST an interference fit of 0.001 to 0.004 inch.
DRIVING FLANGE. (47-620-521) Refer to Illustrated Parts Catalog for part
numbers.
b. Leave pinion assembly in place in spider when check

Note has been completed. Use 47-620-001-1-T291 pressing plug.
Lubricate pinion pin (3) with castor oil. Align recess in
The underside of 47-620-521 flange may be underside of head with recess in spider, and start pin into
grooved. This is caused by normal contact with place. Press pinion pin downward to remove T100234 pin.
47-620472 bearing. Continue to press downward until 1/8 inch clearance exists
between spider and underside of head. Insert steel ball (4)
a. Inspect flange for wear (figure 4-3A). The flange may in recess in pin, and push downward until head is flush
be used if it meets the following conditions. with spider.
1. The worn groove must be smooth and c. Assemble, check, and install each pinion assem-
symmetrical. bly in the same manner.
2. The thickness of the flange, measured at the d. Ascertain that shear screws, can be inserted in
point of greatest wear (grooved area) (Dimension A, planetary spider (by hand) until threads bottom prior
figure 4-3A), must not be less than a minimum of to installing drive flange. If threads do not bottom,
0.100 inch. clean threads as required.
4-6 Rev. 3
MAINTENANCE
e. Position drive flange on spider to obtain optimum Note

hole alignment. Clean oil film around shear screw
head contact area and torque shear screws initially, to Inspect ring gear roller as follows:
60 inch-pounds, diagonally in order to properly seat the
drive flange. Fabricate a plug, 7.460" diameter, 1" wide,
to fit the I.D. of the ring gear. Mount plug to
right angle block on surface plate, so ring
CAUTION gear can be mounted on plug. Revolve gear
on plug to position roller flat level. With
a needlepoint dial indicator graduated in
Do not torque shear screws over 65 inch- 0.0001" increments, inspect roller flats of
pounds. gear for wear. If roller has worn any flat
in excess of 0.0007", replace the gear.
f. Back off shear screws individually and re-torque to a
revised value to 40 to 45 inch-pounds. Lockwire each shear
screw to two screws nearest each shear screw (one on each b. Examine inner faces of steel retainer rings (upper
shear screw). and lower roller guides) for galling by ends of rollers.
If appearance indicates chattering of rollers, turn
4-12. DISASSEMBLY-FREEWHEELINGUNIT. retainer over to assemble with unworn surface next
to rollers. Replace retainer when both sides become
a. Remove cotter pins and nuts from freewheeling roller unserviceabe.
retainer bolts. Lift oil deflector (1, figure 4-44) and upper
guide (2) off assembly. c. Inspect parts dimensionally. (Figure 4-4.)
d. Refer to Section I for magnetic particle and fluorescent

b. Hold retainer in place, invert the freewheeling
unit, and lay on a clean flat surface. Force ring gear
down, pushing bolt heads above surface of lower
guide. Lift lower guide (3) and bolts out of race.
4-15. REASSEMBLY- FREEWHEELING UNIT.
c. Lift ring gear (4), springs (5), plates (6) and
rollers (7) from outer race (8). a. Place bolts in lower guide (3, figure 4-4) and lay
guide flat, bolts erect, threaded ends upward. Install outer
4-13. CLEANING - FREEWHEELING UNIT. Clean race (8) on guide, bolts passing through small holes in
outer race. Place ring gear (4) inside of outer race so that
all metal parts with dry cleaning solvent and dry
all metal parts with dry cleaning solvent roller slots incline outward in a counterclockwise direction
with compressed air.
as seen from top looking down.
4-14. INSPECTION - FREEWHEELING UNIT. b. Place spring (6) in plate (5). Place cushion (5A)
under spring. If cushion binds against spring and plate,
a. Visually inspect all parts for wear or damage. file ends of cushion to obtain clearance. Place rollers
Inspect rollers and roller slots in ring gear for flat (7) in slots of ring gear (4), with assembled plates on
spots, burrs, and brinelling. Inspect gears for chipped, clockwise side of rollers and flanged edges of plates
cracked, broken, or worn teeth. outboard. (Figure 4-5.)
Rev. 3 4-6A
Section IV BELL HELICOPTER COMPANY Model47D-1,47G, &47G2
DIMENSIONA
MIN. THICKNESS AT GREATEST
POINT OF WEAR MAY BE USED
IF NOTLESSTHAN0.100
DIM B
2.295 MIN
47620-243
Figure 4-3A. Flange Wear Limits (Flange May be used)
DIMENSIOND
MIN THICKNESS AFTER REWORK
NOT LESS THAN 0.105
DIMENSION E
2.300MIN 2.375
0.030 MIN. RADIUS

DIMENSIONC
4.450 MIN DIA.
SURFACES
PARALLEL
WITHIN
0.004 T.I.R. 47620-244
20 RMS OR
BETTER
Figure 4-3B. Flange Rework Limits (Flange After Rework)
4-6B Rev. 3
MAINTENANCE
1. Shear Bolts 6. Spider

2. Drive Flange 7. Cage
3. Pinion Pins 8. Inner Race
4. Steel Balls 9. Pinion
5. Thrust Washer
ITEM
10 Pinion Rollers OD 0.31481 0.31511 *

11 Flange - Drive - Spline
(Use a .2065 Dia. Pin.) 2.3393 2.3432 2.3452
12 Flange - Driving - Screw - Shear ID 0.3750 0.3760 0.3765
13 Screw - Shear Flange OD 0.3735 0.3745 0.3730
14 Pin - Pinion - Spider - Upper OD 0.5906 0.5909 0.5905
15 Spider Upper - Pin - Pinion ID 0.5899 0.5907 0.5909
16 Race - Inner - Pinion ID 0.5907 0.5910 0.5911
17 Race - Inner - Pinion OD 0.9024 0.9027 0.9022
18 Pinion - Gear ID 1.5331 1.5334 1.5337
19 Pinion Gear - Teeth
(Use a 0.1728 Dia. Pin) 2.5313 2.5342 2.5289
47620-99A
* Replace if under minimum.
Figure 4-3. Disassembled View and Limits Chart - Upper Spider

Rev. 3 4-7
1. Oil Deflector
2. Upper Guide
3. Lower Guide
4. Ring Gear
5. Plate
5A. Cushion
6. Spring
7. Rollers
8. Outer Race
ITEM
*9 Race-Outer-Clutch ID 9.0000 9.0010 9.0025

10 Roller-Clutch OD 0.2998 0.3000 0.2996
11 Ring-Internal-Clutch-Slots
(Use a 0.3000 Dia. Pin to lock @5 °
from CL.) 9.000 9.001 8.9995
12 Ring-Internal-Clutch-Gear-Teeth
(Use a 0.1440 Dia. Pin.) 7.4811 7.4869 7.4898
13 Ring-Internal-Clutch-Gear OD 8.932 8.942 8.927
14 Ring-Internal-Clutch-Gear ID 7.420 7.422 7.423
4
7620-169C
* Out of round limit 0.0015.
Figure 4-4. Disassembled View and Limits Chart - Freewheeling Unit

4-8
MAINTENANCE
cotter pin holes so that they are parallel to outside

circumference of assembly to prevent interference
at installation. Install cotter pins.
4-16. DISASSEMBLY - ACCESSORY DRIVE GEAR.
a. Place gear assembly in T100632 or T100881 holding

fixture and remove bearing retaining nut (1), using
T100312 wrench.
b. Support gear on a suitable pressing plate, and press

ROTATION LOCK SECTION AA bearings (2, figure 4-6) from gear (3) using T100310 plug.
47620-108 4-17. CLEANING - ACCESSORY DRIVE GEAR. Clean

parts with cleaning solvent and dry with compressed air.
Figure 4-5. Plate and Spring Installation 4-18. INSPECTION - ACCESSORY DRIVE GEAR.
c. Place spacer (washers, etc.) on four retaining a. Inspect parts for wear or damage, visually inspect
bolts. Install and tighten nuts. Rotate unit to locked gear for chipped, cracked, broken or worn teeth. Check
position, and examine all rollers, making sure that bearing for chips, cracks, and bnelling.
all rollers are locked securely. Proceed with step d.,
if all rollers are locked. Observe following note if b. Inspect parts dimensionally. (Figure 4-6.)
rollers are not locked.
c. Refer to Section I for magnetic particle and fluorescent
penetrant requirements.
Note
If any roller is not locked securely, re- 4-19. REASSEMBLY- ACCESSORY DRIVE GEAR.
place spring with one having correct radius.
DO NOT BEND SPRING.
a. Place gear (3, figure 4-6) on a suitable pressing plate.
Press one bearing (2) into gear with thrust side of bearing
d. Lubricate freewheeling rollers and ring with up (toward threaded end of gear), and second bearing
engine oiL Place upper guide (2, figure 4-4) and (2) with thrust side down, using T100310 pressing plug.
oil deflector (1) in position, bolts projecting through Thrust sides of bearings should be together. (Figures 4-7
top side of deflector. Install and tighten nuts. Align and 4-8.)
1. Retaining Nut
2. Bearings
3. Gear
ITEM
4 Gear-Drive-Accessory-Spline
(Use a 0.1728 Dia. Pin.) 4.9224 4.9271 4.9199
5 Gear-Drive-Accessory-Bearing ID 4.1329 4.1335 4.1339
6 Bearing-Gear-Drive-Accessory OD 4.1333T 4.1339T
7 Bearing-Gear-Drive-Accessory ID 2.9522 2.9528
T = Tight Fit 47620-101
Figure 4-6. Disassembled View and Limits Chart - Accessory Drive Gear
Rev. 3 4-9
MAINTENANCE
4-20. DISASSEMBLY - LOWER SPIDER.
a. Remove lock-rings (1, figure 4-9) from lower end of

pinion pins, and using 47-620-001-1-T291 plug press pins
(2) out of lower spider assembly.
THRUST BEARINGS
BACKTOBACK b. Slide spider pinions (3) and thrust washers (4)
out of spider. Lift cage (5), rollers (6) and inner
race (7) from spider (8).
47620-107 4-21. CLEANING - LOWER SPIDER.
Figure 4-7. Bearing Installation-Accessory a. Clean all parts, except nylon cages, in dry clean-
Drive Gear ing solvent and dry with compressed air.
b. Clean spider pinion bearing cages with hot water
Note and a good grade of non-alkaline soap. Rinse with
clear hot water. Do not immerse cages in cleaning
The 7015DB bearings, marked "47-620-552-1", solvent or oil.
in matched sets, are the only acceptable
bearings. The thrust sides of these bearings have c. Immerse cages (new or used) in boiling water
been ground so that when clamped together, a for 10 minutes, or soak in water at room temperature
preload is imposed on the balls. After assembly, for several hours before installation.
it will be noted that bearings have a slight drag
when rotated.
Failure to establish a state of moisture
b. Place gear assembly in T100632 holding fixture and equilibrium, in nylon cages, may result
install bearing retaining nut (1, figure 4-6), using T100312 in early failure of cages.
wrench. Torque retaining nut 3600 to 4200 inch-pounds,
until splines of nut align with splines on accessory drive 4-22. INSPECTION - LOWER SPIDER.
gear. (Check alignment by inserting into splines of lower
spider.) a. Visually inspect parts for wear and damage. In-
spect gears for chipped, cracked, or broken teeth.
Check bearings for chips, cracks, and brinelling.
Check nylon cages for brittleness.
A- DIAMETER
B-WIDTH
E C-BORE b. Inspect parts dimensionally. (Figure 4-9.)
D-OUTER RACE
E- THRUSTFACE
F- BALL
THRUSTORBACK SIDE c. Refer to Section I for magnetic particle and fluorescent
I-FRONT ORFACE penetrant inspection requirements.
J- THRUSTFACE
4-23. REASSEMBLY - LOWER SPIDER.

TAKES
SINGLE ROW Note
Restore moisture content of nylon cages before

reassembly. (Refer to paragraph 4-21, step b.)
a. Slide cage (5, figure 4-9) and inner race (7) into pinion
gear (3), and place T100233 pin into inner race. Insert
rollers (6) into cage, and place thrust washer (4) in
position. Carefully invert gear assembly, install rollers
in opposite side of cage, and place other thrust washer
in position. Hold both thrust washers against inner race,
and check for 0.0006 to 0.0024 inch clearance between
FACE TO FACE BACK
TOBACK TANDEM washers and ends of rollers. Leave T100233 pin in place
47640-27 to maintain alignment. Slide pinion assembly into position
Figure 4-8. Typical Bearing Installation in spider (8).
4-10 Rev. 3
MAINTENANCE
1. Lock-ring 5. C age
2. Pinion Pins 6. Rollers
3. Pinions 7. Race
4. Thrust Washers 8. Spider
ITEM
9 Pinion Pin OD .5906 .5909 .5905

10 Washer ID .5920 .5950 .5970
11 Inner Race ID .5907 .5910 .5911
12 Inner Race OD .7840 .7843 .7838
13 Pinion Gear ID 1.2572 1.2575 1.2578
14 Rollers OD .23607 .23637 *
15 Spider - Pin Hole ID .5899 .5907 .5911
16 Pinion Gear Teeth 2.1290 2.1319 2.1265
(Use .1728 Dia. Pin.)
17 Spider Spline ID 4.2582 4.2646 4.2678
(Use .1920 Dia. Pin)
18 Spider Spline (Lower) 4.3548 4.3625 4.3644
(Use 0.192 pin)
* Replace if under minimum.
47620-102A
Figure 4-9. Disassembled Viewand Limits Chart - Lower Spider
Check for an interference fit of 0.001 to 0.004 inch b. Leave pinion assembly in place in spider when
between thrust washers and spider. checking has been completed. Use pressing plug,
47-620-001-1-T291, to push in pinion pin and to push
Note out pin, T100233. Lubricate pinion pin (2) with castor
oil, start pin into top of spider, aligning flat side of
Three thicknesses of washers are pro- head with boss on spider, and press into place. In-
vided to permit making a selection which stall lock-ring (1) on lower end of pin.
will insure proper interference fit of 0.001
to 0.004 inch. Refer to Section IV, Illus- c. Assemble, install and check each pinion in the
trated Parts Catalog for part numbers. same manner.
4-11
MAINTENANCE
1. Lock-ring
2. Needle Bearings
3. Gear
ITEM
4. Gear-Sun-Lower-Teeth
(Use 0.1728 Dia. Pins.) 4.0217 4.0273 4.0189
5. Gear -Sun- Lower- Bearing-Mast ID 1.2450 1.2454 1.2454
6. Gear-Sun-Lower-Tooth - Width 0.1230 0.1245 0.1225
47620-103
Figure 4-10. Disassembled View and Limits Chart - Lower Sun Gear
4-24. DISASSEMBLY - LOWER SUN GEAR. (Fig- c. Refer to Section I for Magnaflux and Zyglo re-
ure 4-10.) quirements.
a. Remove lock-ring (1) from groove above needle 4-27. ASSEMBLY - LOWER SUN GEAR. (Figure
bearing in lower end of gear. 4-10.)
Note
CAUTION
If there is also a lock-ring in groove be-
low the bearing, remove and omit from
assembly. It is mandatory that needle bearing be re-
placed with a new bearing when removed
b. Insert T100925 plug (without guide) through large from sun gear. Do not wash new bearing
end of gear and press bearing (2) from gear (3). in solvent.
4-25. CLEANING - LOWER SUN GEAR. Clean all a. Examine upper edge of needle bearing bore in
parts in dry cleaning solvent and dry with compressed gear. Polish edge of bore with emery and crocus
air. cloth, if it appears sharp or burred, to prevent bear-
ing picking up metal while being pressed into place.
4-26. INSPECTION- LOWERSUNGEAR. Inspect needle bearing for proper alignment of rollers
to bearing bore. Pack bearing in grease, Specification
a. Inspect all parts for wear and damage. Visually MIL-G-25537 (alternate MIL-G-3278) and coat OD
inspect spline for chipped, cracked, broken, or worn of bearing with castor oil.
teeth.
b. Start needle bearing (2) into gear (3) from large
b. Inspect parts dimensionally. (Figure 4-10.) end of gear, name on bearing pointing upward. Slip
4-12
MAINTENANCE
1. Retaining Bolts 5. Gear

2. Bearing Retainer 6. Shim
3. Bearing 7. Case
4. Liner
ITEM
8 Case-Tach. Gen. -Pilot-Outer ID 2.1250 2.1260 2.1265

9 Case-Tach. Gen. -Pilot-Inner ID 1.9370 1.9380 1.9385
10 Case-Fan-Pilot-Inner ID 2.1880 2.1890 2.1895
11 Case-Fan-Pilot-Outer ID 2.4370 2.4380 2.4385
12 Liner-Bearing-Case-Lower ID 3.1495 3.1503 3.1509
13 Liner-Bearing-Case-Lower OD 3.3135 3.3145
14 Bearing-Case-Lower ID 1.9680 1.9685
15 Bearing-Case-Lower OD 3.1491 3.1496
16 Case-Generator-Pilot-Outer ID 2.6250 2.6250 2.6265
17 Case-Generator-Pilot-Inner ID 2.2810 2.2820 2.2825
18 Case-TRD-Pilot-Outer ID 2.4370 2.4380 2.4385
19 Case-TRD-Pilot-Inner ID 2.1880 2.1890 2.1895
47620-104
Figure 4-11. Disassembled View and Limits Chart - Lower Case

4-13
MAINTENANCE
plug guide onto pressing plug, T100925 and insert (5) into opening in case. Position bearing (3) in lower
plug assembly into gear with lower end of plug in- case liner. Press bearing into place, using pressing
side the needle bearing and guide firmly seated on plug T100892. Install bearing retainer (2) and bolts
top of gear. Place assembly in arbor press, and push (1). Tighten bolts and install lockwire.
bearing into place until head of plug bottoms against
guide. b. Insert setting plug, 47-620-200-1-T290, incooling
fan drive port of lower case, and slide collar for
c. Remove plug assembly from gear. Check bearing setting fan drive gear over pilot end of setting plug.
rollers for free movement. Install lock-ring (1) in
groove above bearing. Test assembly for proper fit c. Turn case in upright position. Pullupwardonbear-
on mast, as follows: ing inner race to remove all axial play, pass feeler
gage through inner race and insert between inner
1. Hang mast vertically (bearing end down). race and setting collar.
2. Slide gear into position and check bearing for d. Examine back of fandrive gear. If fiuresdo
proper fit on mast. not appear on gear, the distance measured withfeeler
gage equals the thickness of shims to be used under
gear. If figures appear on gear (such as 1.123)
CAUTION subtract amount marked on gear from mounting
distance. (Mounting distance is 1.125.) (See figure
4-12.) Add this difference to the distance measured
Do not install sun gear in transmission if with feeler gage. Insert shims (6, figure 4-11) of
binding occurs. this thickness into lower case assembly by cupping
shims slightly.
4-28. DISASSEMBLY - LOWER CASE. (Figure 4-11.)
4-32. DISASSEMBLY - CENTRIFUGAL CLUTCH.
a. Cut lockwire, remove bolts (1) and lift bearing (Figure 4-13.)
retainer (2) from lower case assembly.
a. Pull clutch spider assembly away from clutch
b. Tip cooling fan drive gear and shims upward on drum (1).
edge. Insert pressing plug, T100892, in lower case,
past gear and shims, with the two ears on plug resting b. Cut lockwire and remove bolts (2), and bearing
in cut-outs of lower case liner and against inner race retainer (3) from upper surface of clutch spider.
of bearing. Insert a rod of suitable length into top
of case and press against plug until bearing (3) is c. Using pressing plug, 47-620-200-12T210, remove
free of lower case. bearing (4) from clutch spider. Remove snap-rings
(5) from bottom ends of pivot pins (6). Push pivot
Note pins out of spider (8) and remove shoes (7).
Do not remove liner (4) from case unless 4-33. CLEANING - CENTRIFUGAL CLUTCH. Clean
replacement is necessary. all parts except clutch shoe linings with dry cleaning
solvent. Dry with compressed air.
c. Remove cooling fan drive gear (5), and shims (6)
from case (7) by passing them downwardthrough cut- 4-34. INSPECTION- CENTRIFUGALCLUTCH.
outs provided in liner.
a. Visually inspect all parts for wear and damage.
4-29. CLEANING- LOWERCASE. Clean all parts Inspect splines for chipped, cracked, or worn teeth,
in dry cleaning solvent and dry with compressed air. and check bearings for chips, cracks, and brinelling.
Recondition glazed shoe linings by wire-brushing,
4-30. INSPECTION - LOWER CASE. replace shoe if lining is worn to 0.062 inch thickness.
Inspect case for cracks. Check bearing for chips, b. Inspect parts dimensionally. (Figure 4-13.)
cracks, and brinelling.
c. Refer to Section I for Magnaflux and Zyglo re-
b. Inspect parts dimensionally. (Figure 4-11.) quirements.
c. Refer to Section I for Magnaflux and Zyglo re- 4-34A. INSPECT - TO DETERMINE IF CLUTCH
quirements. DRUM, Part Number 47-620-691-1, IS
REGRINDABLE. (Figure 4-13A.)
4-31. REASSEMBLY - LOWER CASE. (Figure 4-11.)
a. Inspect inner diameter 9.750 ± 0.003 of clutch
a. Invert lower case assembly (7), and insert gear drum for dimension shown on figure 4-13A and for
4-14
MAINTENANCE
surface condition. If the I.D. is less than 9.740 or if 4-36. ASSEMBLY- CENTRIFUGALCLUTCH.
the surface of the I.D. is badly grooved or smeared
with flowed metal; inspect clutch drum to determine a. Position clutch shoes (7, figure 4-13) on spider (8) with
if clutch drum may be reground. Accomplish inspec- free ends of shoes pointing counterclockwise (when viewed
tion as follows: from bearing side of spider). Align pivot pin holes, insert
and press pins (6) into place with heads on bearing side of
(1) Measure O.D. at open end. If dimension is less spider. Install snap-rings (5) on lower end of pins.
than 10.420 diameter, scrap clutch drum.
Note
(2) Measure O.D. at closed end. If dimension 10.
420 is less than 10.120 diameter, scrap clutch drum, Check contact of shoe lining with clutch drum
or if dimension 10-312 diameter, is less than 10.292 on assembly using prussian blue or equivalent
diameter, scrap clutch drum.
then soak clutch shoes in engine oil, for
(3) Measure 0.780 to 0.775 dimension from hub approximately 30 minutes prior to assembly.
surface to edge of open end. If dimension is greater than Sand hgh spots as necessary to obtain a
0.800 or it varies more than 0.002, scrap clutch drum. minimum of 80 percent, preferably 100
percent, contact over length and width of
(4) Lay clutch drum on a surface plate and check lining. Clean with
lining Clean with brush
brush after
after obtaining
obtaining proper
flatness with a feeler gage. If waviness is greater than contact to remove any grit imbedded in lining.
0.008 is found on either side, scrap clutch drum.
b. Press bearing (4) (without shields) into spider, using
(5) If the above checks show clutch drum to be 47-620-200-12T210 plug. Position retainer (3) over bearing
useable, regrind I.D. to 9.749 to 9.753 diameter, or up to and install, tighten and lockwire bolts (2). Position spider
9.769 diameter, maximum (overside) and clutch drum assembly in clutch drum.
must be concentric to bearing diameter within 0.004
TI.R. Surface finish to be 63 to 100 RMS. To break in 4-36A. INSPECTION TO DETERMINE IF 47-620-333-1
new lining on assembly, check lining for proper con- OR 47-620-336-1 IS REGRINDABLE.
tact.
Note
4-35. REPLACING CLUTCH SHOE PIVOT PINS AND
BUSHINGS. Worn clutch shoe pivot pins and wear of Applicable to 47-620-609 and 47-620-669
pin holes in spider or shoes can be repaired by installing clutch assemblies.
hardened shoe bushings and oversize pins.
a. It is essential when installing a new clutch assembly or
a. Remove and disassemble clutch. when installing new clutch shoes in a used clutch drum to
obtain a minimum of 85 percent contact between the face
Note of each clutch shoe and the drum. Apply a light coat of
Prussian blue to the shoe contact surface of the drum.
Clutch assembly can be removed without Install the shoe assembly, apply hand pressure to each
complete disassembly of transmission. Remove shoe and move to and fro against the drum several times
transmission (paragraph 44). Cut lockwire and to determine the surface contact to the drum. If contact
remove screws from clutch drum lock-nut. is less than 85 percent, sand the face of the lining on each
Install T100879 clutch drum holding strap, shoe as necessary until specified fit is acquired. Upon
fitting strap tightly around outside of drum completion, clean Prussian blue from clutch drum and
and securing tool to lower case with bolts and shoes with light engine oil. Before installing new shoes
wing nuts. Use T100230 wrench to remove in a used drum inspect the shoe contact surface on the
clutch drum lock-nut. Remove holding strap. drum for a smooth finish and the diameter of the drum for
Pull clutch assembly off sun gear splines. any out-of-round condition or toe-in at the open face of
the drum.
b. If bushings are not installed, ream pivot pin holes in
clutch shoes 0.4668 to 0.4673 inch and press in bushings. b. Lay clutch drum flat on a surface plate. Use a dial
indicator and check the top of the drum for warpage. If
c. Line ream pin holes in spider to clean up any warpage of surface from center boss to outer ring or rim
worn condition and to obtain a press fit of pin selected is over 0.025 inch clutch drum must be replaced. If
from chart. (Figure 4-14.) warpage is within limits check for toe-in at the open face
of the drum. If toe-in is in excess of 0.006 inch on the
d. Ream shoe bushings to dimension listed in chart diameter, regrind the drum (32 micro inch finish). To
opposite pin size. check, clamp the drum to a right angle block on a
Rev. 3 4-14A
Section IV BELL HELICOPTER COMPANY Model 47D-1,47G, & 47G2
surface plate, with boss on back of drum flat against face c. Clutch drum must be replaced when diameter exceeds
of angle block. Use a dial indicator. Find the lowest spot 10.020 inches, or if wall thickness of the 47-620-636-1
on the drum and move the dial indicator the total width drum is less than 0.160 inch measured from the top of
of the drum and check the difference between the open the cooling fin or for the 47-620-333-1 drum the minimum
face and closed face of the drum. Check the drum at four wall thickness is 0.110 inch.
locations 90 degrees apart. If the difference is over
0.003 inch, regrind the drum. Check the depth of any pock d. At the normal 600 hour inspection of the clutch, if
marks that appear on the shoe contact surface of the drum. clutch shows evidence of overheating check dimensionally
If pock marks are over 0.001 inch in depth, regrind the as specified and if necessary regrind before installing new
drum. To regrind the drum remove only sufficient material shoes.
to obtain a smooth finish. The diameter securing the clutch
bearing and the shoe contact surface must be held e. After a drum is reground, check for cracks bymagnetic
concentric within 0.006 inch. particle inspection before returning to service.
4-14B Rev. 3
MAINTENANCE
DIALINDICATOR DIALINDICATORSTEM
INDICATOR
STEM \ STRUCTURESTATIONARY
WITHRESPECTTO DRIVE
DRIVE
ASSEMBLY
DRIVE ASSEMBLY
GEARSHAFT
SHAFT DIM. E
DIAL INDICATORCLAMP
TYPICALMETHODOF INSTALLING
DIAL INDICATORTO CHECKPLANE
OF ROTATIONBACKLASH
TYPICALMOUNTING
DISTANCEOF PINION
TYPICAL MOUNTING
DISTANCEOFGEAR
TYPICALMOUNTINGDISTANCES
OF SPIRALGEARS
BACKLASH IN
PLANE OF
ROTATION AT
MATING DIMENSION DIMENSION
GEAR NORMAL "E" "E"
NAME OF GEAR PART NO. PART NO. BACKLASH IN INCHES IN INCHES
*Fan Drive 47-620-530 47-620-207 0.002" 0.004" 0.0021" 0.0042" 0.800"
Tail Rotor Drive 47-620-568 47-620-523 0.005" 0.007" 0.0065" 0.0090" 0.800"
Pinion Gear - Tail 47-645-097-5 47-645-097-3 0.002" 0.004" 0.0025" 0.0055" 0.800"
Rotor Gear Box
Pinion Gear - Tail 47-645-232-5 47-645-232-3 0.002" 0.004" 0.0025" 0.0055" 0.800"
Rotor Gear Box
*With clutch assembly held in upward to remove axial play of support bearing and move gear into mesh.
Dimension "E" is distance from of shaft to dial indicator. Use dial indicator with stem acting against
a clamp or stop at correct "E" dimension from shaft center. 47620-191D
Figure 4-12. Gear Data Chart

4-15
1. Clutch Drum
2. Bolts
3. Bearing Retainer
4. Bearing
5. Snap-rings
6. Pivot Pins
7. Clutch Shoes
8. Spider
ITEM
1 Drum-Clutch-Centrifugal-Shoe ID 9.9950 10.0050 10.0200

2 Pin-Pivot-Clutch-Centrifugal OD 0.3745 0.3750 0.3742
3 Bushing-Shoe-Clutch ID 0.3750 0.3760 0.3765
4 Bushing-Shoe-Clutch OD 0.4693 0.4698
5 Shoe-Clutch-Bushing ID 0.4668 0.4673 0.4683
6 Spider-Clutch-Centrifugal-Pin ID 0.3735 0.3740 0.3743
7 Spider-Clutch-Centrifugal-Spline
(Use a 0.2400 Dia. Pin.) 4.4088 4.4123 4.4140
8 Spider-Clutch-Centrifugal-Bearing ID 3.8750 3.8760 3.8765
9 Bearing-Spider-Clutch-Centrifugal OD 3.8740 3.8750
10 Bearing-Spider-Clutch-Centrifugal ID 2.9370 2.9380
11 Drum-Clutch-Centrifugal-Bearing OD 2.9360 2.9370 2.9355
12 Drum-Clutch-Spline-Space-Width 0.1250 0.1270 0.1275
47620-105
Figure 4-13. Disassembled Viewand Limits Chart - Centrifugal Clutch

4-16 Rev. 3
Models 47D-1, 47G & 47G-2 BELL HELICOTER COMPANY Section IV
MAINTENANCE
10.312
DIA.
+0.010
10.140
DIA.
+ 0.010
47-620-691-1
BEARINGSURFACE --BEARING SURFACE CLUTCHDRUM
0.780
0.775
SEENOTE
9.750
DIA.
±.003
10.450
DIA.
+ 0.010
Note
PERMISSABLE
TO GRINDI.D. TO MAXIMUM9.769AFTER
GRINDING, CLUTCH DRUM MUST BE CONCENTRIC TO
BEARINGDIAMETERSURFACEWITHIN0.004 TIR. SURFACE
FINISH TO BE 63-100 RMS
47620-224
Figure 4-13A. Inspection - To Determine if Clutch Drum is Regrindable and Allowance to Regrind
4-16A
1. Shoe Assembly
2. Pivot Pin
3. Clutch Spider
4. Bushing
REAM BUSHING IN LINE REAM

PIN NO. PIN DIA. CLUTCH SHOE TO SPIDER TO
47-620-619-1 * .3745-.3750 .375-.376 .3735-.3740

47-620-619-3 .3825- .3830 .383- .384 .3815- .3820
47-620-619-5 .3895-.3900 .390-.391 .3885-.3890
47-620-619-7 .3975- .3980 .398- .399 .3965-.3970
Standard size. Other pins listed are oversize.

47620-94
Figure 4-14. Replacing Pins and Bushings in Clutch Assembly
4-37. REASSEMBLY-MAJORASSEMBLIES. (Figure stem of dial indicator against a stationary object,

4-2.) and turn dial face to zero. Rotate shaft of drive as-
a. Lubricate all bearings with liberal supply of oil sembly in direction of rotation until teeth contact.
on installation. Place lower case (22) in an arbor Read backlash on indicator. Check for a reading of
press. Start accessory drive gear assembly (21) 0.005 to 0.007 inch.
onto case and press into place using pressing sleeve,
T100364. Return lower case assembly to work bench, d. Remove dial indicator. Rotate gears severalturns
position over previously drilled holes in bench, and in each direction. Remove drive assembly, and check
insert bolts. Install lock-washer (20), and start re- gear patterns. Adjust shims (betweendrive assembly
taining nut (19) onto threads. Torque retaining nut and case)to obtain proper patterns. (See figure4-15.)
3600 to 4200 inch-pounds using wrench, T100311 with
guide. Bend tang of lock-washer into slot in retaining
nut.
In adjusting shims to obtain proper gear
b. Place shims on studs at tail rotor drive port of patterns make sure backlash remains
lower case. Coat teeth of accessory drive gear and within 0.005 to 0.007 inch.
tail rotor pinion gear with a suitable gear marking
compound. Insert the overhauled tail rotor drive e. Remove drive assembly after adjustments are
assembly into transmission and install nuts. made. Clean marking compoundfrom teeth of gears.
Place shims for generator drive androtortachometer
c. Attach a dial indicator to shaft of tail rotor drive drive on studs at proper mounting port. Insert the
assembly. (See figure 4-12.) For accuracy observe overhauled drive assembly, and secure with washers
dimension "E" on chart measuring from center of and nuts. Check backlash and gear tooth pattern as
shaft to center line of indicator actuating stem. Place in paragraphs c. and d.
4-17
MAINTENANCE
EXAMPLES OF NO-LOAD TOOTH CONTACT PATTERNS
ROTOR SHAFT GEAR

(Load Side)
PINION GEAR
(Drive Side)
CORRECT INCORRECT INCORRECT

Move Pinion Away Move Pinion Toward
From Cone Center Cone Center
47645-1B
Figure 4-15. Typical Gear Teeth Pattern
Note h. Place shims on studs at fan drive port of lower

case. Coat teeth of fan drive gear and fan drive
If thickness of shims under fan drive gear pinion gear with a suitable gear marking compound.
has been determined, proceed with step f. Install fan drive assembly into transmission and
If thickness of shims has not been deter- install nuts. Adjust shim between drive assembly
mined, refer to paragraphs 4-31 and 4-70. and case to obtain proper gear pattern. Clean off
marking compound.
f. Insert lower sun gear (17, figure 4-2) into cooling
fan drive gear. Make certain shim is in place under i. Attach a dial indicator to shaftof fan drive assem-
fan drive gear, and press sun gear into place. bly. (See figure 4-12.) For accuracy observe dimen-
sion "E" on chart, measuring from center of shaft to
g. Place holding fixture, T100090, in position en- center line of indicator actuating stem. Place stem of
gaging dowels of fixture with through-bolt holes dial indicator against a stationary object and turn dial
in case and teeth of lower sun gear. Invert assembly, face to zero. Rotate shaft of fan drive assembly in
clamping side of holding fixture in a vise. Slide direction of rotation until teeth contact. Read indicator
centrifugal clutch assembly (16) onto lower sun gear and add or remove shims between fan drive gear and
splines, and start clutch drum lock-nut (15) onto lower sun gear to adjust backlash. Set backlash to the
threads of sun gear. Torque nut 1500 to 1800 inch- low end of the 0.005 to 0.007 inch tolerance.
poundsusing spanner wrench, T100230.
j. Install lower spider (18) engaging pinions of
spider with teeth of sun gear. Lay free wheeling
unit (12) on bench with oil defector up (heads of bolts
Do not install locking-screws in clutch
toward bench). Grasp ring gear, turn gear clockwise,
drum locknut until gear tooth pattern and
backlash of fan drive assembly have been Note
established.
If locking does not occur, unit is not cor-
rectly assembled. Disassemble and re-
assemble correctly.(Refer to paragraphs
4-12 and 4-15.)
Place a block under clutch and lower sun
gear and allow lower case to hange (to
position the lower case bearing inner race k. Clean O-ring seal grooves in mating surface of
in the up position.) lower case and freewheeling unit. Install O-ring seal
4-18
MAINTENANCE
(13), position free wheeling unit (deflector side up),

align match-marks on ring and lower case, and in-
stall freewheeling unit. Clean seal grooves in both
sides of center case (8), install O-ring seal (9) on
freewheeling unit, and place center case in position,
aligning matchmarks. Clean mounting surfaces on
upper ring gear (6), place O-ring seals (7) and (4)
on both shoulders of gear, and place on top of center
case. Align matchmarks. Insert upper sun gear (11),
engaging teeth with splines of lower spider.
4-18A
Models 47D-1, 47G & 47G-2 BELL HELICOPTER COMVPANY Section IV
1. Place bronze thrust bearing (10) into recess connect hoist and remove hoisting ring. Torque bolts
in upper sun gear shoulder. Install upper spider as- 100 to 140 inch-pounds. (See figure 4-16.) Cover top
sembly (5), engaging teeth of spider pinions with of transmission to prevent entrance of foreign ma-
upper sun gear and upper ring gear. Clean seal terial. Connect oil inlet lines and oil transfer line
groove in upper case assembly (3), align match- to transmission.
marks, and lower into place. Coat through-bolts (1)
with zinc chromate primer, install and torque 100 c. Install cooling fan drive (paragraph 4-62). In-
to 140 inch-pounds. Place transmission on bench stall tail rotor drive assembly (paragraph 4-70).
and bolt in place.
d. Install generator (Section V). Install rotor tachom-
m. Install oil strainers (2) in upper and lower sec- eter generator (paragraph 4-39). Install fan belts
tions of transmission. (Strainer on upper end has (Section V). Install air intake duct ( Section V).
two outlets.)
Note
4-38. INSTALLATION - TRANSMISSION.
On models equipped with rotor brake
Note connect hydraulic line and bleed brake.
If a complete transmission (accessory drive e. Install inner snap ring and pack spline coupling
assemblies attached), is being installed, on tail rotor drive and drive shaft with grease,
remove fan and tail rotor drive assemblies Specification MIL-G-3545. Engage sprocket on for-
and replace shims, washers and nuts on ward end of short shaft into coupling of tail rotor
transmission studs. Cover ports of trans- drive. Slide dust boots over couplings and lockwire.
mission. Install tail rotor shaft guard on top of intake mani-
fold (47D1 and 47G).
a. Attach hoisting ring, T100089, to transmission
upper case studs. Connect hoist and take up slack. f. Examine main rotor mast bearing. Remove and
Raise transmission above engine. Clean mounting replace bearing if damage is evident. (Refer to Sec-
surfaces of lower case and adapter plate. Install tion III.) Clean seal groove in top of upper case sec-
aluminum gasket on adapter plate. Lower trans- tion of transmission, and place O-ring seal in groove.
mission into place (port for tail rotor drive assem- Hoist mast and controls assembly, and lower into
bly pointing aft). transmission. Rotate slightly, while loweringto engage
splines. Align match-marks on case and cap. Continue
Note to lower assembly until studs enter cap and bearing
enters into top of transmission. Tap lightly (with a
If clutch splines do not engage clutch drum non-metallic hammer) on flange of swashplate support
driving flange, raise transmission enough to force bearing downwarduntil studs extend through
to permit clutch spider to rotate slightly, cap and support. Start nuts onto threads, and draw
then lower transmission. down alternately and evenly. Torque nuts 100 to 140
inch-pounds and lockwire. Torque two shear nuts
b. Install mounting bolts, washers and nuts. Dis- 80 to 85 inch-pounds.
INSTALL THIS BOLT WITH HEAD

DOWN ON OPPOSITE SIDE TO AVOID
INTERFERENCE WITH GENERATOR.
HEAD DOWN
HEADS DOWN
T-l
47S20-109A
Figure 4-16. MountingBolt Pattern - Transmission

4-19
MAINTENANCE
right rear section of the engine mount, or turn gen-

CAUTION erator to be clear of transmission and suspend se-
curely with safety wire in outer part of engine mount
The mast and controls assembly is de-
signed to have a slight amountof clearance d. Cut lockwire, remove nuts and washers which
(up to 0.009 inch) between the cap and top secure drive assembly to transmission. Pull drive
case section.
case section. Do NOT over-torque
Do NOT over-torque bolts
bolts assembly from transmission and secure shims to
in an effort to close this gap. studs. Do not lose or mix shims. Cover openingto
g. Install main rotor. (Refer to Section II.) Connect prevent entry of foreign matter
fore and aft, lateral, and collective pitch control - GENERATORDRIVE. (Figure
4-42. DISASSEMBLY
tubes to swashplate. Check rigging of flight controls.
(Refer to Section VII.)
h. Start and warm-up engine. (Refer to Flight Manual.) a. Place generator drive assembly in a suitable
Check operation of centrifugal clutch for full engage- holding fixture, and remove nut assembly, using socket
ment at approximately 1700 rpm. Engine and main wrench, 47-620-286-1-T210. Press seal (1) from nut
rotor tachometer needles shall be synchronized at (2), using a suitable pressing plug.
all speeds greater than 1700 rpm. Operate engine at
3100 rpm, and cut throttle quickly to check operation b. Insert gear holder, T100323 into gear splines
of freewheeling unit. Function of the unit can be (pushing cork from gear and clamp holder in a vise).
checked by the sudden drop of engine speed and a Bend tang of lock-washer from slot in lock-nut. Un-
gradual drop of rotor speed as indicated on the dual screw lock-nut (3), using spanner wrench 47-620-
tachometer. 286-1-T211. Remove lock-washer (4).
Note c. Place drive assembly in a press, and push gear

(5) from assembly, using a suitable pressing plug.
It is recommended that a new transmis- Invert assembly in press, and press outer bearing
sion or one in which parts have been re- (6), spacer (7), and inner bearing (8) from sleeve (9).
placed, be run in before the helicopter is Remove O-ring seal (10).
flown. Ten minutes should be utilized to
gradually approach full rpm, ten minutes 4-43. CLEANING - GENERATOR DRIVE. Clean all
at full rpm and 10 minutes to drop from parts with dry cleaning solvent or kerosene. Dry with
rpm to shut-off. This total of 30 minutes filtered compressed air. Do not allow bearings to
is the minimum recommended time of rotate while cleaning.
operation before flight.
4-44. INSPECTION - GENERATOR DRIVE.
i. Examine transmission for evidence of leaks,
cracks, and security. Remove oil strainers, and a. Visually inspect all parts for wear or damage.
inspect for foreign material. Check bearings for freedom of operation, chips,
cracks and brinelling. Check gear for chipped, cracked
4-39. GENERATORDRIVEASSEMBLY. or broken teeth. Check studs for security, damage
and looseness.
4-40. DESCRIPTION.The generator drive assembly
is mounted on the right side of the transmission lower Note
case. It is driven by the accessory drive gear, and Various oversize studs are available for
drives the generator through a splined coupling at the generator drive sleeve assembly. Re-
its outer end. fer to Section IV of Illustrated Parts Cata-
log
log for
for part
part numbers
numbers of of these
these studs.
studs.
4-41. REMOVAL- GENERATORDRIVE ASSEMBLY.
b. Replace seals at reassembly. Replace all un-
a. Place battery switch in "off" position, disconnect
battery and tape terminals.
c. Refer to Section I for Magnaflux and Zyglo re-
b. Release screw cap and pull plug from generator
receptacle. Cover external threads on receptacle
with tape to prevent damage. d. Inspect parts dimensionally. (See figure 4-17.)
c. Remove nuts and washers from studs attaching 4-45. REASSEMBLY - GENERATOR DRIVE.
generator to drive assembly, pull generator out- (Figure 4-17.)
board until free of studs. Lower outboard end of
generator, turn clockwise positioning the receptacle a. Position sleeve (9) on end, place a heat lamp
down, turn inboard end of generator aft and lift through about 9 inches from end of sleeve, apply heat until
4-20
MAINTENANCE
sleeve feels hot to a bare hand. Lubricate inner bear-

ing (8) with engine oil and start bearing into sleeve
(9). Place sleeve assembly in a press andpress bear-
ing into place, using a suitable pressing plug. Invert
4-20A
MAINTENANCE
4. Lock-Washer
6. Outer Bearing
7. Spacer
8. Inner Bearing
9. Sleeve
10. O-ring
ITEM
11 Sleeve - Drive - Bearing ID 2.0457 2.0465 2.0468

12 Bearing - Sleeve - Drive OD 2.0467 2.0472
13 Bearing - Sleeve- Drive ID 1.1806 1.1811
14 Gear - Drive - Bearing- Fwd OD 1.1810 1.1814 1.1805
15 Gear - Drive - Bearing- Aft OD 1.1810 1.1814 1.1805
16 Bearing- Sleeve- Drive - Aft ID 1.1806 1.1811
17 Bearing- Sleeve- Drive- Aft OD 2.1649 2.1654
18 Sleeve - Drive - Bearing - Aft ID 2.1639 2.1647 2.1650
19 Sleeve - Drive OD 2.6235 2.6245 2.6230
20 Sleeve - Drive OD 2.2795 2.2805 2.2790
47620-110
Figure 4-17. Disassembled View and Limits Chart - Generator Drive
sleeve assembly and support inner bearing. Start gear using spanner wrench, 47-620-286-1-T211. Bend tang
(5) into inner bearing and press into place. of lockwasher into slot of lock-nut.
b. Position sleeve (9) on end, place a heat lamp about d. Lubricate seal using engine oil, press seal (1) (with
9 inches from end of sleeve, apply heat until sleeve part number on seal facing outboard) into nut (2) and
feels hot to a bare hand. Invert assembly and slide start nut into threads. Torque nut 960 to 1200 inch-
spacer (7) onto gear shaft. Lubricate outer bearing pounds, using socket wrench, 47-620-286-1-T210. Re-
(6) with engine oil, slide bearing onto gear and start move assembly from gear holder, T100323.
into sleeve. Press bearing into place with a suitable
pressing plug. e. Coat cork with shellac and insert into internal
end of shaft assembly. Push cork into shaft until it
c. Insert gear holder, T100323, through inner end is approximately 1 1/2 inches from inboard end.
of gear assembly and engage splines on opposite
end. Clamp holder in a vise. Install lockwasher (4) 4-46. INSTALLATION - GENERATOR DRIVE.
and start threads of locknut (3) onto shaft. Place in-
ternal tang of lockwasher into slot in shaft, pointing a. Uncover generator drive port on transmission,
toward gear end. Torque unit 600 to 720 inch-pounds position original shims, (or same thickness as original)
4-21
MAINTENANCE
on studs. Moisten O-ring seal in engine oil, and in- Note

sert drive into transmission. Install washers and nuts
on mounting studs. Check rotational backlash. (Refer Do not press bearing (16) from housing
to paragraph 4-31.) After backlash has been checked (17) unless replacement is necessary.
for 0.005 to 0.007 inch, lockwire nuts together in
pairs. Lockwire seal nut to one pair. 4-51. CLEANING - ROTOR TACHOMETER DRIVE.
Clean all parts with dry cleaning solvent or kerosene.
b. Position gasket on mounting studs, insert out- Dry with filtered compressed air. Do NOT permit
board end of generator through engine mount with bearings to rotate while cleaning.
receptacle down, move generator forward and out-
board until studs align with holes in mounting plate. 4-52. INSPECTION - ROTOR TACHOMETER DRIVE.
Press generator inboard on studs only far enoughto
hold generator in position. a. Visually inspect all parts for wear or damage.
Check bearings for freedom of operation, chips,
c. Align splines of generator drive shaft with drive cracks and brinelling. Check gears for chipped,
gear splines and press generator in position. Secure cracked, or broken teeth.
with washers and nuts.
b. Replace seals at reassembly. Replace all un-
d. Remove tape from receptacle and connect elec- serviceable parts.
trical plug. Connect battery.
Note
4-47. ROTOR TACHOMETER DRIVE ASSEMBLY.
Various oversize studs are available for
4-48. DESCRIPTION.The rotor tachometer drive the rotor tachometer drive. Refer to Sec-
assembly is mounted in the left side of the trans- tion IV of Illustrated Parts Catalog cover-
mission lower case. It is driven by the accessory ing part number of these studs.
drive gear in the transmission, and drives the rotor
tachometer generator. c. Refer to Section I for Magnaflux or Zyglo re-
quirements.
4-49. REMOVAL - ROTOR TACHOMETER DRIVE.
d. Inspect parts dimensionally. (See figure 4-18.)
a. Disconnect electrical cordage from rotortachom-
eter generator. 4-53. REASSEMBLY- ROTOR TACHOMETERDRIVE.
b. Remove nuts and washers which secure tachom- (Figure 4-18.)
eter generator to drive assembly and remove from
transmission. Remove two remaining nuts and washers a. Lubricate bearings with engine oil. Start inboard
and pull rotor tachometer drive from transmission. bearing (8) into sleeve (10), and press into place using
Replace shims on studs of transmission. Do NOTlose a suitable pressing plug. Install bearing retaining
or mix these shims. Cover port to prevent entrance snap-ring (7) in sleeve. Invert assembly, and place
of foreign matter. an arbor against inner race of bearing. Press gear
(4) into bearing until inner race of bearing contacts
4-50. DISASSEMBLY - ROTOR TACHOMETER shoulder on gear. Remove arbor from sleeve, place
DRIVE. (Figure 4-18.) spacer (6) on shaft, and press outboard bearing (5)
into place.
a. Separate housing and sleeve assemblies, and re-
move gasket (1). Place holding block, T100222, over b. Place lock-washer (3) in position (internal tang
drive gear, pass bolt through shaft of gear, and in- in slot on shaft). Place holding block, T100222over
stall washer and nut. Clamp holding block in a vise. gear, pass bolt through shaft, and install washer and
Straighten tang of lockwasher and remove lock-nut nut. Install lock-nut (2) and torque 500 to 600 inch-
(2) using socket wrench, 47-620-287-1-T220. Slide pounds, using spanner wrench 47-620-287-1-T220.
lock-washer (3) from shaft. Remove holding block, Bend tang of lock-washer into castellation in nut.
and pull gear (4) from sleeve assembly. Clean groove in sleeve and install O-ring seal (9).
b. Remove outboard bearing (5), and lift spacer (6) Note

from sleeve assembly. Remove inboard bearing snap-
ring (7) and press inboard bearing (8) from sleeve. Accomplish following step c. if bearing
Remove O-ring (9) from sleeve (10). (16) has been removed from housing (17).
Proceed with step d. if bearing was not
c. Remove seal snap-ring (11) and pull seal (12) removed.
from housing assembly. Remove snap-ring (13) and
thrust washer (14), and pull gear (15) from housing. c. Lubricate bearing (16) with engine oil, and press
Press bearing (16) from housing (17), using pressing into housing (17) using pressing plug, 47-620-297-
plug, 47-620-297-1-T200. 1-T200.
4-22
Models 47D-1, 47G & 47G-2 BELL HELICO P TER COMPANY Section IV
MAINTENANCE
1. Gasket 10. Sleeve

2. Lock-Nut 11. Snap-Ring
3. Lock-Washer 12. Seal
4. Gear 13. Snap-Ring
5. Outboard Bearing 14. Thrust Washer
6. Spacer 15. Gear
7. Snap-Ring 16. Bearing
8. Inboard Bearing 17. Housing
9. O-Ring
ITEM
18 Gear Teeth-Fwd-Rotor Tach.

Gen. Drive OD 1.8510 1.8530 *
19 Gear Teeth-Aft-Rotor Tach.
Gen. Drive OD 0.7210 0.7230 **
20 Gear-Forward-Rotor Tach.
Gen. Drive OD 0.7867 0.7871 0.7865
21 Bearings-Forward Gear ID 0.7871 0.7874
22 Bearings-Forward Gear OD 1.5746 1.5748
23 Sleeve-Forward Gear Bearings ID 1.5735 1.5740 1.5743
24 Gear Teeth-Aft Gear OD 1.6480 1.650 1.647**
25 Gear-Aft OD 0.6245 0.6250 0.6243
26 Bearing-Aft Gear OD 0.8110 0.8120
27 Bearing-Aft Gear ID 0.6249 0.6254 0.6256
28 Housing-Aft Gear ID 0.8110 0.8120 0.8125
* Total backlash mated to production gear Part No. 47-620-030 at gear dim,
"E", 0.005 to 0.007.
**Check using gage pin 0.054 dia.
NOTE: Do not disassemble aft drive gear from housing to inspect
Figure 4-18. Disassembled View and Limits Chart - Rotor Tachometer Drive
4-23
MAINTENANCE
d. Install gear (15), thrust washer (14), and snap- 4-58. DISASSEMBLY - COOLING FAN DRIVE. (Fig-
ring (13) into housing (17). Place seal (12) over gear ure 4-19.)
shaft. press into housing and install snap-ring (11).
a. Remove O-ring seal (1) from fan drive assembly.
Place fan drive assembly in holding fixture, 47-620-
CAUTION 200-3-T210, and clamp fixture in a vise. Cut lock-
hold pulley with a strap wrench and remove
pulley until forward cone and pulley are loose on
gear splines. Remove forward cone (4), pulley (5)
Be careful not to damage seal on end of and aft cone (6) from drive assembly.
gear shaft.
Note
e. Place gasket (1) between housing and sleeve as-
semblies, and carefully push assemblies together.
Two sections of aft cone (referred as (6)
4-54. INSTALLATION - ROTOR TACHOMETER in paragraph a.) are a matched set and in-
DRIVE. dexed by a corresponding number on wide
end of each half of cone. (Identify, each cone
a. Uncover rotor tachometer drive port of trans- half, if numbers are not visible.) Cones
mission, and make sure shims are in place. Moisten must be installed in matched sets only.
O-ring seal with engine oil, and insert rotor tachom-
eter drive assembly into transmission with outboard
assembly removed and bolt installed in aft hole. b. Cut lockwire and remove outer retaining nut as-
sembly from sleeve, using socket wrench, 47-620-
b. Install and tighten nuts. Check rotational back- 284-1-T210. Place retaining nut assembly in a press,
lash. (Refer to paragraph 4-31.) Install outer housing and push seal (7) from retaining nut (8), using suit-
assembly. able plug. Pull O-ring (9) from groove of nut. Pull
spacer (10) from shaft of gear.
c. Place tachometer generator on housing assembly.
Install washers and nuts. Install through-bolt and nut. c. Support sleeve assembly with holding fixture,
Connect electrical cordage to rotor tachometer gen- 47-620-200-3-T210, and place fixture in an arbor.
erator. Press gear (11) from sleeve assembly using a
suitable pressing plug. Remove assembly from arbor.
4-55. COOLING FAN DRIVE ASSEMBLY.
d. Remove snap-ring (12) from sleeve. Pull inner
4-56. DESCRIPTION. The cooling fan drive assem- bearing (13) and outer bearings (14) from sleeve (15)
bly is mounted into the forward side of the transmis- using bearing puller, T100891.
sion lower case, and is driven by the fan drive bevel
gear. The fan drive pulley is secured to the splined Note
shaft by a pair of cones and a bolt, which is threaded
into the forward end of the shaft. Do not remove cork from inside of gear
shaft unless evidence of oil leaks appear.
4-57. REMOVAL - COOLING FAN DRIVE.
4-59. CLEANING - COOLING FAN DRIVE. Clean
a. Remove
Section
(Seefan belt.V.) parts in dry cleaningsolvent or kerosene. Dry with
filtered compressed air. Do NOT allow bearings to
b. Disconnect fore and aft cyclic control push-pull rotate while cleaning.
tubes from swashplate lever and bellcrank on top of
fan drive assembly. 4-60. INSPECTION - COOLING FAN DRIVE.
c. Remove nuts and washers which secure fan drive a. Visually inspect all parts for wear or damage.
assembly to transmission and lift fore and aft cyclic Check bearings for freedom of operation, chips,
control bellcrank and bracket assembly from trans- brinelling. Checkgearfor chipped,cracked
mission. Insert two 5/16, 18 thread, x 2 1/2 inch bolts or broken teeth .
(full thread to head of bolt) into two puller holes in
flange of fan drive assembly. b. Replace seals at reassembly. Replace all un-
serviceable parts.
d. Turn bolts evenly to free fan drive from trans-
mission, and pull assembly from studs. Place shims c. Refer to Section I, for Magnaflux or Zyglo re-
on studs. Do NOT lose or mix these shims. Cover quirements.
port in transmission to prevent entrance of foreign
matter. d. Inspect parts dimensionally. (See figure 4-19.)
4-24
MAINTENANCE
4-61. REASSEMBLY - COOLING FAN DRIVE.

(Figure 4-19.)
a. Position sleeve (15) on end, place a heat lamp
about 9 inches from end of sleeve, apply heat until
sleeve feels hot to a bare hand. Lubricate inner bear-
ing (13) with engine oil, start bearing into sleeve (15)
and press bearing into place using pressing plug,
T100420. Install snap-ring (12) in groove of sleeve.
b. Position sleeve (15) on end, place a heat lamp

sleeve feels hot to a bare hand. Lubricate outer bear-
ings (14) with engine oil. Place bearings together face
to face (see figure 4-8) and start bearings into sleeve.
Press into place using pressing sleeve, T100420.Pass
shaft of gear (11, figure 4-19) through inner bearing
and start gear into outer bearing. Slidepressing sleeve,
4-24A
MAINTENANCE
1. O-ring Seal
2. Retaining Bolt
3. Washer
4. Fwd. Cone
5. Pulley
FACE 6. Aft Cone
TO 7. Seal
720-960 12. Snap-ring
14. Outer Bearing
TORQUE
250-300
INCH- POUNDS
T = Tight Fit 47620-237

ITEM
1 Sleeve-Drive-Bearing ID 1.8494 1.8500 1.8501

2 Bearing-Sleeve-Drive OD 1.8499 1.8504
3 Bearing-Sleeve-Drive OD 0.9800 0.9804 0.9799
4 Gear-Drive-Bearing-Forward OD 0.9800 0.9804 0.9799
5 Gear-Drive-Bearing-Aft OD 0.7873 0.7877 0.7870
6 Bearings-Aft-Gear-Drive ID 0.7870T 0.7874T
7 Bearings-Aft-Gear-Drive OD 1.6530T 1.6535T
8 Sleeve-Drive-Bearing-Aft ID 1.6530 1.6535 1.6538
9 Sleeve-Drive OD 2.436 2.437 2.4355
10 Sleeve-Drive OD 2.187 2.188 2.1865
11 Gear-Drive-Spline-Tooth-Width 0.1840 0.1850 0.1820
12 Pulley-Upper-Spline-Space-Width 0.1860 0.1880 0.1900
Figure 4-19. Disassembled View and Limits Chart - Cooling Fan Drive
4-25
Section IV BELL HELICOTER COMPANY Models 47D-1, 47G & 47G-2
MAINTENANCE
T100419-5, over splines of shaft and seat against Note

inner race of outer bearings. Place assembly in an
arbor (supported on sleeve, T100419)and press gear On models equipped with rotor brake as-
into place using pressing plug, T100419. sembly fromconnect
tail rotor lines and remove
oil drive
brake from tail rotor drive assembly.
c. Press seal (7) into retaining nut (8), using a suit- b. Remove nuts and washers which secure drive
able pressing plug. Insert spacer (10) through seal assembly to transmission. Thread a 5/16 inch, 18
with flange side of spacer inboard. Dip O-ring seal thread, by 2 1/2 inch bolt (full thread to head) into
(9) in engine oil and install in groove of retaining nut.
Slide nut assembly over splines of gear shaft, and assembly. Tighten bolts evenly and pull drive as-
start nut into threads of sleeve. Place sleeve assembly
sembly into holding fixture, 47-620-200-3-T210, and transmission Do NOT lose or mix these
clamp fixture in a vise. Torque retaining nut 720 Do NOT lose or mix these
of transmission case. transmission
to 960 inch-pounds, using socket wrench, 47-620-.
284-1-T210. Lockwire nut to sleeve. prevent entrance of foregn matter
d. Place inboard split cone (6) (matched set) onto gear DISASSEMBLY -- TAIL
4-66 DISASSEMBLY
4-66. TAIL ROTOR
ROTORDRIVE.
DRIVE
shaft "Large end inboard" and install pulley (5) and (Figure 4-20.)
forward cone (4). Slide washer (3) onto retaining bolt (2) a. Clamp holding fixture T100227, in a vise, and
with chamfered side of washer toward head of bolt. place tail rotor drive assembly in fixture. Hold cou-
Start bolt into threads of gear shaft. Torque bolt 250 ping with a strap wrench and remove coupling re-
to 300 inch-pounds. Install lockwire from pulley to bolt taining bolt (1), lockwasher (2), plain washer (3), and
and then diametrically to opposite side of pulley. pull coupling (4) from splines of shaft.
e. Dip O-ring seal (1) in engine oil and place in b. Cut lockwire and remove bearing retaining nut
groove provided on sleeve. assembly from sleeve, using socket wrench, 47-620-
284-1-T210. Remove O-ring seal (5) from groove in
4-62. INSTALLATION - COOLING FAN DRIVE. nut. Place retaining nut assembly in an arbor, and
press seal (6) from nut (7), using a suitable pressing
a. Uncover fan drive port of transmission, and sleeve. Remove spacer washer (8) from drive shaft.
make certain shims are in place. Moisten O-ring
seal with engine oil, and insert fan drive assembly c. Remove drive assembly from holding fixture, and
into transmission with large hole in sleeve at top. place in an arbor. Press gear (9) from sleeve as-
Install fore and aft cyclic control bracket and bell- sembly using a suitable pressing plug. Remove lock-
crank. Install and tighten nuts. (Refer to paragraph ring (10) and pull inner bearing (11)and outer bearings
4-71. Establishment of Criteria for Obtaining (12) from sleeve (13) using puller, T100901. Remove
Recommended Cooling Fan Drive and Pinion Gear O-ring seal (14) from groove in sleeve.
Backlash and Pattern.)
4-67. CLEANING - TAIL ROTOR DRIVE. Clean all
parts in dry cleaning solvent or kerosene. Dry with
filtered compressed air. Do NOT allow bearings to
CAUTION rotate while cleaning.
4-68. INSPECTION - TAIL ROTOR DRIVE.

Do NOT over torque bolts in swashplate
control levers as damage may result to a. Visually inspect all parts for wear or damage.
the lugs. Bolts should be finger tight. Check bearings for freedom of operation, chips,
cracks andbrinelling. Check gear for chipped, cracked,
4-63. TAIL ROTOR DRIVE ASSEMBLY. or broken teeth.
4-64. DESCRIPTION.The tail rotor drive assembly b. Replace seals at reassembly. Replace all un-
is mounted in the aft side of the lower case of the serviceable parts.
transmission. This assembly is driven by the acces-
sory drive gear in the transmission, and drives the c. Refer to Section I for Magnaflux or Zyglo re-
tail rotor drive shaft through a splined coupling at quirements.
its aft end.
d. Inspect parts dimensionally. (See figure 4-20.)
4-65. REMOVAL - TAIL ROTOR DRIVE.
4-69. REASSEMBLY - TAIL ROTOR DRIVE.
a. Cut lockwire and slide dust covers off both cou- (Figure 4-20.)
plings. Remove snap-rings from each coupling. Push
shaft forward to clear aft coupling. Lift aft end up a. Position sleeve (13) on end. Place a heat lamp
and slide shaft aft until clear of forward coupling. about 9 inches from end of sleeve, apply heat until
4-26
MAINTENANCE
1. Retaining Bolt
2. Lock-Washer
3. Plain Washer
4. Coupling
5. O-Ring
6. Seal
8. Washer
9. Gear
10. Lock-Ring
11. Inner Bearing
12. Outer Bearings
13. Sleeve
14. O-Ring
ITEM
15 Sleeve-Bearing-Forward ID 1.8494 1.8500 1.8502

16 Bearing-Forward-Sleeve OD 1.8499 1.8504
17 Bearing-Forward-Sleeve ID 0.9800 0.9804 0.9799
18 Gear-Drive-Bearing - Forward OD 0.9800 0.9804 0.9800
19 Gear-Drive-Bearing-Aft OD 0.7873 0.7877 0.7870
20 Bearing-Aft-Gear-Drive ID 0.7870 0.7874
21 Bearing-Aft-Gear-Drive OD 1.6530 1.6535
22 Sleeve-Bearing-Aft ID 1.6529 1.6535
23 Gear-Drive-Spline-Teeth-Width 0.1840 0.1850 0.1835
24 Sleeve-Drive OD 2.187 2.188 2.1865
25 Sleeve-Drive OD 2.4360 2.4370 2.4355
47620-113
Figure 4-20. Disassembled View and Limits Chart - Tail Rotor Drive
4-27
MAINTENANCE
sleeve feels hot to a bare hand. Dip O-ring seal (14) 4-71. ESTABLISHMENT OF CRITERIA FOR OB-
with engine oil, and insert in groove of sleeve (13). TAINING RECOMMENDED COOLING FAN
Lubricate inner bearing (11) with engine oil Start bear- DRIVE AND PINION GEAR BACKLASH AND
ing into sleeve and press into place using pressing PATTERN
plug, T100420. Install lock-ring (10).
SPECIAL TOOLS REQUIRED
b. Position sleeve (13) on end, place a heat lamp
sleeve feels hot to a bare hand. Lubricate outer bear- PART NO. NOMENCLATURE
ings (12) with engine oil. Place bearings together face
to face (see figure 4-8) and start bearing into sleeve. 1. T100090 Holding Fixture
Press into place using pressing plug, T100420. Pass 2. T100230 Socket Wrench
shaft of gear (9, figure 4-18) through inner bearing 3. Service Letter Sun Gear Centering Fixture
and start gear into outer bearing. Slide the -5 sleeve No. 127
of T100419, over splines of shaft and seat against 4. 47-620-200-1- Gage Tool
inner race of outer bearings. Place assembly in an T290
arbor (supported on -5 sleeve of T100419) and press 5. Backlash Check- Figure 4-25
gear into place using -3 plug of T100419. Remove as- ing Tool
sembly from arbor, and slide washer (8) onto gear
shaft. a. Invert the lower case and insert cooling fan drive
gear with teeth downward, place 0.034-0.036 inch
c. Press seal (6) (with part number on seal facing shims on drive gear. Brush coat drive gear teeth,
outboard). Press seal (6) into retaining nut (7) using sparingly, with a suitable gear marking compound,
a suitable pressing plug. Dip O-ring seal (5) in engine priot to installation. (Alternate method may be used
oil, and install in groove of retaining nut. Slide as- to determine starting shim thickness by using gage
sembly over splines of shaft and start threads of nut tool, part No. 47-620-1-T290. Refer to current Main-
into sleeve. Place drive assembly into holding fix- tenance and Overhaul Instruction Handbook.)
ture 47-620-200-3-T210 and clamp fixture in a vise.
Torque retaining nut 720 to 960 inch-pounds, using b. Install bearing in lower case liner as follows:
socket wrench, 47-620-284-1-T210. Lockwire nut to
sleeve assembly. Remove assembly from fixture. (1) When installing ball bearing, part No.47-620-
664-1, position the bearing in liner, with lettering to-
d. Slide coupling (4) onto splines of shaft. Be care- ward retaining plate, and press into place.
ful not to damage seal. Place lock-washer (2) and
plain washer (3) onto retaining bolt (1), and start Note
threads of bolt into gear shaft. Torque bolt 160 to
180 inch-pounds. Remove assembly from holding It is receommended to use bearing part No.
fixture. 47-620-680-1, in lieu of bearing part No.
47-620-664-1.
4-70. INSTALLATION - TAIL ROTOR DRIVE.
(2) When installing roller bearing, part No. 47-
a. Uncover tail rotor drive port of transmission, 620-680-1, remove rollers and retainer washer and
and make certain shims are in place. Moisten O-ring position outer race in liner, with the open end toward
seal with engine oil, and insert tail rotor drive as- bearing retaining plate, and press into place. Place
sembly into transmission. Install washers and nuts. the rollers in the outer race (either position) and
Tighten nuts securely. Check rotational backlash. place retainer ring on bearing with lettering twoard
(Refer to paragraph4-31.) retaining plate. Serial number on outer race must be
identical to serial number on inner race.
Note c. Install bearing retaining plate and bolts.

On models equipped with rotor brake as- Note
sembly, install brake and connect oil lines.
Bleed brake system. Do not lockwire retaining plate bolts until
gear tooth pattern and backlash of fan drive
assembly have been established.
b. Install inner snap-ring in coupling. Lubricate in-
side of coupling with grease, Specification No. MIL- d. Upright case and insert lower sun gear into cool-
L-3545. Enter sprocket of shaft into forward coupling. ing fan drive gear. Make certain that the shims are
Push forward until aft coupling can be engaged. Pull in place under the drive gear. Place case in an arbor
shaft aft into aft coupling. Install snap-rings in both press on a suitable sleeve that supports the inner
couplings. Slide dust covers over couplings and in- race of lower case bearing. Press sun gear into
stall lockwire. place.
4-28
MAINTENANCE
e. Place holding fixture, T100090, in position en- i. Procedure for checking and adjusting the backlash
gaging dowels of fixture with through-bolt holes in and pinion gear pattern:
case and teeth of lower sun gear. Invert assembly,
clamping side of holding fixture in vise. Slide centri- Note
fugal clutch assembly onto lower sun gear splines.
(CAUTION: TO PRECLUDE THE POSSIBILITY OF A backlash checking tool may be manu-
CLUTCH NUT BOTTOMING AGAINST END OF SUN factured, as shown on figure 5-25.
GEAR SPLINES CHECK THAT SPLINES DO NOT
PROTRUDE BEYOND SURFACE OF DRUM WHEN -
INSTALLING CLUTCH ASSEMBLY, Part No. 47-620-
669.) If adjustment is required, place shims (same
type used under part No. 47-620-207-1 gear), as re-
quired between the clutch drum and lower case bear-
ing. Position the clutch drum locknut on threads of Fan pulley must be installed on shaft, and
the lower sun gear and torque to 1500-1800 inch- the retaining bolt torqued to 300 inch-
pounds, using socket wrench, T100230. pounds when checking the backlash and gear
pattern. Check the fan drive pulley runout
Note to 0.010 T.I.R. maximum allowable.
Do not install locking-screws in clutch (1) CHECKING:

drum locknut until gear tooth pattern and
backlash of fan drive assembly have been (a) Rotate sun gear holding fan pulley, or vice
established. versa, to obtain gear pattern.
f. Upright the lower case, remove fixture T100090, (b) Check for 0.003 inch nominal backlash,
and place the case on a flat metal, wood or micarta (0.002 inch minimum to 0.004 inch maximum) with
plate covering the clutch spider area. dial indicator pointer located 0.800 inches, from cen-
ter line of pinion shaft. Backlash shall be checked at
Note three positions, 120 degrees apart. No reading shall
be under 0.002 inch or to exceed 0.004 inch with the
The weight of the case assembly willmove sun gear supported. A difference of 0.001 inchto 0.002
the lower sun gear and clutchassembly up- inch maximum backlash between teeth of a gear is
ward, effectively removing the axial play possible due to gear runout. This is not cause for
of the bearing. rejection of gears.
g. Center the lower sun gear, using the machined (c) Place the case assembly lower fange on
beveled area (inner diameter approximately half- blocks so that clutch and sun gear are unsupported.
inch below top) of the lower case as the controlled Check backlash at three positions to assure 0.007
reference point. Refer to Service Letter No. 127, for inch maximum for ball bearing and 0.0055 inch maxi-
sun gear centering tool. mum for roller bearing is not exceeded. If these un-
supported readings are exceeded with a sun gear sup-
h. Place 0.030-0.032 inch shims on studs at fan ported setting of 0.003 inch nominal backlash, check
drive port of lower case. Brush coat teeth of fan bearing axial play as follows:
pinion gear, sparingly, with a suitable gear marking
sembly into transmission and install and tighten at able block under clutch and allow transmission case
least two nuts opposite each other. Exercise care, to ang free.
when installing quill, to preclude tooth contact dam-
during meshing
of gears. 2. Place dial indicator gage on top surface
of sun gear and set dial to zero.
Note
3. Place case lower flange on blocks so
Fan quill sleeve MUST FIT TIGHT into that clutch and sun gear hang unsupported and read
lower case bore to preclude pattern and dial indicator. The maximum axial movement allowed
backlash shift under load conditions, for the 47-620-664-1 ball bearing is 0.006 inch and
maximum allowed for the 47- 620- 680-1 roller bearing
is 0.004 inch. (Most 47-620-680-1 rollerbearingswill
Check existence of backlash during quill installation. average 0.002 inch - 0.003 inch.) If these limits are
If necessary, increase shim under quill in 0.002 inch exceeded, the bearing should be replaced. Care should
increments until some backlash can be felt with quill be exercised to prevent false readings due to sun gear
fully installed. (Alternate method - Repeat paragraph wobble. Use of centering tool or other suitable means
h. without shims using a feeler gage to determine the of preventing sun gear from wobbling laterally is re-
correct shim thickness.) commended.
4-29
MAINTENANCE
Note DESIRED NO LOAD RED LEAD PATTERN POSITION

It is recommended to use bearing part No. Drive side of pinion gear P/N 47-620-530
47-620-680-1, in lieu of bearing part No. OPTIMUM
PATTERN
POSITION
47-620-664-1.
CROWN 0.045"-0.050"
(d) Remove fan drive assembly and check gear
pattern. Refer to figures 4-21 and 4-22.
HEEL I TOE --
Note
Red lead pattern obtained with used gears ·
may extend the entire length of the gear MAINAREAOF
teeth and cannot be evaluated by measure- PATTERN
TOUCHING
ment criteria set forth in figures 4-21 or ORSLIGHTLY
OFF
4-22. Use Criteria set forth in figure 4-24. ROOT TOE
Used gear teeth should be coated with
Dychem metal layout ink, or equivalent, in
order to detect a pattern trend under op- AFTLIMIT
erational load. 0.040"
MIN.
(2) ADJUSTING: When the backlash and/or the
gear pattern are not acceptable, adjust 47-620-530-1
pinion quill shims and/or 47-620-207-1 gear shims
until acceptable, using the criteria below:
(a) When shims are added to the 47-620- QUADRANT

530-1 pinion quill, the 47-620-530-1 pinion gear
pattern will normally move deep (toward root) and MAJORLOADCONCENTRATION 0.020 MAX.
aft (toward heel). Removing shims from the quill OF REDLEADPATTERN.
will normally move the 47-620-530-1 pinion gear (CENTER AREA)
OFWIDEST
pattern higher and toward the toe, however there
may be exceptions to this. HIGHLIMIT
-0.030" MIN.
(b) As a general rule of thumb for each 0.002
inch shim change under the quill sleeve, the backlash
will change approximately 0.0005 inch and under the
47-620-207-1 gear, the change will be approximately
0.001 inch.
(c) Usually, removing or adding shims under

the 47-620-207-1 gear will have a major effect on
backlash and minor effect on changing pattern posi- LOAD
MAJOR -0.010"
CONCENTRATION MAX.
tion. OF RED LEAD PATTERN
(CENTER OF WIDESTAREA)
(d) Removing or adding shims under the part
No. 47-620-530-1 pinion gear, fan quill sleeve, will
have a minor effect on backlash and major effect on
changing pattern position. (Refer to paragraph (a) Note
above.) 1. Major load concentration of red lead pattern
should always be located within the lower toe
(e) An effort should be made to obtain an op- quadrant of gear tooth.
timum desired red lead pattern within limits set 2. Under load, pattern concentration will move
forth in figure 4-21. diagonally toward crown and heel.
3. Corresponding red lead pattern on the 47-
(f) In the event satisfactory backlash and red 620-207 gear will locate in the upper toe
lead pattern cannot be achieved within minimum speci- quadrant of the tooth and may run off the
fied limits set forth in figure 4-22, change parts in crown. This is acceptable. Under load,
the following sequence until satisfactory pattern is pattern will move diagonally toward root
achieved: and heel
47620-216
1. 47-620-530-1 pinion gear.
2. 47-620-207-1 gear.
3. Fan Quill sleeve. Figure 4-21. Gear Pattern
4-30
MAINTENANCE
NEVER EXCEED LIMIT - NO LOAD RED LEAD j. Place O-ring moistened with engine oil, on fan
PATTERN POSITION. drive quill assembly, and install quill assembly. Use
Drive side of pinion gear, P/N 47-620-530. caution during quill installation to prevent part No.
47-620-530-1 gear damage during mesh with part No.
47-620-207-1 gear. Remove centering fixture and in-
CROWN vert case. Remove clutch and lockwire lower case
DESIRED) bearing retainer plate bolts. Reinstall clutch assem-
bly. Line up two screw holes in locknut with two in
HEEL clutch drum. Install and tighten lock screws. Lock-
wire screws together drawing lockwire around collar
of locknut. After shimming, check pinion teeth for any
-TOE indentations due to pushing quill into mesh. If any are
found, discard the pinion and start over.
ROOT k. Under load, tooth pattern will move aft (toward

0.030" MAX.
(0.0" ORSLIGHTLY heel) and up (toward crown) from the red lead position
OFFTOEDESIRED) on the 47-620-530-1 pinion gear with corresponding
movement down and toward heel on the 47-620-207-1
REDLEAD LOADCONCENTRATION gear.
(CENTER OF WIDESTAREA)
Note 1. It is advisable and highly recommended to check
1. Major load concentration of red lead load pattern position after a few hours flight time.
pattern should be located within the Pressure point of pattern can be identified by a long
lower toe quadrant of gear tooth. thin shiny line of worn dulite. Position of this line
47620-217 should be within limits outlined in figure 4-23. When
re-installing quill care should be exercised to pre-
vent tooth damage when gears are meshed.
Figure 4-22. Gear Pattern
4-31
MAINTENANCE
DESIRED LOAD PATTERN POSITION AFTER 1 TO 10 HOURS OF OPERATION.

(Red lead pattern position within desired limits
specified in Figure 1)
DRIVE SIDE OF PINIONGEARP/N 47-620-530
LOADCONCENTRATION
(WORNDULITE COATING-
THIN BRIGHTAREA)
HEEL
0.030" MIN.
(0.040"-0.045"
DESIRED)
TOE
ROOT- / TOOTH
CENTERLINE CENTEROF LOADCONCEN-
TRATIONMUSTBE ON TOE
SIDE OF TOOTHCENTER
LINE.
NEVER EXCEED LOAD PATTERN POSITION AFTER 1 TO 10 HOURS OF OPERATION.

(Red lead pattern position per Figure 2)
DRIVE SIDE-530 PINION GEAR DRIVE SIDE -207 DRIVE GEAR
LOAD
LOADCONCENTRATION
CONCENTRATION 0.200" MAX. WIDTH
(WORNDULITE COATING PATTERN OFF TOPOF
-THIN BRIGHTAREA) PERMITTED
DIM
NOTE TOP CHAMFER DIM A CROWN

NOTE 1
CROWN
EEL TOE
TOP OF LOAD
HEEL CONCENTRATION
(DULITE WEAR)
I MUSTNOT TOUCH
LOWEREDGEOF
DULITE TOP CHAMFER ROOTDULITE
DISCOLORA- OF TOOTH DISCOLORATION
TION PATTERN
Note
Note
A must be equal to or less
Dimension 2. Load pattern position of -207 gear will
1. Dimension A must be equal to or less correspond with -530 pinion gear and
B. than dimension is of little concern. Normally pattern
will not be defined by a bright thin area
of Dulite wear but rather by Dulite dis-
coloration.
47620-218

4-32
MAINTENANCE
DESIRED NO LOAD RED LEAD PATTERN POSITION

FOR USED SERVICEABLE GEARS
Drive side of pinion gear P/N 47-620-530
1. Red lead pattern of used gears will
normally cover more tooth area than
new gears due to surface wear. Size
of pattern will vary and probably run
I from toe to heel, therefore, position-
-- HEEL I TOE ing by measurement is not possible.
ROOT LOWER
TOE 3. Load pattern after 1 to 10 hours of
QUADRANT MAJORLOADCONCENTRATION
OF RED LEAD PATTERN (CEN- operation shall be in accordance
TER OF WIDESTAREA)SHOULD with Figure 3.
BE LOCATEDWITHINTHE LOWER
TOE QUADRANTOF GEAR TOOTH. 47620-219
0.560 DIA.
0.8125 NO. 10- 24 THD. NUT FIT
DRILL & REAMS.F.

FORDET. -5 (2 PLCS
30° NO. 10-24 THD. STUD FIT 0.25-

TYP
0.80 FAN PULLEY BOLT (REF) 75
WITHPULLEY INSTALLED
TORQUETO 300 INCHPOUNDS
1. Material CRS - 1/2" x 1" x 2"

2. Material CRS - 1/2" x 1/2" x 2"
3. Wing Nut No. 10-24 2 Reqd
4. Material CRS 3/16" Dia x 1-3/4" 2 Reqd
5. Series No. 10 Drill Rod 3/16" Dia x 3/4" 47620-226A
Figure 4-25. Fan Drive Backlash Checking Tool

4-33/4-34
Models 47D-1 & 47G BELL HELICOPTER COMPANY Section V (Part 1)
MAINTENANCE
Section V - Part 1
Power Plant and Related Systems
5-1. POWER PLANT. (Figures 5-1 and 5-2.) c. Drain engine oil by opening magnetic drain plug
in oil sump. Disconnect oil filter hose from engine.
5-2. DESCRIPTION. The power plant and related Disconnect oil cooler intake duct. Disconnect and
systems consist of the engine, engine mounts, cool- remove engine oil inlet line. Disconnect throttle con-
ing system, engine controls, fuel, oil, and air in- trols at carburetor and remove throttle control rod
duction systems, and accessories. The transmission at top of engine. Disconnect carburetor drain line.
is mounted on top (drive) end of engine, and drives Disconnect oil pressure and manifold pressure lines
the rotors, cooling fan, generator, and rotor tachom- at couplings under right side of engine. Disconnect
eter generator. The magnetos are mounted on the manifold pressure line at manifold, oil pressure
accessory case at lower end of the engine. Due to line from inlet fitting, and remove lines.
vertical mounting, engine manufacturer's designa-
tions such as "right" or "left" are reversed in d. Remove wires from starter switch, and discon-
relation to normal viewing, thus the "right magneto" nect cable from switch arm. Disconnect electrical
is actually located at the left-hand side of the engine connections at carburetor temperature bulb, engine
compartment. tachometer generator, oil temperature bulb, magneto
ground wires at magnetos, and engine ground wire
5-3. ENGINE SPECIFICATIONS. from engine. Unzip right side of cooling fan shroud,
disconnect thermocouple at number three cylinder,
Franklin and thread wires and unit out of cooling fan shroud.
(Aircooled Motors) Model 6V4-200-C32
Horsepower 200 at 3100 RPM e. Disconnect safety cables at right and left forward
Idle Speed 1550 to 1700 RPM side of engine compartment, and at upper cross tube
Bore 4.5 inches aft of engine. Remove nuts and bolts from clevises
Stroke 3.5 inches of sprag mount. Disconnect fuel inlet line, and car-
Compression ratio 8.5:1 buretor air heat controls. Cut safety wire, remove
Displacement 335 cubic inches tape holding all electrical cordage to engine mount,
Firing order 1-4-5-2-3-6 and move wiring clear of mount. Disconnect and
Spark plugs Champion LA-10 (non shielded) remove main rotor push-pull tubes.
(AC-LA-47 (shielded)
Spark plug gap LA-10 - 0.013 to 0.016 Note
LA-47 - 0.011 to 0.014
Magnetos Scintilla S6RN-21 (shielded) Identify push-pull tubes to avoid confusion
Scintilla S6RN-23 (unshielded) on installation.
Ignition timing 36° BTC
Oil pressure 40 to 60 PSI f. Attach hoist to hoisting ring on transmission,
Valve clearance and take up slack. Remove bolts through upper Lord
(lifters bled) 0.040 inch (cold) mounts on each side of mount and lift engine from
Valve travel 0.530 inch helicopter. Place assembly on stand 47-600-001-1-
Weight (dry) 336 pounds T212.
5-4. REMOVAL - POWER PLANT.
5-5. DISASSEMBLY - STRIPPING ENGINE. (Fig-
a. Disconnect battery. Drain fuel and remove fuel ure 5-3.)
tank(s) and support(s) as an assembly. (Refer to
paragraph 5-112.) Remove main rotor and mast a. Support engine in stand, 47-600-001-1-T212. Re-
controls assembly. (Refer to Section II.) Install move transmission. (Refer to Section IV.) Cut lock-
hoisting ring, T100089, on studs at top of trans- wire, remove bolts, cotter pins and locking plates,
mission. and remove spline ring and dowels from end of
engine crankshaft. Remove oil jet from end of crank-
b. Remove tail rotor drive shaft guard from top of shaft for use in replacement engine. Remove adapter
intake manifold and remove forward section of tail plate and engine mount as an assembly. (Refer to
rotor drive shaft. (Refer to Section VI.) Disconnect paragraph 5-10.) Remove adapter plate supportblocks
heated air intake from exhaust shroud, disconnect from front and sides of engine case. Remove oil
exhaust manifolds at expansion joints and remove sump plate and gasket, and remove dowels (or
from helicopter. Disconnect carburetor air intake countersunk screws) and sprag adapter from engine.
duct. Reinstall gasket and oil sump plate.
5-1
Section V (Part 1) Models 47D-1 & 47G
b. Remove cooling fan shroud and baffles. (Refer to exhaust stacks from engine. Remove air control valve
paragraph 5-75.) Remove cooling fan. (Refer to para- from carburetor intake. Remove any fittings not fur-
graph 5-63.) Loosen adapter clamp bolt and unscrew nished with replacement engine. Cover all openings
tachometer generator and adapter from drive as- on engine.
sembly at lower end of engine (or remove four bolts
from flange and remove tachometer generator). Re- 5-6. ASSEMBLING - ENGINE BUILD-UP.
move drive assembly also, if needed for use with
replacement engine. Remove forward safety cable a. Mount engine on stand, 47-600-001-1-T212. In-
fitting from starter mounting studs, and remove stall engine tachometer generator. (Refer to Section
cable and thimble from left aft side of engine, and IX.) Remove cover plate from bottom of oil sump.
cable and fitting from right aft side of engine. Remove Install gasket, position sprag adapter on studs and
Section V (Part 1) BELL HELICOPTER COMPANY Models 47D-1 & 47G
MAINTENANCE
1. Cooling Fan and Support Assembly 11. Lord Mount - Engine Mounting Frame
2. Fan Belts (Matched Sets) to Center Frame
3. Cooling Shroud and Engine - Shroud 12. Adapter Plate - Engine to Engine Mounting
Supports Frame
4. Sprag Safety Cables 13. Gasket - Engine to Adapter Plate
5. Support Bracket - Engine to Adapter 14. Exhaust Manifold
Plate 15. Exhaust Short Stacks
6. Mounting Pads - Engine to Adapter 16. Adapter - Sprag Mount
Plate 17. Adapter - Engine Tachometer
7. Manifold Pressure Line 18. Engine Tachometer
8. Trunnion Pins 19. Engine Breather Tube
9. Clutch Drive Gear 20. Guard - Starter Cable
10. Engine Mounting Frame 47600-22
Figure 5-3. Engine Adapting Parts Diagram

5-4
MAINTENANCE
& OVERHAUL INSIRUCIONS
Stud Stud Torque Nut Torque

Engine Model No. No. Stud Height Inch-Pounds Inch-Pounds Remarks
+0
6V4-200-C32 1 13/16-1/32 in. 250-550 450-500
+0
2 13/16-1/32 in. 250-550 450-500
+0
3 13/16-1/32 in. 250-550 450-500
+0
4 13/16-1/32 in. 180-360 450-500 Replace studs which
+0
5 13/16-1/32 in. 180-360 450-500 turn at minimum
+0
6 13/16-1/32 in. 250-550 450-500 torque with oversize
+0
7 13/16-1/32 in. 250-550 450-500 studs (as required)
+0
8 13/16-1/32 in. 250-550 450-500 to meet height and
+0
9 13/16-1/32 in. 250-550 450-500 torque requirements
+0
10 13/16-1/32 in. 180-360 450-500
13+0IN.
47600-24
Figure 5-4. Adapter Plate Stud Torque and Heights
e. Install gasket and short exhaust stack on studs transmission. When installing two bolts which pass
at each cylinder exhaust port, and torque nuts 145 to downward through transmission flange, adapter plate,
180 inch-pounds. Install baffle plates between cyl- and ends of forward support bracket, install spacer
inders on aft side, using wedge blocks and through and shim on each bolt, between bracket and adapter
bolts. Install cooling shroud. (Refer to paragraph plate, to obtain 0.005 inch maximum gap before
5-77.) tightening bolt.
g. Install carburetor. (Refer to paragraph 5-45.)
f. Install transmission. (Refer to Section IV.) Leave Install spark plugs. Attach all sprag safety cables
T10089 hoisting ring and plate in place on top of except left aft. (Refer to paragraph 5-25.)
Rev. 3 5-5
MAINTENANCE
5-7. INSTALLATION- POWER PLANT. 5-8. ENGINE MOUNTAND ADAPTER PLATE.
a. Attach a hoist to T100089 hoisting ring on top

of transmission. Lift power plant and lower into 5-9. DESCRIPTION.The engineissupportedbymeans
helicopter structure. Align upper Lord mounts in of an adapter plate mounted between engine andtrans-
support brackets and install through-bolts, withbond- mission and suspended by trunnion pins in a mount
ing braid jumper under head of bolt at left mount. frame constructed of welded steel tubes. The mount
Install bolts attaching sprag rod clevises to lugs of incorporates two cylindrical vibration dampening
adapter on bottom of engine. mounts (Lord mounts), through which it is attached
b. Thread wires and cylinder head temperature to the center frame structure. Sprag mounts attached
thermocouple through cooling shroud and screw into to
to lower
lower end
end of
of engine
engine hold
hold engine
engine and
and main
main rotor
rotor
number three cylinder. Close zipper in cooling fan mast
mast in
in proper alignment
alignment to
to helicopter.
helicopter.
shroud. Connect oil temperature thermobulb, magneto 5-10. REMOVING - ENGINE MOUNTANDADAPTER
ground wires, and wires to starter switch. Connect PLATE.
starter switch actuating cable. Connect oil line to
filter. a. Remove engine. (Refer to paragraph 5-4.)
b. Remove transmission. (Refer to Section IV.)
c. Install and connect oil and manifold pressure
lines. Install carburetor air control valve, exhaust c. Cut lockwire, remove nuts and washers from
manifolds, and connect air-heat control valve spring. adapter plate mounting studs, and lift engine mount
Install shroud on right exhaust manifold, connect hot and adapter plate assembly from engine. Cover top
air duct, and connect drain line to valve. Connect of engine to prevent dirt entering.
fuel line to carburetor, and connect mixture and heat d. Remove taper pins through adapter plate and
controls to carburetor. Connect throttle control and trunnion pins. Remove trunnion pins (keep shims, if
check controls for full travel andfreedom of operation. installed, with pins) and lift engine mount from
adapter plate.
d. Connect wiring to rotor tachometer generator and e. Remove clamp bolts and guard from clamp ring
generator relay. Tape all electrical cordage to at each side of mount frame and remove Lord mounts.
engine mount at reasonable intervals. Coat tape
with shellac, and wrap with a strand of lockwire.
Connect oil cooler duct to cooler and install inlet PLATE. Clean all parts, except Lord mounts, with PD-680
line. Connect sprag safety cables. cleaning solvent or kerosene. Wipe Lord mounts with dry
cloth.
CAUTION 5-12. INSPECTION - ENGINE AND MOUNT AND

ADAPTER PLATE.
a. Visually inspect mount assembly for security of
Replace any cable that shows more than installation and for dented or damaged tubing. Carefully
six wires broken in any one inch of length.
If corroded or badly worn, the cable
should be replaced even though the num- b. Inspect Lord mounts for condition and proper
ber of broken wires is less than speci- installation. Inspect support brackets on center frame
fied for replacement. structure for evidence of mount clamps striking inside
surface of brackets during engine operation.
e. Install mast controls assembly. (Refer to Section
III.) Install short forward section of tail rotor shaft. plate for wear in trunnion pin holes.
(Refer to Section VI.) Install drive shaft guard on Replace plate or repair by installing bushings when pin
top of intake manifold. Install main rotor. (Refer to hole diameter exceeds 0.755 inch. (Refer to
Section II.) Align engine and adjust sprag cables. paragraph 5-13.)
(Refer to paragraphs 5-20 and 5-25.) Install fuel
tank(s) and support(s). (Refer to paragraphs 5-113 d. Inspect trunnion pins. Pin diameter maximum 0.7495,
or 5-114.) minimum 0.7485. Replace at 0.7475.
f. Fill sump with proper grade of oil. Fill fuel e. Refer to Section I for magnetic particle and
tanks. Start, warm-up and ground test engine. (Refer fluorescent penetrant inspection requirements.
to Section I.)
5-13. REPAIR OR REPLACEMENT - ENGINE MOUNT
Note AND ADAPTER PLATE.
If engine is new, drain corrosion-resist- a. Replace engine mount frame immediately if cracks
ing oil from sump at magnetic plug. are found in any area, or for any damage to tubing
5-6 Rev. 3
MAINTENANCE
25/32" 1/2"
Note
INSTALL GUARD WITH
25/32" DIMENSION FORWARD
ON LEFT SIDE AND AFT
ON RIGHT SIDE.
10
1. Pivot Pin (Trunnion) 10. Sprag Mount Cables - Aft

2. Tapered Pin 11. Lord Mount - Sprag
3. Shim 12. Spacer
4. Mounting Frame 13. Rod - Fore and Aft Sprag Mount
5. Guard 14. Rod - Lateral Sprag Mount
6. Engine Mount - Upper 15. Adapter Plate - Sprag Mount
7. Clamp Bolt 16. Sprag Mount Cables - Forward
8. Body Frame (Ref.) 17. Lubrication Fitting
9. Through-Bolt 47612-1
Figure 5-5. Engine Mount Installation

5-7
5-7
MAINTENANCE
other than as follows: Small smooth dents which have 4. Bore and ream trunnion pin holes in ends of
not removed any material from tubing, and which adapter plate 1.440 inches deep, with 0.015 inch radius
occur at least 1 1/2 inches from any weld cluster at inner end, to obtain 0.0005 to 0.001 inch inter-
or intersection of tubes with gussets, maybe repaired ference fit with bushings. (Detail D.) Center line of
by tack-welding a piece of welding rod to center of holes must pass through center line of plate within
dents, preheating material 1300to 1400 F.,and pulling 0.005 inch. (Details A and D.)
out dent. Take precautions to maintain bearing align-
ment during repair, and thoroughly inspect area 5. Countersink outer ends of holes 90 degrees x
visually and by magnetic particle after repair. 0.925 inch diameter. (Detail D.)
6. Press bushings into plate. Machine ends of
bushings to obtain dimensions of plate assembly as
shown. (Detail B.)
7. Ream bushings 0.750 to 0.751 inch inside dia-
meter. (Detail B.)
Damage to mount tubing may not be re-
paired by patching or insertion, because 8. Match drill (No. 11) and ream holes for taper
the stiffening caused by these reinforce- pins from top of plate. Use Brown and Sharpe taper
ments may result in highly detrimental reamer corresponding to size of taper pin. Use care
stress distribution conditions which may to avoid enlarging existing taper pin holes in plate.
in turn lead to failure. Fit each pin so that small end of tapered shank ex-
tends not more than 1/16 inch from underside of
plate.
b. Replace Lord mounts at normal engine change, if
deteriorated or worn. Replace at once if any of the
following conditions exist: Note
Whennecessary because ofenlarged holes,

1. When edges of mount clamps are striking in-
side of support brackets (on center frame) during
operation, if condition cannot be corrected by proper AN386-3-10A pin with No. 3 reamer).
offset of mount in clamp to compensate for torque.
d. Trunnion pins may be repaired, in the event Welch
2. When separation between rubber and metal has
progressed
progressed approximately
approximately 120 degrees around
120 degrees around cir-
cir- plug in head of pin becomes loose, by silver brazing to
cumference of
cumference of inner
inner or outer member,
or outer member, or or has
has reached
reached retain plug in pin. Remove lubrication fitting, degrease
and clean
and clean parts.
parts. Use
Use Handy Flux and
Handy Flux and Easy-Flo Solder
Easy-Flo Solder
a depth of approximately 1/4 the length of mount at
(This solder melts at 1170°F and
any point. flows at 1270°F.)
3. When flex cracks in rubber have reached a
depth of 1/4 inch. 5-14. INSTALLING - ENGINE MOUNT AND ADAPTER
PLATE.
c. Inspect adapter plate for wear in trunnion pin holes. a. Lay adapter plate on bench. Position engine mount
Replace plate or repair by installing bushings when pin to align trunnion bores in mount and plate (control
hole diameter exceeds 0.755 inch. (Refer to support at left side of mount frame, oil scoop on
paragraph 5-15.) Retire bushed adapter plate when pin plate aft when installed). Insert trunnion pins through
hole wear again exceeds this limit. mount into plate, with grease fittings facing left.
Insert taper pins through adapter plate and trunnion
1. If 47-612-200-1 bushings are not available, make pins, and install counter-bored washers and nuts on
two bushings from 2024-T4 aluminum alloy bar lower ends of taper pins. Check total end play of
(QQ-A-268, temper T4) to dimensions shown. (Figure 5-6.) mount on trunnions. Shim, if necessary, to obtain
0.005 inch maximum total clearance between adapter
2. Determine center lines on lower surface of plate and engine mount using maximum of 0.020 inch
adapter plate, using pairs of holes indicated by single shim thickness under each trunnion pin head.
asterisk (*) to locate longitudinal center line. Locate
lateral center line through holes indicated by double b. Install metal gasket over studs on top of engine.
asterisks (**). (Detail A.) Lift mount and adapter plate assembly to position on
studs. Install washers and nuts on studs, tighten nuts
3. Machine off 0.060 inch from each endof adapter 450 to 500 inch-pounds, and lockwire in pairs. (See
plate. (Detail D.) figure 5-7.)
5-8 Rev. 3
MAINTENANCE
& OVERHAUL INSTRUCIIONS
OF HOLES TO
THROUGH**
PASS
CENTER OF PLATE
WITHIN .005
.005
--- I- .625
DETAIL B
BORE & REAM 1.440 DEEP
AND TO 0.0005 - 0.0010
.750
AFTER INSTALLATION REAM .750 DIA. INTERFERENCE FIT WITH
.751 BUSHINGS
BREAK ALL SHARP EDGES .015
--1.470 .735
COUNTERSINK 90° x .925D.
I
.940
DIA.
.940 DIA.
8760
.8 7 5 7
.015R.
-
020 1.440
.010 .060-
NOTE: TWO BUSHINGSP/N 47-612-200-1 MACHINE OFF
REQUIRED. PROCURE AS KIT ADAPTER PLATE
NO. 47-2459-1
DETAIL C DETAIL D
47612-37
Figure 5-6. Installing Bushings in Adapter Plate

5-9
5-15.ENGINE SPRAG MOUNTS
5-M. DESCRIPTION. The sprag mount installation

holds engine and rotor mast in proper alignment to
the helicopter and consists of one rod fore and aft
and one rod holding lateral alignment. Each rod is
attached to the sprag adapter plate on bottom of engine
oil sump and, through vibration-dampening Lord
mounts,
brackets
to welded on center frame structure.
5-17. REMOVING - SPRAG MOUNTS.
a. With helicopter reasonably level and main rotor

secured from flapping, remove nut and large washer
(and spacer, if so equipped) from outer end of each
sprag rod. Remove bolts attaching rod clevises to
sprag adapter and pull each rod inboard out of Lord
mount.
c. Drain oil from engine sump, when necessary to

remove sprag adapter plate. Remove oil drain cover
and gasket. Remove sprag adapter plate, two dowles
(or countersunk screws) and gasket. Reinstall oil drain
Figure 5-7. Adapter Plate and Crankshaft Ring cover and gasket.
612. INSPECTION - SPRAG MOUNTS.

e. Install Lord mount in clamp ring at each side of
engine mount, open clamp ring sufficiently to allow in- a. Inspect sprag rods and adapter for general condi-
stallation of Lord mount, (Lord mount fits tightly in tion, cracks, dents or other damage, and security of
clamp ring). Install bonding braid terminal under heed installation. Examine clevises and adapter bushings
Of forward bolt on left side. Check installation of for excessivewear. Replace bolts or bushings when
bushings in Lord mounts. if gap in clamp is 0.23 inch looseness of fit doe to wear is noted. Replace un-
or less, install one retainer, if gap, is 0.24 inch or serviceable parts.
greater install two or more retainers. If the instal-
lation requires two or more retainer, perform the b. Inspect Lord mounts for cracks in robber, and
following operations: (See figure 5-8.) for being
soaked
oil or deteriorated.
(1) Install and torque bolts 50 to 70 inch-pounds.
(2) check retainer well straight edge.
(3) If retainers are flat, remove one retainer, re-

install bolts and torque. If next length bolt is required
it will be acceptable. Maximum quantity of retainers
not to exceed three.
NOTE
with engine mount installed into center-

frame and before tightening the bolts, check
for Clearance between each Lord mount
bushing and logs on centerframe. Shim
each Lord mount to obtain 0.000” to 0.005”
maximum clearance, using laminated steel
Shims, Part No. 120-008C40-12 and then
tighten bolts.
47612-20D
d. Install transmission. (Refer to Section IV.) Install

power plant. (Refer to paragraph 67.)
5-10
MAINTENANCE
5-19. INSTALLING - SPRAG MOUNTS. (Figures 5-

9 and 5-10.)
Note
Over-torque of bolts attaching links to

adapter and to sprag rods may prevent
flexing of these hinge-joints and cause
binding, misalignment, and faulty op-
eration of sprag system.
a. Remove oil sump drain cover and gasket. Install
gasket and sprag adapter (with one lug pointing forward
5-10A
MAINTENANCE
and down, other lug right and down), and install two
dowels (or countersunk screws) through adapter into
mounting pad. Install gasket and oil drain cover, DIMENSION
secure with washers and nuts on mounting studs. FORWARD WASHER
b. Place fore and aft Lord mount, withlongest center

core forward, on aft side of bracket, located on -LORD MOUNT
center frame below and aft of engine oil sump, and
install four mounting bolts with heads forward. Place
lateral Lord mount on outboard side of bracket,
located at lower left of center frame, and install
four mounting bolts with heads inboard.
c. Install elastic stop nut backward on each rod.

Place large washer on each rod, insert rods through
Lord mounts from engine side, and install large
washer and nut on outer end of each rod. Align rod
devises on adapter lugs, install attaching bolts with 47612-21A SUPPORT BRACKET
heads down, tighten nuts finger-tight plus one castel-
lation, and secure with cotter pins.
Figure 5-9. Fore and Aft Sprag Mount
5-20. ADJUSTING SPRAG MOUNTS - ENGINE
ALIGNMENT. Adjustment of sprag mounts to align
engine and mast must be accomplished, with mast
and rotor installed, before any check or adjustment
of main rotor controls rigging and after overhaul SUPPORT
or replacement of engine, mast controls, or anysprag BRACKET
mount parts. LORD MOUNT
a. Remove tie-down block and allow rotor to assume

a level position. Jack and level helicopter. (Refer to
Section I.) WASHER WASHER
b. Place a bubble protractor against fore and aft

side of the mast and correct for any deviation from
vertical by adjusting fore and aft sprag rod. Place
protractor on right or left side of mast and correct
for any deviation from vertical by adjusting lateral SPRAG
sprag rod.
c. Adjust sprag safety cables. (Refer to paragraph
5-25.) 1. 2 5 47612-22A
Figure 5-10. Lateral Sprag Mount

Note
Test fly helicopter. If excessive vibration are connected to fittings on the starter mounting
is present after engine alignment, check studs and to fittings welded to the structure at the
balance, track and rigging of main rotor lower end of the forward firewall. The aft cables
and controls. A pounding vibration present are secured to fittings which bolt to the aft crank-
only when executing banking turns indi- case, cross under carburetor, and are attached to
cates bottoming of safety cables, due either fittings welded to the upper cross tube of the engine
to excessively worn or improperly in- compartment.
stalled Lord mounts or to insufficient
slack in safety cables.
5-23. REMOVING - SPRAG SAFETY CABLES.
5-21. SPRAG SYSTEM SAFETY CABLES.
a. Remove cotter pin, nut, and bolt from left for-
5-22. DESCRIPTION. Four safety cables, two forward cable end at structure. Unscrew nut from starter
ward and two aft, are connected to the structure and mounting stud and remove cable and fitting. Replace
engine to maintain approximate engine alignment in nut on starter mounting stud. Remove right forward
the event of sprag mount failure. The forward cables cable in the same manner.
5-11
MAINTENANCE
b. Remove nut and cone from end of cable thimble 5-26. AIR INDUCTION SYSTEM. (Figures 5-11 and
at left engine crankcase fitting, and pull cable, eye- 5-12.)
bolt and cone from fitting. Remove cotter pin, nut,
and bolt from fitting at right upper cross tube fitting 5-27. DESCRIPTION. The air induction system con-
and remove cable. Cut lockwire and remove bolts sists of the cold filtered air intake, control valve,
which secure right cable fitting to crankcase. Remove air temperature bulb, carburetor, and intake mani-
cotter pin, nut, and bolt from upper cross tube fitting fold. When the control is pushed forward in the
and remove cable. quadrant, cold filtered air is drawn into the car-
buretor. Pulling the control aft and down will cause
heated air to be drawn into the carburetor. Inter-
5-24. REPAIR OR REPLACEMENT - SPRAG SAFE- mediate positions of the control will provide corre-
TY CABLES. Replace any cable that shows more sponding mixtures of cold filtered and heated un-
than six wires broken in any one inch length. If filtered air into the carburetor.
corroded or badly worn, the cable should be replaced
even though the number of broken wires is less than 5-28. AIR FILTER. The Air Maze filter in the cold
specified for replacement. air intake is secured in the duct in a fixed position.
Cold air is drawn in through the filter to the car-
buretor.
5-25. INSTALLING - SPRAG SAFETY CABLES.
5-29. REMOVING - AIR FILTER.
a. Connect left forward cable clevis to structure a. On Model 47D1, release quick fasteners in air
fitting with clevis bolt and nut. Remove nut from scoop, remove scoop, and lift filter clear of duct.
starter mounting stud, install cable fitting, align
fitting with direction of cable pull-off, and install b. On Model 47G, release four fasteners in duct
nut on stud. Install right forward cable in like inlet and lift filter from duct.
manner. 5-30. CLEANING - AIR FILTER. Tap filter element
to remove loose dirt. Cleanfilterinunleadedgasoline.
b. Position flat cable fitting on right side of crank- Immerse element in lubricating oil (SAE 10), and
case, aft of No. 1 cylinder (at original location of allow excess oil to drain from filter.
engine mounting bracket) inserting dowel of fitting in
existing hole, and install bolts in existing holes. 5-31. INSTALLING- AIR FILTER. Position filter
Lockwire bolts. Attach clevis end of cable to upper (with short ribs facing outboard) and secure with
left structure fitting with clevis bolt and nut. Place quick fasteners.
cone fitting on eyebolt of cable, insert eyebolt through 5-32. COLD AIR INTAKE.
mount bracket on left side of crankcase and install
cone, washer, and nut. Turn eyebolt to align with 5-33. REMOVING - COLD AIR INTAKE. Remove
cable pull-off, and attach cable clevis to upper right clamps from both ends of flexible duct. Remove nuts
fitting with clevis bolt and nut. and bolts from clips holding duct to structure. Lift
duct clear of helicopter.
c. Level helicopter and align engine. (Refer to para- 5-34. REPAIR OR REPLACEMENT - COLD AIR N-
graph 5-20.) TAKE.
a. Surface scratches and small dents which might
d. Shorten each cable until snug. (Check with pro- occur on the air filter duct are negligible. Broken
tractor on mast to see that engine alignment has spot welds can be repaired by riveting. Damage by
not been changed.) Loosen each cable clevis 6 1/2 chafing is negligible on the flexible duct connecting
turns and safety. the air filter duct to the selector valve. Cracks
developing in the air filter duct can be welded. A
e. Remove bolts which secure sprag rods to sprag 1/4 inch diameter hole or smaller in the filter duct
adapter on engine. Check movement of engine at sprag can be drilled to the nearest bolt size, and a shallow
adapter bolt holes for a maximum lateral movement head machine screw inserted in the hole wth the
of 1 1/8 inches and a maximum fore and aft move- screw head on the inside of the duct and nut on the
ment of 3/4 inch. Reinstall bolts, washers, and nuts outside. This can be done only if the screw or nut
attaching sprag rods to adapter, tighten nuts finger does not interfere with assembly of ducts Holes
tight plus one castellation, and install cotter pins. larger than 1/4 inch diameter can be cut out to re-
move damaged area. A patch of the same thickness
as the duct can be welded or riveted to the duct. The
f. Wrap each aft cable with friction tape at area flexible duct connecting the air filter to selector
where they cross, to prevent chafing. Apply one coat valve can be repaired, only temporarily, by wrapping
of Insul-X (Insl-X Corp., Brooklyn, N.Y.) or equiva- friction tape or its equivalent around the torn area,
lent, over tape. Secure cables, at point of crossing, and then coating the taped area with shellac. The
with one strand of safety wire. area coated with shellac must cover the tape and
5-12
MAINTENANCE
3. Spring
4. Heated Air Intake
5. Carburetor
6. Mixture Control
7. Carburetor Air Control Valve
8. Cold Air Intake Tube
9. Control Cables
10. Carburetor Mixture Control
11. Carburetor Heat Control
47615-2A
Figure 5-11. Air Induction System - 47D-1
duct at least 1/2 inch beyond the taped area. Ducts 5-36. HEATED AIR INTAKE. Heated air is ducted
repaired by this method should be replaced as soon from the exhaust manifold on the right side of the
as possible. helicopter to the carburetor to prevent carburetor
icing under adverse conditions, and to insure proper
b. Damage to ducts, which, if repaired, would inter- engine operation during cold weather. Backfire screens
fere with the assembly of the system or its operation, in the duct eliminate fire hazard in the event of engine
necessitates replacement. Flexible duct must be re- backfire during operation.
placed as soon as possible if it has been patched or
badly chafed. Interior damage to the duct is cause 5-37. REMOVING - HEATED AIR INTAKE. Remove
for replacement. nuts and bolts from halves of carburetor duct and
remove duct and backfire screens.
5-35. INSTALLING - COLD AIR INTAKE. Slide duct
over filter duct and selector valve. Install and tighten 5-38. REPAIR OR REPLACEMENT - HEATED AIR
clamps. Secure duct to structure with clips, bolts DUCT. Repairs may be made in accordance with
and nuts. paragraph 5-34.
5-13
MAINTENANCE
33
3.
4. Cold
HeatedAirAir
Intake
IntakeDuct
Duct
3.
4. Cold AirAir
Heated Intake
IntakeDuct
Duct
5. Air Control Valve
6. Carburetor
7. Mixture Control
8. Control Cables
9. Carburetor Heat Control Lever
10. Mixture Control Lever
47615-3A
Figure 5-12. Air Induction System - 47G
5-39. INSTALLING - HEATED AIR INTAKE. Posi- b. Loosen clamp on cold filtered air duct and slide
tion halves of carburetor duct and backfire screens duct from valve. Remove attaching nuts and bolts.
and secure with bolts and nuts. Loosen hose clamp on drain and slide hose free of
fitting. Remove control valve assembly and gasket
from carburetor and heated air duct.
5-40. CARBURETOR - HEAT CONTROL VALVE.
The control valve mounted on the carburetor is the 5-42. INSTALLING - HEAT CONTROL VALVE.
medium by which cold filtered or heated air is
admitted to the carburetor. The valve is of the damp- a. Place gasket on flange of valve, position valve,
er type, and is operated from the pilot's compartment align mounting holes, install bolts and connect air
of the helicopter. The carburetor air temperature temperature thermobulb.
theromobulb is threaded into the body of the valve
at the carburetor. b. Align control cable with valve arm and insert
clevis pin. Install lug on pin, connect spring and in-
5-41. REMOVING - HEAT CONTROL VALVE. sert cotter pin. Install cable support with two screws
and nuts. Slip drain hose over valve fittingand tighten
a. Disconnect electrical connection to air tempera- clamp. Check valve operation for full travel. Slide
ture thermobulb. Disconnect spring, remove cotter cold filtered air duct over valve and tighten clamp.
pin, and pin operating cable connection at valve arm.
Remove two screws and nuts in cable support and 5-43. CARBURETOR. Both models are equipped with
remove support. a type MA-4-5 carburetor. The unit is a float type,
5-14
MAINTENANCE
incorporating a mixture control, idle speed adjust- by maneuvers are made by the pilot rotating the
ment, idle fuel adjustment, and accelerating pump. throttle cam are utilized to transmit control move-
The carburetor is an up-draft, natural atomization ment to the carburetor throttle lever.
unit, and is bolted to the continuous intake manifold
at the upper side of the engine. 5-47A. CAMBOX. (Refer to figure 5-35.)
5-44. REMOVING - CARBURETOR. a. Disassembly cambox.
a. Remove carburetor heat control valve. Refer to 1. Cut lockwire, remove four screws (15) and
paragraph 5-41. washers (16) which secure cover assembly (11) to hous-
ing assembly (3), cut lockwire from roll pin (14) at
b. Disconnect fuel inlet line. Remove mixture control shaft assembly (1) and remove roll pin (14).
cable bracket by unscrewing two screws in carburetor
cover. Remove cotter pin, pin, and washer, from 2. Cut lockwire and remove roll pin (5) from the
mixture control clevis. Remove nut and bolt which center of lever assembly (4).
attach throttle control to throttle arm. Remove nuts
and washers, and lift carburetor from manifold. 3. Check bearing (10), cam (7), bushings (2) for
wear and rivets (9) at cam bushing (8) for tightness.
5-45. INSTALLING - CARBURETOR.
b. Reassemble cambox.
a. Make certain gasket is in place on intake mani-
fold. Place carburetor on studs, and install washers 1. Insert throttle cam shaft (6) into arm (4), in-
and nuts. Connect fuel inlet line. Install carburetor stall roll pin and lockwire roll pin (5). Insert end
heat control valve. Refer to paragraph 5-42. of shaft (6) into housing assembly (3).
2. Insert bearing (10) into cam assembly (7). Posi-
b. Position mixture control cable bracket on car- tion arm (4) over the bearing (10) and insert throttle
buretor, and install two washers and screws. Connect
cable clevis to mixture control arm with pin, washer
and cotter pin. Connect throttle control to throttle
arm
arm with
with bolt,
bolt, washer,
washer, nut,
nut, and
and cotter
cotter pin.
pin. Check
Check roll pin (14) into shaftassembly (1) and lock-
all controls for full travel. Test andadjust carburetor
to engine. Refer to paragraph 5-46.
5-48. REMOVING - THROTTLE CONTROLS. (Fig-
5-46. TESTING AND ADJUSTING CARBURETOR TO ure 5-13.)
ENGINE.
a. Remove cotter pin, nut, washer, and bolt from
a. Start and warm up engine. Hold main rotor pitch each end of rod connecting main rotor pitch jack-
lever in full low position and open throttle to obtain shaft and throttle cam assembly, and remove rod.
3100 RPM. Close throttle, and before rotor RPM has Remove cotter pin, nut, washer, and bolt from each
reduced to idle speed, adjust engine idle RPM to end of rod connecting cam assembly to bellcrank at
1800 to 1850 RPM. upper fuselage tube, and remove rod.
b. Remove four nuts, bolts and washers which se-

Note cure cam assembly to structure, and cotter pin, and
washer from shaft end, and lift cam free of structure.
As rotor decelerates and engine becomes Remove cotter pin, nut, bolt, and washer from each
loaded, engine idle RPM will stabilize end of rod connecting carburetor throttle arm to
between 1500 and 1700 RPM. bellcrank, and remove rod. Remove cotter pin,
washer, and pin from bellcrank andliftbellcrankfrom
bracket.
CAUTION
5-49. ADDITION OF DRAIN HOLES IN THROTTLE
CAM BOX.
Do not break seal on economizer screw. Note
Economizer is adjusted by the manufac-
turer, and field adjustments are not to be This modification can be made on the
made. cam box installed on any Model 47D1 and
47G helicopter, to provide drainage and
5-47. THROTTLE CONTROLS. The throttle is syn- prevent possibility of throttle cam being
chronized with the main rotor pitch control in such made inoperative by freezing of accumu-
a manner that an increase of rotor pitch increases lated water in cam box. Modification has
power, and a decrease in pitch decreases power. been accomplished on Model 47G, Serial
Finer adjustments in power settings necessitated No. 1381 and subsequent.
5-15
MAINTENANCE
INSTALL WITH
BEND DOWN
1. Throttle Friction Nut

2. Collective Pitch and Throttle
Control Stick
3. Lever - Throttle Control Shaft
4. Control Rod
5. Throttle Cam Pivot Shaft and
Lever
6. Support Bracket
7. Bracket - Cam Box Attachment
8. Cam Box
9. Lever - Cam Throttle Control
10. Control Rod
11. Bell Crank Support Brackets
12. Spacer
13. Bell Crank
14. Spacer
15. Control Rod
16. Carburetor Throttle Lever
47631-33
Figure 5-13. Throttle Control Installation

5-16
MAINTENANCE
a. Disconnect control rod from lever on right-hand

side of cam box. Cut lockwire and remove taper
pin or roll pin through lever and shaft. Pull lever
from shaft.
b. Cut lockwire and remove four screws attaching
cover to cam box. Remove cover. (AN960-816L
washers are sometimes used as shims on one or
both cam box shafts, next to cover. Keep such wash-
ers in original positions for reinstallation.)
c. Drill two 1/4 (f..250 inch diameter) holes through
cover, located as shown. (Figure 5-14.)
d. Inspect and lubricate cam mechanism. Install
cover and lockwire attaching screws. Install lever
on shaft, align holes and install pin, securing with
lockwire. Operate throttle to check for freedom of
operation.
e. Connect control rod to lever with clevis bolt,
nut and cotter pin. Check operation of throttle during
engine run-up.
5-16A
MAINTENANCE
5-50. INSTALLING - THROTTLE CONTROLS.

0
Note
Adjustment and installation may be ac- 1/4 (.250)DIADRAINHOLES

complished at the same time. (Refer to
paragraph 5-51.)
a. Pass end of cam pivot shaft through hole in

bracket on upright center frame tube (left of heli-
copter center line) and install washer and cotter
pin. Position cam box on upright tube (be sure two
brackets are in place between tube and firewall),
and install four bolts through firewall, brackets, and
lugs on cam box. Check for freedom of operation of 31
cam pivot shaft while tightening bolts.
47631-30
b. Install rod, with adjustable end aft, between arm
on cam pivot shaft and throttle lever (eyebolt) on
collective pitch and throttle control jackshaft. In- Figure 5-14. Locating Drain Holes
stall bellcrank in brackets above cam box on lateral in Throttle Cam Box
center frame tube, with long spacer outboard and
short spacer inboard of bellcrank, and with longer
(twisted) bellcrank arm up. Install rod, with adjust- necessary for free operation to both extreme posi-
able end down, between shorter bellcrank arm and tions without springing (tension or compression load
lever on right-hand side of cam box. Install rod, with on lnkage)
adjustable end aft, to outboard side of carburetor
throttle lever and longer arm of bellcrank. (Be sure e. Place control stick full down with grip rotated
that slight bend in rod is down to provide clearance to closed position. Adjust rod (8), between lever on
with lower tubes of engine mount.) Adjust linkage. right side of cam box and bellcrank in bracket on
upper seat-back tube, so that aft edge of upper arm
is slightly forward (1/32 inch) of bracket center line.
5-51. 5-51.
ADJUSTMENT
ADJUSTMENT-THROTTLE CONTROL LINKAGE.
- THROTTLE CONTROL LINKAGE. f. Holding throttle stop arm against idling stop-
screw (13), adjust and connect control rod (10) be-
a. Check collective pitch and throttle control lever for tween bellcrank and throttle butterfly lever.
full travel and freedom of operation. Eliminate any
binding in cam box and throttle control linkage, checking g. Check for freedom of operation through full range
cam box for security of mounting and all rods for of pitch and throttle control movement. Check safety
clearance. of entire system. (See detail, figure 5-15, for safety-
ing of throttle butterfly lever.)
b. Adjust idling stop-screw (13, figure 5-15) on carburetor
to hold face of stop-arm (12) 1/4 inch from face of stop on h. Check and adjust engine idling RPM during ground
carburetor in idling position. Check position of throttle run-up as necessary. (Refer to paragraph 5-46.)
butterfly lever (11) for 32 degrees forward. Adjust position Make further adjustments according to flight test
of lever on serrated shaft, if necessary, by disconnecting behavior. If engine underspeeds, shorten control
rod (5), loosening lever lock-nut, pulling lever from shaft rod (10) in increments of 1/2 turn. Correctoverspeed
(2). Align lever and tighten lock-nut. by lengthening rod. Repeat test flight after each ad-
justment.
c. Check length of control lever (4) on collective
pitch control cross-tube for dimension of 1 and 5-52. CARBURETOR HEAT AND MIXTURE CON-
53/64 inches between
53/64 inches between bolt and surface
center and
hole center
bolt hole surface TROLS. The carburetor air-heat and mixture con-
of outer tube (3). Adjust by disconnecting rod (5), trol quadrnt is mounted on the left side of the in-
loosening lever lock-nut, and screwing lever in or strument pedestal. Both levers are provided with
out of shaft (2). Align lever and tighten lock-nut spring loaded ratchets which hold them in any de-
sired position and are connected to the carburetor
mixture control and air-heat valve by flexible push-
d. Place collective pitch control stick full down and pull cables. The mixture control is moved to the top
rotate grip to closed position. Hold cam shaft lever of the quadrant for full rich and downward to the
(6) full aft. Adjust and connect rod (5) between levers step for a lean mixture. Moving the lever outboard
(4) and (6). Move control stick full up and rotate grip of the step to the bottom of the quadrant is "Cut-Off".
to full open position. Check adjustment by removing The heat control lever is moved to the top of the
bolt at either end of rod. Readjust rod and lever as quadrant to supply cold air to the carburetor and to
Rev. 3 5-17
Section V (Part 1) BELL HELICOPTER COMPANY Models 47D-1 &47G
MAINTENANCE
the bottom to supply heated air. Intermediate posi- c. With carburetor heat control at OFF position, flapper
tions of this control will supply corresponding mix- valve should be visually checked, to ensure that it is
ture of cold filtered, and heated unfiltered air to the seated firmly to close off all hot air. With carburetor heat
carburetor. control at FULL HEAT position, flapper valve should be
visually checked, to ensure that it is seated firmly to
5-53. REMOVING - HEAT AND MIXTURE CON- close off all outside air.
TROLS.
5-55. EXHAUST STACKS. The exhaust stacks are
a. Disconnect clevis at control arm of carburetor an assembly of welded stainless steel tubing. Each
by removing cotter pin, washer, and pin. Remove assembly consists of four sections: The outlet section
clip at carburetor bracket, loosen lock-nut on clevis and three engine attachment sections. The outlet and
and unscrew clevis from cable end. Remove clips engine sections are joined by an expansion joint and
that secure assembly to structure, lateral sprag bolted. The right-hand exhaust stack is equipped with
mount bracket, and forward firewall. a shroud.
5-56. REMOVING - EXHAUST STACKS.
b. Open instrument panel, remove clip in box beam, a. Remove heated air intake duct from right-hand
remove quadrant cover, disconnect cable end from exhaust shroud. Remove bolts, washers, and nuts
control, lift cable from support and thread cable at expansion joints and remove outlet section.
through beam.
b. Remove nuts and washers from engine stub stacks,
and lift stacks clear of engine.
5-54. INSTALLING - HEAT AND MIXTURE CONTROLS.
5-57. REPAIR OR REPLACEMENT - EXHAUST STACKS.
a. Pass aft end of cable through clips at forward
and aft end of beam assembly and into engine com- a.
a. Scratches
Scratches and
and shallow
shallow dents
dents are
are considerednegli-
considered negli-
partment. Attach forward end of cable to control gible and can be ignored
quadrant and install quadrant cover and name plate.
b. Burned out parts or any damage not repairable
b. Route cable aft through structure clips and pass as outlined in paragraph 5-58 will require replace-
terminal end through clip in support on carburetor. ment of parts or entire assembly.
Thread clevis onto cable and tighten locknut. Attach 5-58. DAMAGE REPAIRABLE BY PATCHING OR
clevis to control arm on carburetor and secure with WELDING.
pin, washer, and cotter pin. Check control for full
travel and free movement. Close and secure instru- a. Cracks that appear on any portion of the exhaust
ment panel. stack can be welded. The tail section of the exhaust
1. Collective Pitch and Throttle Control Stick IDLE

2. Throttle Control Shaft 32° OPEN
3. Collective Pitch Control Cross Tube 1/32" 42
4. Throttle Control Lever
5. Control Rod
6. Cam Shaft Lever
7. Cam Box \
8. Control Rod
9. Bell Crank
10. Control Rod INSTALL WITH 1/4"
11. Throttle Butterfly Lever BEND DOWN
12. Stop Arm 8
13. Idling Stop-Screw
1-53/64"
47631-34
Figure 5-15. Throttle Linkage Adjustment Diagram

5-18 Rev. 3
MAINTENANCE
stack can be repaired by welding a new piece on the b. Remove bolts through fan and hub and lift fan
tail section of the main stack. and spacers from hub. Remove bolts through fan
and reinforcement rings, noting location of balance
b. The exhaust flange may be welded, however, care washers, and separate rings from fan.
must be taken that the flange is filed or machined to
a flat surface after welding so as to provide a flat c. Remove bolts through pulley and hub and re-
seat against the gasket at point of attachment to move pulley from front and retainer from aft side of
engine, hub. Move bearing spacer off center and tap either
bearing out of hub. Remove spacer and remaining
c. Lugs holding the engine sections and the main bearing.
exhaust section can be replaced by welding new lugs
on either part. d. Straighten tang of lock-washer and remove re-
taining bolt, lock-washer, and washer from aft end
d. Cracks in shroud can be stop drilled or patched. of shaft. Remove index plate assembly from fan
support.
5-59. INSTALLING - EXHAUST STACKS.
e. Remove screws and separate shroud supportfrom
a. Place gaskets and stub stacks onto engine exhaust index plate and shaft. Remove cotter pins and clevis
ports (lugs extending up) and install washers and pin and remove adjustment lever, locking pin, and
nuts. Torque nuts 145 to 180 inch-pounds. spring from fan support.
b. Slip outlet section onto stub stacks, align holes 5-65. REPAIR OR REPLACEMENT - COOLINGFAN
in lugs, and install bolts, washers, and nuts. Connect ANDSUPPORT.
heated air intake duct to right exhaust shroud.
a. Check fan blades for alignment, cracks and nicks.
5-60. COOLING SYSTEM. Polish out nicks and scratches, replace fan if nicks
or scratches exceed limits outlined in figure 5-17.
5-61. DESCRIPTION. The cooling system consists
of a belt-driven cooling fan, cooling air shroud, oil b. Check discs for cracks, distortion or warping.
cooler air duct, and cylinder baffles. The air blast Check bearings for cracks, chips, or rough opera-
from the fan is directed around the cylinder barrels tion. Replace all unserviceable parts.
and heads by the shroud and baffles, and to the oil
cooler by the oil cooler duct. (Figure 5-16.) c. Inspect support bracket support leg faces, part
No. 47-669-105-1 for indentations, check mounting
holes for elongation, and attaching bolts for wear.
5-62. COOLING FAN. The cooling fan is mounted
on a shaft and support secure to the forward side
of the engine. It is composed of a steel hub which
contains anti-friction bearings, a 20 inch diameter
fan, and support assembly which provides for the
fan belt adjusting mechanism.
5-63. REMOVING - COOLING FAN AND SUPPORT.
a. Disconnect main rotor pitch control and fore and

aft cyclic control tubes at bellcranks and swashplate.
Remove control tubes from helicopter. Mark tubes
so they may be reinstalled in their original locations.
b. Unzip right and left sides of cooling fan shroud
and loosen clamp that secures shroud to shroud
support ring. Push aft on adjusting lock lever and
rotate shroud support upward to loosen fan belts.
Remove belts. Cut lockwire and remove bolts that 1. Oil Cooler Duct
secure support to engine. Remove fan and support 2. Fan Belts
through left side of shroud. 3. Cooling Shroud
4. Engine Cooling Baffle
5-64. DISASSEMBLY - COOLING FAN AND SUP- 5. Slide Fastener
PORT. (Figure 5-18.) 6. Fan Belt Adjustment
7. Fan 47660-2
a. Remove lubrication fitting. Cut lockwire, remove
nut and washer and pull fan and hub assembly from
shaft. Match-mark sections before disassembly. Figure 5-16. CoolingSystem
5-19
MAINTENANCE
Note
MAXIMUM DEPTH OF SCRATCHES OR NICKS WHICH MAY BE
POLISHED OUT. FINISH WITH GRADE 200 OR FINER EMERY
PAPER. FAN SHOULD BE REPLACED IF DAMAGE EXCEEDS
THESE LIMITS.
A-SCRATCHES .010 INCH OR LESS ON INNER 1/3 OF BLADE.

B-SCRATCHES .020 INCH OR LESS ON OUTER 2/3 OF BLADE
FACES.
C-GOUGES UP TO .10 INCH IN EDGES OF OUTER 2/3 OF BLADE
ONLY.
USE A GENEROUS RADIUS.
47661-7
Figure 5-17. Minor Repairs - Cooling Fan Blades
Note f. Fabricate flush type steel bushings 5/16 inch ID

and 0.437 inch OD from steel rod, Specification
Fan support brackets may be used with MIL-S-5626.
indentations on mating face of leg up to
0.020 inch maximum, and elongation of
mounting bolt holes up to 0.020 inch maxi- g. Clamp support to drill jig and line ream support
mum. If bracket is within the wear toler- bracket holes to provide a line to line or up to 0.0003
ance, rework according to the following inch interference fit for bushing. Install bushings.
steps. Prime all surfaces with zinc-chromate primer.
d. Remove indentation from face of each leg by
machining. Minimum thickness of legs after machin- h. Machine 1/32 inch from both ends of spacer,
ing is 0.282 inch. Part No. 47-669-112-3. Install new mounting support
bolts (AN75-A-13) torque bolts to a maximum of
e. Select a rectangular piece of flat chrominum 160 inch-pounds.
molybdenum steel plate (4130, condition A) 0.500 x
8.0 x 7.375 inches. Lay out a rectangle, 6.0 x 5.375
inches equal distant from edges of plate. At each
corner of the rectangle drill and ream four (4) 0.437 i. On installation add enough AN970-5 washers be-
inch holes. Heat treat jig to Rockwell hardness tween spacer and legs of support to replace material
C43 to C44. removed by machining.
Note
Note
If several support brackets are to be re-
worked, drill bushings may be fabricated After installation, fan pulleys must align
from tool steel, heat treated to Rockwell within 5/16 inch maximum. Add washers
hardness 60 to 62. if necessary.
5-20
MAINTENANCE
Note DETAIL "B" APPLIES TO HUB PART NO. 47-660-125-1 OR 47-661-

030-1 REWORKED BY COUNTERBORING PER MANDATORY BULLETIN
NO. 82, 11-2-51.
SEE DETAIL "B"
DETAIL "B" (MODEL 47D1)

(SEE Note)
4. Washer 16. Lock Washer
SEE DETAIL "A"
1. Lubrication Fitting 13. Spacer

2. Shaft 14. Fan Support
3. Retaining Nut 15. Washer
4. Washer 16. Lock Washer
5. Pulley 17. Retaining Bolt
6. Belts 18. Adjustment Index Plate
7. Rings (3) 19. Bearing (Single Row)
8. Fan 20. Spacer
9. Shroud Support 21. Bearing (Double Row)
10. Spacer 22. Adjustment Locking Pin
11. Hub 23. Spring
12. Bearing Retainer 24. Adjustment Lever 47661-6A
Figure 5-18. Cooling Fan and Support

5-21
Section V (Part 1) BELL HELICOPTER COMPANY - Models 47D-1 & 47G
MAINTENANCE
5-66. ASSEMBLING - COOLING FAN AND SUP- bolt. Replace AN3-3A bolt with AN3-4A bolt if neces-
PORT. (Figure 5-18.) sary. To obtain fine balance No. 50 (0.070) inch
diameter holes may be drilled in the AN970-3 washers.
a. Attach adjustment lever to support housing with Maintain fan blade run-out to 1/32 inch maximum.
clevis pin secured by cotter pin. Insert spring and
locking-pin through housing from forward side and 5-69. FAN BELTS. A length-matched set of two
attach locking-pin to lever with cotter pin. V-type belts transmits power from the transmission
b. Position adjustment index plate on back of shroud fan drive pulley to the fan pulley. Each belt is con-
support and install screws. Insert index plate shaft structed of molded rubber reinforced with synthetic
through fan support, place washer and lock-washer fiber and inclosed in a heat-resistant, static-con-
on aft end of shaft and install retaining bolt in shaft. ducting, mildew-inhibited sheath.
Bend tang of lock-washer against flat of bolt head.
5-70. REMOVING - FAN BELTS. Openslidefastener
c. Assemble three reinforcement rings on front of in left side of cooling fan shroud. Loosen clamp-
fan and install bolts, with heads aft and thin washer bolts on shroud ring, pull adjusting lock-lever aft,
under head and under nut. (Additional washers may rotate shroud ring upward and remove belts. Make
be required for balance after fan and hub are assem- adjustment is fully released. Do not force
bled.) Position fan and ring assembly and spacer on
front of hub and install bolts, with heads aft and a
thin washer under each nut. (See Detail B, figure 5- 5-71 CLEANNG - FAN BELTS. Wipe accumulated
18, if equipped with hub modified to Part No. 47- dirt, grease, or oil from belts with a cloth. Do not
669-125-1 by counterboring per Mandatory Bulletin dirt,
use cleaning solvent.
No. 82.)
d. Install single row bearing in fan hub from aft 5-72. INSTALLING - FAN BELTS.
side, bottomed against shoulder in hub with shielded
side of bearing aft. Position bearing retainer on back a. Make certain adjustment is fully released, and
of hub, pulley on front, align holes and install bolts slide belts onto drive and fan pulleys.
(with heads aft) through retainer, hub and pulley. Lay clamp-bolts on shroud ring. Adjust fan
hub face up onbench. Place spacer in hub against inner belts. (Refer to paragraph 573.) Close slide fasten-
race of aft bearing. Install double-row bearing with
shielded side forward. Balance fan assembly. (Refer
to paragraph 5-68.) 5-73. ADJUSTING - FAN BELTS. Check the follow-
e. Slide fan and hub assembly on fan shaft. Install ing parts before attempting to adjust fan belts.
bearing retaining washer and nut on shaft. Tightennut
75 to 100 inch-pounds and lockwire nut to drilled 1. Check condition of drive and driven pulleys.
hole in shaft. Install lubrication fitting and lubri- Replace pulleys if excessive wobble is evident, or
cate hub, if faces are dented or damaged.
5-67. INSTALLING - COOLING FANANDSUPPORT. 2. Check alignment of pulleys. Maximum mis-
alignment is 5/16 inch. (See figure 5-19.)
a. Lift assembly through left side of engine com- 3. Replace belts that show evidence of fraying or
partment and position support legs on front of engine excessive wear. Replace belts in matched sets.
to align with existing holes in crankcase cover.
(Longest support leg up.) Place spacer between a. Loosen clamp-bolts in shroud ring, open slide
crankcase cover and support at each leg and install fasteners at left side of shroud pull adjustment
drilled-head bolts with washers under heads. Torque lever aft and rotate shroud support down to tighten
bolts to 160 inch-pounds and lockwire each bolt to or up to loosen belts. Release lever to allow locking
support leg pin to engage index plate holes. If pin falls between
index holes, engage pin in hole providing less belt
b. Install and adjust fan belts. (Refer to paragraph tension. Close shroud and tighten clamp-bolts in
5-73.) Position clamp ring of fabric shroud on sup- shroud ring.
port ring around fan. Make sure ring is seated in b. Check tension of each belt by hooking a spring
groove at all points. Tighten screw and nut at each scale midway between pulleys and measuring deflec-
side of clamp ring. Re-install control tubes. Close tion while applying prescribed pull. After installation
zipper openings of fabric shroud. of new fan belts, check bolt tension every few hours
and readjust until tension becomes constant. (See fig-
3-68. BALANCING COOLING FAN. Slide a suitable ure 5-20.) Keep belt tension equal and within limits.
shaft through hub bearings (bearings dry) and sup-
port shaft on balancing stand in a wind free area. c. Keep tension of belts equal. If unequal, fan sup-
Statically balance fan assembly by the addition of port may be tilted slightly by installing not more
AN970-3, AN960-10, or AN960-10L washers to disc than one thin washer (AN960-516L) on each of two
bolts. Only one washer may be added to each side of upper attachment bolts, between spacer and support
5-22
b. If necessary to remove metal sections of shroud,

cut lockwire and remove six attaching bolts at each
side of engine. Remove two bolts passing through
transmission, adapter plate, shroud, and forward
support block when removing shroud section from
top of engine. Remove baffles from aft side of cyl-
inders by removing nuts, wedge block, and through-
bolts.
5-76. REPAIR OR REPLACEMENT - COOLING
SHROUD.
a. Small holes and tears in the fabric shroud can

be closed by stitching with cotton thread. Holes and
tears of an appreciable size can be repaired by
applying a patch of like material to the outside of
the shroud.
b. Any damage to the shroud greater than that

5/16 IN. MAX. described in the preceding step is cause for replace-
MISALIGNMENT ment of the shroud.
WITH ALL SHIMS
IN PLACE 5-77. INSTALLING - COOLING SHROUD.
BETWEEN FAN
DRIVE & TRANS. a. Install baffle plates between engine cylinders on
CASE aft side, positioning to allow clearance around spark
plugs, with through-bolts passing through each baffle,
between cylinder fins, through a wedge-block at front
side of cylinders, and secured by a nut.
b. Install four sections of metal shroud at top,

bottom, and side of engine, secured with six bolts
47669-1 at each side of engine. Lockwire bolts in pairs. Two
bolts pass throughtransmission, adapter plate, shroud,
and forward support block on engine.
Figure 5-19. Fan Pulley Alignment Diagram
c. Pass fabric shroud through left side of center
frame and over support ring around fan. Fasten glove
and installing longest belt (as shown by tension) on fasteners attaching fabric to metal shroud. Install
forward pulley. Recheck pulley alignment. If equal and tighten fan belts. (Refer to paragraphs 5-72 and
and correct tension cannot be obtained, replace belts 5-73.) Position clamp ring on support ring around
in matched sets. fan and tighten screw and nut at each side, making
sure that clamp ring is seated in groove of support
5-74. COOLING SHROUD. The cooling fan encircles ring at all points.
the cooling fan, and is the means of directing the
air flow from the fan around the engine and to the d. Secure oil cooler duct to oil cooler. Thread cyl-
oil cooler duct. inder head temperature lead through grommet and
connect to engine fitting. Pass engine breather tube
5-75. REMOVING - COOLING SHROUD. down through grommet and clamp to lower center
frame. Connect blast tube to shroud and generator
a. Disconnect blast tube from generator control control box.
box. Open slide fasteners at each side of shroud.
Disconnect engine breather tube from clamp at- 5-78. STARTING SYSTEM. The starting system con-
tached to structural tube of center shroud. Dis- sists of a direct-cranking type starter mounted on
connect cylinder head temperature lead from engine the accessory end of the engine.
and pull downward out of shroud. Loosen clamp ring
and pull oil cooler duct free of oil cooler. (Unsnap 5-79. ADJUSTING STARTER CONTROL CABLE.
glove fasteners on flat-type cooler.) Remove fan Disconnect coil spring from cable turnbuckle. Dis-
belts. Unsnap all glove fasteners attaching fabric to connect electrical lead from starter switch (tape end
metal sections of shrouding. Loosen screw and nut of lead while disconnected). Cut lockwire and adjust
at each side of clamp ring and slip shroud forward off cable so that starter switch is fully engaged when
support ring around fan and remove fabric shroud starter pedal end is 5/16 to 3/8 inch (thickness of
through left side of center frame. pencil) from floor. Check for approximately 1/2 inch
Rev. 3 5-23
MAINTENANCE
BELT TYPE
AND BELT
PART NO. PULL DEFLECTION REMARKS
Synthetic Fiber 30 lb. 3/4" (±1/8") Check and adjust every

47-661-041 four hours until tension
is stabilized then at first
50 hours and at each 100
hours thereafter.
Adjust whenever deflec-
tion exceeds 7/8".
47669-1000
Figure 5-20. Checking Fan Belt Tension
slack in cable when pedal is released. Lockwire a. Remove magneto from engine. Remove screws
turnbuckle. Hook coil spring in hole in turnbuckle in breaker cover on magneto to expose breaker points.
sleeve and in drilled hole in pulley bracket aft of With magneto held in a horizontal position, turn rotor
turnbuckle. Connect electrical lead to starter. shaft in direction of normal rotation, and snap im-
5-80.MAGNETOS. The two S6RN-21 Scintilla mag- pulse coupling several times to check its operation.
netos are mounted at the accessory end of the engine Next, turn rotor opposite normal rotation, to avoid
and are designated left and right as viewed from engaging impulse coupling until white mark on rotor
the pilot's seat. The right magneto fires one, three, gear is indexed with scribed line on magneto case
and five exhaust spark plugs, and two, four, and six should just start to open with these
intake plugs. The left magneto fires one, three, and lined up.
five intake plugs, and two, four, and six exhaust plugs. b. Disconnect coil and condenser leads from break-
Ignition timing is 36 degrees before T.D.C. er points, and attach a type A-100 timing light across
5-81. REMOVING - MAGNETOS. the points. Install insulator between magneto housing
a. Remove timing mark access cover from engine. ground strap.
Rotate timing gear with T100132 tool until 36 degree
mark alignswith center line of access opening. c. If points do not open when marks line up as in-
dicated by light going out, loosen adjusting screw in
b. Unscrew four retaining screws from spark plug slotted hole of breaker assembly, and pivot screw
wire adapter plate, and remove adapter plate, and in hole at outer end of assembly. Shift breaker as-
wires from magnetos. Disconnect ground wire. Re- sembly slightly sothat points just open when marks
move two nuts and washers from mounting flange, are
and lift magneto free of engine. d. Clean breaker points, when necessary, with un-
5-82. BENCH TIMING MAGNETO. leaded gasoline and dry with filtered compressed
air. Avoid spreading points more than 1/16 inch to
Note prevent damage to spring. Moisten felt with just
enough SAE 60 oil so that oil appears on surface
The following procedure is to establish of felt only when squeezed with fingers.
internal timing of magneto. It is to be
used when there is any doubt as to inter-
nal timing of magneto, as when a new set CAUTION
of points are installed. Normal points will
show a dull, slightly rough contact surface.
If points have deep pits or excessiveburn- Use of carbon tetrachloride for cleaning
ed areas, the complete breaker assembly breaker point assembly is not recommend-
must be replaced. Replace the cam if it ed, as splitting of cam follower may re-
is worn excessively. suit.
5-24 Rev. 3
MAINTENANCE
5-83. INSTALLING - MAGNETO. b. Rotate magneto in its flanged slots until timing
marks align in cover window, and tighten nuts se-
a. Rotate engine timing gear to 36 degree mark, curely. Install adapter plate and wires. Install ground
align magneto timing marks, and install magneto on wire.
mounting flange and secure with washers and nuts.
5-84. OIL SYSTEM.
Note 5-85. DESCRIPTION. The oil system (figure 5-21)

consists of an engine oil sump (which acts as a supply
Tighten nuts just enough to prevent mag- tank), engine driven pressure pump and relief valve,
neto to be moved in its mounting flange oil cooler, temperature thermobulb, and adequate
slots. tubing and hoses. The complete system is enclosed
1. Pressure Gage 7. Oil Pressure Gage Line

2. Oil Cooler 8. Engine Pressure Line
3. Thermostatic Valve 9. Oil Filler Cap
4. Thermo Bulb 10. Oil Filter
5. Engine Oil Inlet Line 11. Oil System Drain
6. Transmission Inlet Line 12. Engine Breather
47670-4B
Figure 5-21. Oil System Diagram

5-25
MAINTENANCE
within the body of the helicopter in the engine com- any other cleaning material. Connect cooler to flush-
partment, and is serviced from the left side. A dip ing equipment so that pressure will enter at outlet
stick attached to the filler cap denotes oil level. port of cooler.
5-86. OIL COOLER. The oil cooler is a flat type,

honeycomb radiator incorporating a thermostatic
control valve. The thermostatic valve is operated
by temperature to by-pass oil around the cooler or Power flushing equipment should be equip-
direct it through the cooler, as required. Cold oil is ped with a suitable filter to prevent re-
diverted from the cooler core into cooler muff until circulations of foreign material, and be
the core is heated by the action of the warm oil passing provided with a relief valve set to re-
through the muff. When the oil has warmed sufficiently lieve at 75 PSI to prevent damage to cooler.
to close the thermostatic valve, the oil is diverted
through the cooler core. (Figure 5-22.) e. Close by-pass (center) port leaving inlet port
open. Pump solvent through cooler for 30 minutes.
5-87. REMOVING - OIL COOLER. (This cleans the inside of core and warm-up pas-
sage.) Open by-pass port and close intake port.
a. Disconnect oil inlet and outlet line from cooler Continue flushing for five minutes. (This removes
fitting. Unsnap cooling air intake duct from inboard dirt which may be trapped in the by-pass passage.)
side of cooler, and slide duct from cooler.
f. Repeat preceding step e., using a fresh solvent.
b. Remove nuts, washers, and bolts from clips attop Drain cooler thoroughly and flush with clean, light
of cooler, and nuts, washers, and bolts from support lubricating oil (SAE 10) at a temperature of 71.1°C
plate at bottom of cooler. Lift cooler from structure. (160°F).
5-88. CLEANING - OIL COOLER. 5-89. TESTING OIL COOLER AND THERMOSTATIC
VALVE.
Note
a. Attach a sealing plate and gasket to thermostatic
Clean oil cooler at each normal engine valve mounting flange of cooler, and provide a suit-
change. Replace cooler if removed be- able fitting to connect an air line. Attach air line
cause of internal engine failure. and adjust pressure to 75 PSI maximum.
a. Remove cap screws and lift temperature regulator

valvegasket
and gaskets from cooler. Remove drain plug Remove cooler
water and check for leaks.
from water, shut off pressure and
and Tilt oil cooler in all directions and drain
and gasket. Tilt oil cooler in all directions and drain disconnect air line. Blow excessive
disconnect air line. Blow excessive water from
water from
residual oil from cooler. Unscrew thermal unit, re- cooler
cooler and
and dry
dry in
in an
an oven
oven at
at 121
121 to
to 135°C
135°C (250
(250 to
to
move from housing
moveand
and
fromdiscard
discard gasket.
housing
gasket. 275F) for approximately one hour. Correct leaks
b. Immerse cooler (tubes vertical) in a bath of dry or replace cooler, as quired.
cleaning solvent, and allow to stand for five minutes.
c. Submerge thermostatic valve in warm water and
Maintain vertical position, and move cooler up and c. Submerge thermostatic valve in warm water and
down occasionally to force liquid through tubes to
loosen dirt. 54.4°C (130°F) and observe valve. (The valve will
start to expand if it is operating properly.) Increase
heat to 71.1°C (160°F) and check valve for being fully
extended (closed). Replace valve if necessary.
d. Place new gasket on thermal unit, thread unit into
housing and tighten securely. Position a new gasket
Do not use solvents which are normally on temperature regulator mounting flange, position
used to clean copper coolers. These sol- assembly on cooler, install and tighten cap-screws.
vents are highly corrosive to aluminum,
and will result in destruction of the alu-
minum cooler. 5-90. INSTALLING - OIL COOLER.
c. Remove cooler from bath, and drain with tubes a. Rest oil cooler on support plate, attached to diag-
in a vertical position. Use an air gun, and blow through onal structure member, and install bolts, washers,
tubes from face of cooler to remove all foreign and nuts. Position clips at upper mountingholes and
particles. install bolts, washers, and nuts.
d. Check power flushing equipment for being filled b. Slide cooling air intake duct over inboard side
with dry cleaning solvent. Wash out and thoroughly of cooler, and secure duct to cooler with snap fasten-
flush equipment if it has previously been used with ers. Connect inlet and outlet lines to cooler fittings.
5-26
MAINTENANCE
OUTLET TO ENGINE
AND TRANSMISSION
OIL INLET OIL INLET
OIL FLOW WITH VALVE OPEN OIL FLOW WITH VALVE CLOSED
47671-2
Figure 5-22. Diagram of Oil Cooler Operation
Note 5-94. CLEANING - OIL FILTER. Washfilter screens

individually in clean, unleaded gasoline, or dry clean-
The inlet line to the cooler is the line from ing solvent, using a soft bristly brush. Dry screens
the oil filter, with filtered compressed air.
5-91. OIL FILTER. An Air Maze filter is incorpo- 5-95. ASSEMBLING - OIL FILTER. Replace head
rated in the oil system. The oil is pumped through gasket if flattened or damaged. Replace filter pack
the filter cartridge, composed of seven circular if screens are punctured, collapsed or excessively
screen assemblies, to the cooler. In the event the clogged. Install filter pack, retaining nut, and lock-
screens become clogged, a check valve incorpo- nut. Position container, and install washer and nut.
rated in the filter opens, and allows the oil to be Tighten and lockwire nut.
pumped directly through the system.
5-96. INSTALLING- OIL FILTER. Position filter
5-92. REMOVING- OIL FILTER. Drain engine oil. on mounting bracket, install two screws and safety
Disconnect filter inlet and outlet lines. Cut safety wire. Connect inlet and outlet lines to filter. Service
wire, and remove two screws in mounting bracket. oil system.
Lift filter from structure.
5-97. CHECK VALVE. A check valve, Part No. 527-
5-93. DISASSEMBLING - OIL FILTER. Cut safety 100 (Parker Applicance Co., Los Angeles, Calif.),
wire, and remove container retaining nut and washer. or Part No. 879A-10TT (J. P. Clark, Pasadena,
Remove container and allow engine oil to drain. Calif.) is incorporated in the oil system to prevent
Unscrew filter pack lock-nut and retaining nut from the filter-to-cooler line draining when the engine
stud. Slip filter pack from stand pipe. is not running.
5-27
MAINTENANCE
5-98. REMOVING - CHECK VALVE. Place a suit- 5-106. OIL PUMP. The oil pump is installed in the
able pan under filter, remove filter container, and base of the engine adjacent to the oil sump. The pump
allow oil to drain. Disconnect oil line from forward forces the oil from the sump, through the relief
eng of check valve, and unscrew valve from filter valve, to the cooler, and to the engine and trans-
fitting. mission.
5-99. CLEANING - CHECK VALVE. Unscrewaft end
of check valve. Clean parts in clean, unleaded gasoline, 5-107. REMOVING - OIL PUMP.
and check condition of flapper, seal, and spring. Make
certain flapper operates freely. Assembly checkvalve.
a. Drain oil from engine sump. Disconnect rocker
5-100. INSTALLING - CHECK VALVE. Screw check box drain hose at engine sump.
valve into filter with flow arrow pointing toward
filter. Tighten securely making certain "TOP" (on b. Loosen lower hose clamp on engine crankcase
end fitting) is at the top. Install filter container, drain hose. Remove nuts and bolts from sump support
connect oil line and refill oil system to proper level. brackets, and disconnect sprag mount rods from
adapter.
5-101. OIL PRESSURE RELIEF VALVE. The relief
valve, located at the left rear of the accessory c. Remove pal nuts and nuts from sump base, and
section behind the intake manifold, by-passes ex- lower sump from engine. Slide screen from pump.
cessive oil pressure back to the oil pump. Remove nuts from pump flange, and lower pump from
5-102. ADJUSTING - OIL PRESSURE RELIEF
VALVE. The oil pressure relief valve is a "non-
adjustable" type. Normal pressure is 40 to 60 pounds 5-108. CLEANING - OIL PUMP. Wash screen in
at 3100 RPM after oil temperature has stabilized. .
If oil pressure is abnormal, check oil supply and
external oil system. Remove relief valve spring and
plunger, clean and inspect for grit and burrs. In- 5-109. INSTALLING - OIL PUMP.
spect plunger bore in oil pump. If these parts are
satisfactory, reassemble valve. Increase oilpressure a. Install oil pump and screen in engine. Raise
by replacing spring or by installing not more than engine sump, engage drain hose and press upward
two washers (AN960-416) in recess of cap behind into place. Install nuts and pal nuts.
spring. To decrease pressure, grind off end of spring
to reduce length. b. Attach support brackets to sump with bolts and
nuts. Connect sprag mount rods to adapter, andtighten
5-103. REMOVING - OIL PRESSURE RELIEF hose clamp on engine crankcase drain hose. Connect
VALVE. Loosen right inboard hose clamps on mani- rocker box drain hose. Refill system with proper
fold hose connection, remove two bolts in manifold grade engine oil.
packing retaining plate at number two cylinder, and
pull lower left section of intake manifold free of
upper section. Straighten tang on lock-washer and 5-110. FUEL SYSTEM - MODELS 47D1 AND 47G.
remove relief valve cap, lock-washer, spring and (Figures 5-23 and 5-24.) The fuel system consists
plunger. of the fuel tank (two are installed on Model 47G),
shut-off valve, fuel strainer, fuel level transmitter,
fuel level gage and suitable tubing, hoses and fittings.
Fuel flows by gravity from the tank(s) through the
5-104. CLEANING - OIL PRESSURE RELIEF shut-off valve, to the fuel strainer and to the car-
VALVE. Wash plunger and spring in kerosene, or buretor.
dry cleaning solvent.
5-111. FUEL TANK AND SUPPORT ASSEMBLY -
5-105. INSTALLING - OIL PRESSURE RELIEF MODELS 47D1 AND 47G. The fuel tank and support
VALVE. assembly on Model 47D1 is mounted to the struc-
ture, above and aft of engine. Tanks and support
a. Coat spring and plunger with engine oil and in- assemblies on Model 47G are mounted to the struc-
sert in oil pump. Install cap and lock-washer, bending ture above and to each side of the engine. A float
tangs of lock-washer to secure cap from turning, type fuel level indicator is mounted in the tank (one
in each tank on Model 47G). The system is serviced
b. Slip end of manifold into hose connection and from the left side on Model 47D1. On Model 47G,
upper section. Fit packing into upper section, and service from either or both sides. If a tank is over-
fasten retaining plate with two cap screws. Tighten filled, or fuel is spilled on the tank during refueling
hose connection. Start and warm-up engine. Check operations, excess fuel drains into well formed by
for proper oil pressure reading. firewall, and overboard through a drain line.
5-28
MAINTENANCE
5-112. REMOVING - FUEL TANK AND SUPPORT - Note

MODELS 47D1 AND 47G.
To remove fuel tank only, follow step c.

a. Disconnect battery. Drain fuel from system. To remove tank and support as an as-
sembly, omit step c. and follow step d.
b. Disconnect vent line from top of tank, loosen
clamps and rotate line out of way. Disconnect wire c. On Model 47D1, remove screws attaching cover
from fuel level transmitter. Disconnect tank and to bottom of firewall sump housing, lower cover and
firewall sump lines, and fuel feed line from tank disconnect flexible fuel line from shut-off valve. On
outlet. On Model 47D1, disconnect control cable Model 47G, remove tank drain valve. On either model,
clevis from fuel shut-off valve arm. (If tank is to disconnect bonding jumper between tank and support,
be removed from support, remove arm from shaft cut lockwire and disconnect strap turnbuckles, and
of valve.) left tank from support.
1. Fuel Tank 9. Fuel Tank Support

2. Fuel Tank Vent Line 10. Firewall Sump Drain Line
3. Finger Screen 11. Fuel Tank Sump Drain Line
4. Fuel Tank Sump 12. Fuel Strainer
5. Fuel Shut-Off Valve 13. Fuel Inlet Line - Strainer to Carburetor
6. Fuel Line - Tank to Strainer 14. Carburetor - (Ref.)
7. Firewall Sump 15. Carburetor Air Control Valve Drain Line
8. Fuel Tank Sump Drain Lock 16. Fuel Shut-Off Valve Control
47680-2
Figure 5-23. Fuel System Diagram - 47D-1

5-29
Section V (Part 1) BELL HELICOPTER COMPANY _ Models 47D-1 & 47G
d. On Model 47D1, remove bolts from support leg fuel line to tank outlet. Connect, tighten and lock-
clamps, and lift tank and support from helicopter. wire tank strap turnbuckles, with pads in place on
On Model 47G, remove bolts attaching interconnect- straps. Connect, bonding jumper between forward
ing fireshield to support. Remove bolts from support end of support and bracket on tank.
brackets aft of cabin firewall and nut and washer
from through-bolt at engine mount bracket. Lift
tank and support from helicopter. Remove opposite c. Connect drain line to tank drain valve. Connect
tank in same manner. vent line to top of tank and tighten support clamps.
Connect wire to fuel level transmitter. Install opposite
tank and support in same manner.
5-113. INSTALLING - FUEL TANK AND SUPPORT
MODEL47D1. d. Close all drain valves. Connect battery. Filltanks
with fuel, checking for leaks and proper operation
a. Lift support (or tank and support assembly) into of fuel level gage.
position, and install attaching bolts.
5-115. FUEL STRAINER. A strainer is incorporated
Note in the fuel system to filter all fuel supplied to the
carburetor.
Follow step b. if fuel tank was removed
from support. 5-116. REMOVING - FUEL STRAINER. On all
models except 47D1, remove strainer and fuel shut-
b. Place tank in support, install and tighten turn- off valve as an assembly. (Refer to paragraph 5-119.
buckles in support straps. Lockwire turnbuckles. or 5-120.) On Model 47D1, close fuel shut-off valve,
Insert flexible fuel line through grommet in firewall disconnect fuel inlet and outlet lines from strainer,
sump housing and connect to shut-off valve. Position remove two bolts attaching strainer to support, andre-
cover on bottom of firewall sump housing, and install move strainer.
screws. Seal joint with heavy putty, EC612 (Minnesota
Mining and Mfg. Co., St. Paul, Minn.) or equivalent. Note
Install arm on shaft of fuel shut-off valve. Connect
bonding jumper between tank and support. To remove bowl and filter element only,
close shut-off valve, loosen bolt to permit
c. Install tank drain valve and connect drain lines pivoted bowl support to swing out of way,
to valve and firewall sump. Connect control cable and remove bowl and filter element.
clevis to arm of shut-off valve. Connect wire to fuel
level transmitter. Service tank and check for leaks 5-117. INSTALLING - FUEL STRAINER. On all
and proper operation of fuel level gage and fuel shut- models except 47D1, install strainer and fuel shut-
off valve. off valve as an assembly. (Refer to paragraph 5-121
or 5-122.) On Model 47D1, position strainer support
5-114. INSTALLING - FUEL TANKS AND SUP- install attachment bolt, and connect fuel inlet and
PORTS - MODEL 47G. outlet lines. Open fuel shut-off valve and check for
leaks.
a. Lift support (or tank and support assembly) to
position, inserting forward legs of support between 5-118. FUEL SHUT-OFF VALVE. The fuel shut-off
brackets aon structure behind cabin firewall. Align is an on-off type valve in the fuel line between the
bracket on tank support with aft end of through-bolt fuel tanks and strainer. It is operated by a control
at engine mount bracket and install washer and nut. located in the cabin.
Place lower end of brace tube against inboard side
of inboard bracket at cabin firewall and install bolt 5-119. REMOVING - FUEL SHUT-OFF VALVE -
through brace, bracket and support leg. (Upper end MODEL 47D1. Drain fuel. Remove fuel tank from
of brace is bolted to tank support structure near support. (Refer to paragraph 5-112.) Unscrew screen
forward end.) Install bolt through outboard bracket housing and shut-off valve assembly from tank outlet.
and support leg. Align holes in interconnecting fire- Unscrew valve from nipple on screen housing.
shield and support andinstall bolts (from top), washers
and nuts. Seal joint with heavy putty, EC612 (Minnesota 5-120. REMOVING - FUEL SHUT-OFF VALVE -
Mining and Mfg. Co., St. Paul, Minn.) or equivalent. MODEL 47G. Drain fuel. Disconnect drain lines
from strainer and from interconnecting fireshield,
Note and flexible fuel line from stainer outlet. Remove
actuating arm from shaft of shut-off valve. Remove
If tank was removed from support, follow bolts attaching interconnecting fireshield to each
step b. tank support firewall and screws attaching fire-
shield brackets to strainer support, and remove
b. Lift tank into support, insert drain fitting through fireshield. Disconnect flexible fuel lines from both
grommet in support, and install drain valve. Connect sides of tee fitting. Remove two bolts through support
530
MAINTENANCE
1. Filler Caps 7. Fuel Strainer

2. Tank Vent Lines 8. System Drain
3. Fuel Tanks 9. Tank Sump Drains
4. Tank Fuel Strainer 10. Carburetor Air Control Valve Drain Line
5. Fuel Level Indicator 11. Carburetor (Ref.)
6. Fuel Shutoff Valve 12. Fuel Shutoff Control
47680-3
Figure 5-24. Fuel System Diagram - 47G

5-31
MAINTENANCE
and top of strainer. Remove strainer, valve and inlet nipple, and strainer on outlet nipple. Position
adapter as an assembly. Unscrew nipples from each assembly to strainer support, with valve shaft ex-
side of fuel shut-off valve and separate parts. tending up through support, and install two bolts
through support and strainer head. Connect flexible
5-121. INSTALLING- FUEL SHUT-OFF VALVE - fuel hoses to tee fitting. Position interconnecting
MODEL 47D1. Screw fuel shut-off valve on nipple in fireshield to align with holes in tank support fire-
screen housing. Install nipple in valve outlet. Screw walls, and install bolts. Align fireshield brackets
screen housing into tank outlet. Be sure that valve with holes in strainer support and install two screws.
shaft extends downward and valve outlet points aft. Position actuating arm on valve shaft and install
Install tank in support. (Refer to paragraph 5-113.) clevis pin. With valve and control knob both "OFF"
Check operation of shut-off valve. Service system or both "ON", connect control cable clevis to arm.
with fuel and check for leaks and proper operation. Connect flexible fuel line to strainer outlet elbow.
Connect drain lines to interconnecting fireshield
5-122. INSTALLING- FUEL SHUT-OFF VALVE - and strainer drain valve. Service system with fuel
MODEL 47G. Install nipples in inlet and outlet sides and check for leaks and proper operation of shut-off
of valve. Screw interconnecting tee and adapter on valve.
5-32
Section V (Part 2)
Model 47G-2
Section V - Part 2
Power Plant and Related Systems
5-l. POWER PLANT.
(Model 47G-2 Serial No’s.
1459 through 2478.)
Note
Model 47G-2 Serial No’s. 2556 through
2570. (Refer to paragraph 5-104.)
5-2. DESCRIPTION. (Figure 5-25.) The power plant

assembly consists of the Model VO-435-A1B, VO-
435A1D or VO-435-A1E Lycoming engine (VO-435-
A1A used
on Model 47G kit installations prior to
availability of -A1B), engine adapter plate, engine
mount, cooling fan, shroud and baffles, exhaust
stacks, carburetor, air intake System, and acces-
sories. The transmission is mounted at the top of
drive end of the engine. The generator and rotor
tachometer generator are mounted on and driven by
the transmission. Other accessories, including starter,
engine tachometer generator, oil pump, hydraulic
pump, magnetos, and handcrank coupling are located
on the accessory case at lower end of engine. The
cooling fan is mounted cm front of engine and driven
by belts from a drive assembly geared to transmis-
sion. Viewed looking forward from aft Of engine,
top cylinder on left-hand Side IS cylinder NO. 1 and
remaining cylinders of that bank are odd-numbered.
Bank of cylinders at right Side are even-numbered, Figure 5-25. Power Plant Assembly
with No. 2 cylinder St top. The right-hand magneto
on the VO-435-A1B and VO-435-A1D engines has an
impulse coupling. (On -A1A engines only, the magneto Horse Power (as derated) 200 at 3100 rpm
having impulse coupling is actually located at left- Number of Cylinders 6
hand side of helicopter; however, it should be con- Bore, inches 4.815
nected to the ignition switch So as to be ready to fire stroke, inches 3.875
when switch is set on “R”.) The right-band magneto
on the VO-435-A1E engine has dual breaker points piston Displacement, cubic inches 434.0
(normal and retarded breaker) and requires a Start- Compression Ratio 7.30:1
ing vibrator to Supply the necessary voltage at crank- Firing Order l-i-5-2-3-6
ing speed for a hot spark since impulse coupling
is not used. Auto-Lite SH-2M
AC S 86-R
Spark Plug Gap, inch 0.015 to 0.018
Magnetos (impulse) S6LN-20, S6RN-21 (impulse)
Magnetos (dual breaker) S6RN 200, S6LN 204
Before attempting to start the engine with Ingition Timing 25 Degrees BTC
handcrank, magneto wiring Should be
checked to insure that right magneto (which Oil Pressure Minimum 65 psi
has the impulse coupling) is wired to the Maximum 85 psi
right terminal on the ignition Switch Idle Minimum 25 psi
Oil Temperature
5-3. SPECIFICATIONS - ENGINE. (Maximum inlet)
Models VO-435-A1B, Grade Oil Required
VO-435-A1D or Lycoming Div. (Above 40 degrees) 1108 (SAE 50)
VO-435-A1E AVCO Mfg. CO. (Below 40 degrees) 1065 (SAE 30)
5-l
Section V (Part 2) BELL HELICOPTER COMPANY Model 47G-2
MAINTENANCE
Fuel Minimum 5-4. TROUBLE SHOOTING.

(Aircraft grade) 80/87
INDICATION OF TROUBLE PROBABLE CAUSE CORRECTIVE ACT ION
Failure of engine to start Lack of fuel Check fuel system for leaks. Clean
lines, strainer, or fuel valves. Fill
fuel tanks
Underpriming Open throttle rapidly two or three

times
Overpriming Place mixture control in "Cut-off."
Close throttle. Leave ignition on.
Turn engine over until it starts.
Immediately return to "RICH" mix-
ture
Incorrect throttle setting Open throttle to one-tenth its range
Defective spark plugs Clean, adjust, or replace plugs
Defective ignition wire Check with electric tester and re-
place defective wires
Improper operation of Check points. Check internal timing

magneto breaker of magnetos
Lack of sufficient fuel flow Disconnect fuel line at carburetor

and check fuel flow
Manual mixture control Check linkage

in "CUT-OFF"
Fuel shut-off valve in Check linkage and valve

closed position
Water in carburetor or fuel Drain carburetor and fuel lines
system
Internal failure Check oil screens for metal parti-
cles. If found, complete overhaul
may be indicated
VO-435-A1B and D
Failure of engine to idle Incorrect carburetor idle Adjust throttle stop
properly adjustment
VO-435-A1E Incorrect carburetor idle Adjust controls
adjustment
Incorrect mixture setting Adjust mixture control linkage
Leak in induction system Tighten all connections in induction
system. Replace defective parts
Low cylinder compression Check condition of piston rings and
valves
Faulty ignition Check entire ignition system
5-2
Model 47G-2 BELL HELICOPTER COMPANY Section V (Part 2)
MAINTENANCE
Low power and uneven Mixture too rich, indicated Check control adjustment, overhaul
running by sluggish engine operation carburetor
red exhaust flame at night.
Extreme cases indicated by
black smoke from exhaust
Leak in induction system Tighten all connections; replace de-

fective parts
Defective spark plugs Clean, adjust, or replace plugs
Poor fuel Drain and refill tanks with recom-

mended grade of fuel
Magneto breaker not working Clean points. Check internal wiring

properly of magnetos
Defective ignition wire Check wire with electrical tester.

Replace defective wire
Improper ignition timing Check magnetos for timing and syn-

chronization
Defective spark plug termi- Replace connectors on spark plug

nal connectors leads
Failure of engine to develop Throttle control out of ad- Adjust throttle controls
full power justment
Leak in induction system Tighten all connections and replace

defective parts
Improper fuel flow Check lines, strainer and fuel flow
at carburetor inlet
Improper fuel Drain tanks, and refill with recom-

mended grade fuel
Restriction in air intake Check air intake system. Clean

filters or remove restrictions
Faulty ignition Tighten all connections. Check sys-
tem with tester. Check timing
Defective spark plugs Clean, adjust or replace plugs
Low oil pressure Relief valve improperly ad- Adjust relief valve
jested
Insufficient oil or oil of Check oil supply for quantity and
improper grade proper grade
Dirt in relief valve Remove and clean oil pressure re-
lief valve
High oil termperature See "High oil temperatures".
Defective pressure gage Replace gage
Obstruction in oil pump Check lines for obstruction. Clean

intake passage filter screens
5-3
MAINTENANCE
Failed or failing bearings Check sump for metal particles

Obstruction in external oil Check all parts of system
High oil temperatures Insufficient oil supply Fill supply tank to proper level
Improper grade of oil Drain and refill with recommended

grade of oil
Excessive blow-by Usually caused by worn or stuck

rings. Complete overhaul required
Failed or failing bearings Examine sump for metal particles.
If found, complete overhaul is in-
dicated. Inspect main rotor mast
bearing for deterioration.
Improper engine operation Check entire engine
Defective temperature gage Replace gage
Oil cooler malfunction Check cooler thermostat and re-
place if defective
Interrupted air flow cooler Clean air flow path through cooler
Cooling fan malfunction Check cooling fan and belts
Excessive oil consumption Low grade oil Drain and refill supply tank with oil
of recommended grade
Failed or failing bearings Check sump for metal particles. If

found, overhaul engine
Worn piston rings Install new rings

Incorrect installation of Install new rings
piston rings
Cold weather difficulties Overpriming Place mixture control in "Cut-off"
Close throttle leave ignition on and
turn engine over until it starts. Im-
mediately return to "RICH" mixture
Weak battery Replace with fully charged battery.

Use external power if available
Engine does not stop Linkage does not permit full Adjust linkage
travel of "Idle cut-off"
Leak in "Idle cut-off" Overhaul carburetor
Faulty ignition ground Overhaul switch, check ground wires
5-5. REMOVING - POWER PLANT ASSEMBLY. d. Remove main rotor. (Refer to Section II.)
a. Disconnect battery. e. Remove mast and controls assembly. (Refer to

Section III.) Install hoisting ring, T100089, on studs
b. Drain fuel and oil systems. at top of transmission.
c. Remove fuel tank and support assemblies. (Refer f. Remove short forward section of tail rotor drive
to paragraph 5-61.) shaft. (Refer to Section VI.)
5-4
MAINTENANCE
g. Disconnect flexible oil lines at engine oil pump b. Remove cooling shroud, fan and support, and
inlet and outlet and following lines: fuel feed line baffles. (Refer to paragraphs 5-72 and 5-86.)
from carburetor inlet; manifold pressure gage
line at aft end of flexible line below en-
gine; oil pressure gage line from tee on oil pump; c. Remove engine breather tube and fitting from left
and blast tube from electrical junction box. Remove front of engine. Plug opening.
hydraulic pump from mounting pad without discon-
necting hoses from pump, and stow pump out of way. d. Remove sprag safety cables. (Refer to paragraph
Cap or cover all lines and openings. 5-26.)
h. Disconnect electrical leads from following ac-

cessories or locations; generator, rotor tachometer
generator, engine tachometer generator, starter,
magneto (ground leads), transmission oiltemperature
bulb, engine oil temperature bulb, carburetor air
temperature bulb, thermocouple lead (aft side of No.
2 cylinder), and ground cables from each side of ac-
cessory case. Detach cordage where taped to engine
mount.
i. Disconnect control cables from carburetor mix-

ture lever and support bracket, and from carburetor
heat control valve. Stow cable ends clear of engine.
j. Disconnect throttle control cable from carburetor

throttle arm and support bracket from oil pump
housing.
k. Remove air induction system. (Refer to paragraph

5-39.)
1. Remove exhaust manifolds. (Refer to paragraph

5-33.)
m. Remove lateral cyclic torque tube. Disconnect

push-pull tubes from fore-aft bell crank on trans-
mission. (Refer to Section VII.)
n. Disconnect fan shroud from oil cooler.
o. Attach hoist to hoisting ring and take up slack to

aid in holding engine in alignment. Remove sprag
mount swivel plate and spindle, leaving adapter on
engine sump if existing. (Refer to paragraph 5-20.)
Disconnect safety cables from center frame fittings.
p. Lift engine slightly to relieve weight on mount

bolts. Remove bolts passing through center frame
bracket and Lord mount at each side of engine mount.
Check that no line, linkage, or electrical lead is
connected between power plant assembly and heli-
copter structure. Lift power plant clear of helicopter
and place on a stand.
5-6. DISASSEMBLING - STRIPPING ENGINE. (Fig-

ure 5-26.)
a. With engine supported on a stand, remove trans-

mission. (Refer to Section IV.)
5-4 A
MAINTENANCE
1. Engine Breather Fitting

2. Engine Tachometer Generator
3. Starter
4. Oil Pump Fittings
5. Adapter Support Bracket and Spacer
6. Adapter Plate Assembly
7. Engine Mount
8. Drive Coupling
9. Adapter Plate Gasket
10. Carburetor Inlet Fittings
11. Manifold Pressure Gage Line and Fitting
12. Support Bracket (2)
13. Mixture Control Cable Bracket
14. Exhaust Manifold (2)
15. Exhaust Adapter Stack (6)
16. Aft Safety Cables
17. Hydraulic Pump
*18. Sump Adapter
19. Forward Safety Cables
21. Baffles
22. Cooling Fan and Support
*0-435-23 Engine only
5-5
MAINTENANCE
e. Remove sprag adapter from engine sump if ex-

isting. (Refer to paragraph 5-20.) CAUTION
f. Remove starter, and engine tachometer generator.

Install cover plates on mounting pads. If coupling is Part No. 47-620-801-1,
check for possible interference of crank-
g. Remove carburetor and install cover plate. Re- shaft pilot with radius of coupling counter-
move throttle lever and carburetor inlet fittings for bore. If necessary, carefully chamfer
installation on new or overhauled carburetor. sharp edge of crankshaft pilot to clear
radius in coupling. With coupling seated
on pilot, check with feeler gage for clear-
h. Remove spark plugs and replace with dehydrator between flanges of crankshaft and
plugs. coupling. If clearance exists, use shim
0.001 to 0.002 inch thicker than feeler
i. Remove thermocouple fitting from aft side of No. measurement. Coupling Part No.
2 cylinder. 47-620-801-3 does not require this in-
spection or rework.
j. Remove engine oil temperature bulb, oil pump
inlet and outlet fittings, and transmission supply line
and tee. Plug openings. c. Install adapter plate and engine mount assembly,
and support brackets on engine. (Refer to paragraph
k. Remove ignition harness brackets and clips, and 5-16.) (VO 435-A1D omit forward bracket.)
any other fittings needed on replacement engine.
d. Lift engine and place on a stand.
1. Lift engine from stand and place on shipping case
or suitable support, with drive end raised. e. Install hoisting plate and ring T100089,on studs
at top of transmission. Install transmission. (Refer
m. Remove engine mount and adapter plate assem- toSection IV.) Installforeandaft bell crank andsupport
bly and support brackets. (Refer to paragraph 5-11.) collective pitch bell crank and support, lateral torque
tube support, and dampers if existing on transmis-
sion. (Refer to Section VII, Part II.)
n. Remove lockwire, nuts, and washers around base
of clutch drive coupling, and pull coupling from f. Install cooling baffles. (Refer to paragraph 5-88.)
crankshaft.
g. Install spark plugs. (Refer to engine manufactur-
5-7. REPAIR OR REPLACEMENT - POWERPLANT. er's instructions.) Connect leads to plugs and secure
ignition harness to engine. (See figure 5-27.)
a. Overhaul engine and accessories according to
manufacturer's instructions. h. Remove plug and install fitting and engine breather
line at left front of crankcase.
b. Refer to applicable paragraphs of this section for
repair or replacement of parts furnished by Bell i. Install cooling fan and support, belts, and shroud.
Helicopter Corporation. (Refer to paragraph 5-79.)
j. Install thermocouple fitting in threaded recess in
c. Check adapter plate mounting studs, on top face aft side of No. 2 cylinder.
of engine, for proper height (0.86 inch above engine
face) and tightness at minimum torque (250 inch- k. Install sprag adapter on engine sump if existing.
pounds). If necessary, replace with oversize studs (Refer to paragraph 5-23.)
set to proper height at 250 to 550 inch-pounds.
Install safety cables on engine. (Refer to para-
5-8. REASSEMBLING - ENGINE BUILD-UP. graph 5-30.)
graph 5-30.)
a. Support engine in shipping case or other suitable m. Remove plugs and install inlet and outlet fittings
support, with drive end raised. (On -A1A engine only: and oil temperature bulb in oil pump housing. Install
Remove pipe plug from end of crankshaft and install tee fitting in aft upper side of pump housing, and
oil jet, staking at four points.) install external line between right end of tee and oil
strainer on transmission upper case.
b. Install clutch drive coupling on crankshaft bolts,
securing with washers, nuts, and lockwire. Tap n. Remove plug from aft side of intake manifold, above
coupling with soft mallet, to seat on crankshaftflange, carburetor mounting pad. Install 90 degree elbow
while tightening nuts. fitting, pointing up, for manifold pressure gage line.
5-6
c. Install sprag mount spindle and lockwire bolts.
Install swivel plate and link assembly. Connect brace
rods to links. (Refer to paragraph 5-25.)
d. Install exhaust manifolds, with shroud assembled

on left manifold. (Refer to paragraph 5-36.)
c. Install air induction system. (Refer to paragraph

5-44.)
f. Connect control cables to carburetor heat control

valve and carburetor mixture control lever. (Refer
to paragraph 5-48.)
g. Connect throttle control linkage to carburetor.

(Refer to paragraph 5-52.) Connect fuel line between
fuel strainer and carburetor inlet. Connect manifold
pressure gage line to fitting above carburetor.
h. Connect flexible hoses at oil pump inlet and out-

let. Connect oil pressure gage line to tee fitting on
oil pump housing. Clamp engine breather line to
hand-crank drive pad stud.
i. Connect blast tube between cooling fan shroud

Figure 5-27. Clamping Ignition Harness to Engine and electrical junction box.
o. Install carburetor, with adapter and 45 degree j. Connect electrical leads to: Generator, starter,
fitting in right inlet port. Install mixture control engine tachometer generator, transmission and en-
support bracket on existing screws at left side of gine oil temperature and carburetor air temperature
carburetor cover. (Refer to paragraph 5-48.) If bulb, thermocouple fitting (aft side of No. 2 cylinder),
priming system is not to be used, cap tee in primer magnetoes, and ground cables to each side of acces-
line at upper aft side cd crankcase. sory case. Tape leads to center frame and engine
mount structure leaving slack for engine movement in
operation. Lockwire Cannon plugs.
p. Remove cover plate and install gasket and engine
tachometer generator, with electrical plug facing
k. Remove hoisting, T100089, and pour two quarts
down, on mounting pad aft of magneto on right side of
accessory case. of oil into top cd transmission. Install mast and con-
trols assembly. (Refer to Section III.)
q. Remove cover plate and install gasket and starter,
with electrical connection facting forward, on mount- 1. Install main rotor. (Refer to Section II)
ing pad on right side of accessory case.
m. Level helicopter and align engine and mast. (Re-
r. Remove cover plate and install gasket and hy- fer to Paragraph 5-17.) Adjust and connect safety
draulic Pump, with inlet port forward, on mounting cables. (Refer to paragraph 5-30.)
Pad on left side of accessory case. If pump was left,
attached to hydraulic system install after engine is n. Install short forward section of tail rotor drive
placed in helicopter. shaft. (Refer to Section VI.)
o. Install and rig main rotor cyclic and collective

5-9. INSTALLING POWERPLANT. pitch control linkage. (Refer to Section VII, Part II.)
Check adjustment of throttle linkage. (Refer to para-
a. Install sprag mount brackets (if removed), com- graph 6-53.
plete with
rods,Lordbefore
mountslifting
and brace
engine into helicopter. (Refer to Paragraph 5-23.) p. Install fuel tanks and supports. (Refer to --
graph 5-63.)
b. Attach hoist to hoisting ring, T100089, Installed
on studs at top of transmission. Lift and lower power q. Fill fuel, oil, and hydraulic systems and check
plant assembly carefully into helicopter centerframe. for leeks.
Align Lord mounts in center frame support brackets
and insert a bolt, with head forward (and bonding r. Inspect power plant installation. Connect battery.
braid terminal under head of left bolt), through each
bracket and Lord mount. s. Ground test engine. (Refer to Section I.)
s-7
MAINTENANCE
1. Center Frame Support Bracket

2. Clamp Ring Guard
3. Lord Mount
4. Mount Frame
5. Support Bracket
6. Adapter Plate
7. Lockwire
8. Transmission Mounting Bolts
9. Support Bracket
10. Adapter Plate Mounting Studs
11. Lubrication Fitting
12. Trunnion Pin
13. Taper Pin
SHIMAS NECESSARYUSINGNOT MORE

THAN0.020 BETWEENENGINEMOUNT
ANDADAPTER PLATE 47612-59A
Figure 5-28. Engine Mount Installation

5-8
MAINTENANCE
5-10. ENGINE MOUNTING SYSTEM. The engine is have not removed any material from tubing, and which
mounted by means of an adapter plate installed be- occur at least 1 1/2 inches from any weld cluster
tween engine and transmission and suspended by or intersection of tubes with gussets, may be re-
trunnion pins in a mount frame contructed of welded paired by tack-welding a piece of welding rod to
steel tubes. The mount frame incorporates two cyl- center of dent, pre-heating material 1300to 1400°F
indrical vibration-damping Lord mounts through which and pulling out dent. Take precautions to maintain
it is bolted to support brackets oncenter frame struc- bearing alignment during repair, and thoroughly
ture. The lower end of the engine is held in alignment inspect area visually and by Magnaflux after repair.
by a sprag mount installation attached to the sump,
with four brace rods extending forward, aft, andlater-
ally to Lord mounts on the center frame. Four safety WARNING
cables are provided to maintain approximate engine
alignment in event of sprag system failure.
Damage to mount tubing may not be re-
5-11. REMOVING - ENGINE MOUNT AND ADAPTER paired by patching or insertion, because
PLATE. the stiffening caused by these reinforce-
ments may result in highly detrimental
a. Remove engine, (Refer to paragraph 5-5.) stress distribution conditions which may
in turn lead to failure.
b. Remove transmission. (Refer to Section IV.)
c. Cut lockwire and remove nuts and washers from b. Replace Lord mounts at normal engine change,
adapter plate mounting studs. Remove engine mount if deteriorated or worn. Replace at once if any of
and adapter plate assembly from engine. Cover top
of engine to prevent entry of dirt. (See figure 5-28.) 1 When edges of mount clamps are striking
inside
inside surface
surface of
of support
support brackets
d. Remove taper pins through adapter plate andtrun- (on center frame)
brackets (on center frame)
Remove
nion pins. tapertrunnion
Remove pins pins (keep during operation, if this condition cannot be corrected
shims, if in-
stalled, with pins) and lift engine mount from adapter proper offset of mount in clamp to compensate
plate.
e. Remove bolts, guard, and Lord mount from clamp 2. When separation between rubber and metal
ring at each side of mount frame. has progressed approximately 120 degrees around
circumference of either inner or outer member, or
5-12. CLEANING - ENGINE MOUNT AND ADAPTER has reached a depth of approximately 1/4 the length
PLATE. Clean all parts of adapter plate and engine of the mount at any point.
mount, except Lord mounts, with dry cleaning solvent
or kerosene. 3. When flex cracks in rubber has developed to
a depth of 1/4 inch.
5-13. INSPECTION - ENGINE MOUNT AND ADAPTER
PLATE. 5-15. REPAIR BY BUSHING TRUNNION PIN HOLES.
(Figure 5-29.) Repair adapter plate, when trunnion
pin holes are worn to exceed 0.755 inch diameter,
damaged tubing. Carefully inspect welds for cracks.
b. Visually inspect Lord mounts for condition. In- Inspect trunnion pins for wear. Pin diameter mini-
spect support brackets on center frame structure for mum 0.7485" maximum 0.7495". Replace at 0.7475".
evidence of mount clamps striking inside surface of
brackets during engine operation.
c. Inspect adapter plate for wear in trunnion pin holes.
Replace plate or repair by installing bushings when
pin hole diameter exceeds 0.755 inch. (Refer to
paragraph 5-15.) a. If 47-612-200-1 bushings are not available, make two
bushings from 2024-T4 aluminum alloy bar (QQ-A-268,
d. Refer to Section I for magnetic particle and temper T4) to dimensions shown. (Detail C.)
fluorescent penetrant inspection requirements.
b. Determine center lines on adapter plate, using

5 REPAIR OR REPLACEMENT -ENGINE dowel pin holes to locate both center lines. (Detail
MOUNT AND ADAPTER PLATE.
A.)
a. Replace engine mount frame immediately if cracks
are found in any area, or for any damage to tubing c. Machine off 0.060 inch from each end of adapter
other than as follows: Small smooth dents which plate. (Detail D.)
Rev. 3 5-9
MAINTENANCE
DOWELL PIN
HOLES
-3.000 .001
OF HOLES TO
PASS THROUGH
CENTER OF PLATE DETAIL A
WITHIN .005
16.995 +000
.005
DETAIL B
AFTER INSTALLATION REAM 750 DIA. BORE AND REAM 1.440 DEEP
.751 AND TO .0005 - .0010
INTERFERENCE FIT WITH
BUSHINGS
BREAK ALL SHARP EDGES .015
1.470--- 735
.737 COUNTERSINK
.090 90° x .925
.940 DIA. .8760 DIA.
.010 1.440
NOTE: TWO BUSHINGS P/N 47-612-200-1 .060
REQUIRED. PROCURE AS KIT MACHINE OFF
NO. 47-2459-1
ADAPTER PLATE
DETAIL C
DETAIL D '47612-39
Figure 5-29. Installing Bushings in Adapter Plate

5-10
d. Bore and ream trunnion pin holes in ends of
adapter plate 1.440 inches deep, with 0.015 inch
radius at inner end, and to obtain 0.005 to 0.0010
inch interference fit with bushings. (Detail D.) Center
lines of holes must pass through center cd plate
within 0.095 inch. (Details A and B.)
e. Countersink outer ends of holes 90 degrees x

0.925 inch diameter. (Detail D.)
f. Press bushings into plate. Machine ends of bush-

ings to obtain dimensions of plate assembly as shown.
(Detail B.)
g. Ream bushings 0.750 to 0.751 inch inside dia-

meter. (Detail B.)
h. Match drill (No. 11) and ream holes for taper

pins from top of plate. Use Brown and sharpe taper
reamer corresponding to size of taper pin. Use care
to avoid enlarging existing taper pin holes in plate.
Fit each pin so that small end of tapered shank
extends not more than 1/16 inch from underside of
plate.
Note
Figure 5-30. Coupling and Adapter Plate Installed
When necessary because of enlarge holes
use next oversize taper pin and reamer
(AN386-2-10A pin with No. 2 reamer, or e. Place Lord mount clamp ring at each side
l AN386-3-10A pin with No. 3 reamer). of mount frame. Install guards and clamp bolts, with
long end of guard forward on left-band mount and
long end aft on right-band guard. Install bonding
5-16. INSTALLING - ENGINE MOUNT AND ADAP- braid jumper terminal under head of forward clamp
TER PLATE.
bolt at left-hand side. Position each Lord mount
against lip on long end of guard and tighten clamp
Note bolts (100 to 140 inch-pounds) thus off-setting Lord
mounts in clamps to compensate for torque of main
Parts may be assembled and installed as rotor. (See figure 5-8.) Check installation of bushings
follows, or by installing adapter plate on in Lord mounts.
engine before assembling mount frame on
adapter plate.
a. Lay adapter plate face up on bench with the longer With engine mount installed into center-
portion aft. Place engine mount over adapter plate, frame and before tightening the bolts,
with wide support gusset, to right. Install trunnion pins, check for clearance between each Lord
through engine mount and into adapter plate, with mount bushing and lugs on centerframe.
grease fittings to left. Install taper pins with counter- Shim each Lord mount to obtain 0.000”
bored rashers and nuts. Shim if necessary, maximum to 0.005” maximum clearance, using lam-
total tolerance between adapter plate and engine mount inated steel shims, Part No. 120-008C40-
0.005 (a maximum 0.020 inch shim may be used, be- 12 and then tighten bolts.
tween engine mount and adapterplate). See figure 5-28.
b. Install metal gasket over studs at top of engine.

Lift mount and adapter plate assembly to position
on mounting studs, with oil scoop aft, and install
l two dowel pins. Install washers and nuts on studs,
torque nuts 450 to 500 inch-pounds and lockwire
in pairs, lockwire dowel pins with adjacent studs.
(Figure 5-30.)
MAINTENANCE
d. Position adapter plate support bracket ontwoupper e. Adjust safety cables. (Refer toparagraph5-30.)
studs projecting from side of engine case above and
aft of cylinders, inserting bolt down through adapter 5-18. SPRAG MOUNTS. (Figure 5-31.)
plate into bracket to check alignment. Install washers
and nuts on studs. Install bracket on opposite side 5-19. DESCRIPTION. A sprag mount installation
in same manner. Install spacers or shims as needed provides cushioned suspension to hold the powerplant
to eliminate clearance between brackets and adapter and mast assembly in vertical alignment and absorb
plate. operating vibration and movement. Four adjustable
brace rods are attached to the center frame struc-
e. Remove nut and washer from upper stud at for- ture through Lord mounts, and to the engine sump
ward side of engine case, install T-shaped support through a swivel plate, spindle, and adapter assembly.
bracket on stud, (forward support not required on
VO-435-A1D engines) inserting twoboltsdownthrough 5-20. REMOVING- SPRAG MOUNTS.
adapter plate into bracket to maintain alignment, a. With helicopter reasonably level and main rotor
(spacer between bracket and plate on outboard bolt). release tension on each brace
Install washer and nut on stud. Shim as necessary loosening nut on outboard end of rod.
to eliminate clearance between support and adapter
plate. b. Remove bolts to disconnect brace rods from links,
f. Install transmission. (Refer to Section IV.) Install leaving links attached to swivel plate.
drilled head bolts in holes which align with adapter
c. Remove nut, washer, and swivel plate assembly
plate support brackets, and in from spindle. to separate links from
bolt in each side support bracket, and lockwire in
pairs. Install other transmission mounting bolts in
normal manner. d. Cut lockwire, remove bolts, and pull spindle from
g. With hoisting ring, T100089, install on studs at
top of transmission, attach hoist and lift power plant
assembly into helicopter center frame. Lower as- e. If adapter is installed to sump remove nuts from
studs at left and aft sides of engine sump. Remove
sembly,
sembly, align
align Lord
Lord mounts
mounts in support brackets at
support brackets three studs at left side of sump and remove adapter.
each side of center frame, and install a bolt through
each bracket and Lord mount. (Bondingbraidterminal Keep studs with engine.
under head of left bolt.) f. Remove nuts on outboard ends of brace rods and
h. Complete installation of power plant. (Refer to pull rods inboard out of Lord mounts.
paragraph 5-9.) g. Remove Lord mount from each bracket by re-
moving four bolts.
5-17. ADJUSTMENT - ENGINE ALIGNMENT. Ad-
justment of engine sprag mount rods determines h. When necessary to remove mountbrackets, mark
vertical alignment of engine and main rotor mast in locations for reinstallation. Remove tail rotor cables
relation to the helicopter. Accomplish alignment from pulleys on forward and aft brackets. Remove
after engine change, replacement or adjustment of bolts, clamps, spacers, and brackets and keep in
any sprag mount parts. Check adjustment before any sets.
main rotor controls rigging procedure.
5-21. INSPECTION - SPRAG MOUNTS.
a. Jack and lever helicopter. (Refer to Section I.) a. Inspect parts for general condition, cracks, dents,
elongated bolt holes, and excessive wear.
b. Check cylindrical Lord mounts at each side of
engine mount for proper offset in clamp rings to b. Inspect Lord mounts for cracks in rubber, separa-
compensate for main rotor torque. (Refertoparagraph tion between rubber and metal, and for being oil
5-16.) soaked and deteriorated.
c. Place bubble protractor or square head against c. When installed inspect for security andalignment.
forward or aft side of mast, check for vertical align-
ment. If adjustment is required, adjust the nuts on 5-22. REPAIR OR REPLACEMENT - SPRAG
the four Lord mount sprag braces without preloading MOUNTS.
the mounts to position mast vertical.
a. Replace bolts,bushings or links when play exists.
d. Preload Lord mounts by backing off each inboard Replace all worn or damaged parts.
nut 2 1/2 turns and tightening each outboard nut to
seat washers against inner bushing of Lord mount. b. Replace Lord mounts at normal engine change,
Recheck mast alignment. or when deteriorated or worn.
5-13
0
1. Forward Right Cable 6. Crankcase Boss

2. Cable Lug 7. Hand Crank Adapter
3. Starter Mounting Flange 8. Left Forward Cable
4. Spacer 9. Cable Lug
5. Aft Cables 10. Centerframe Lugs
t
MAINTENANCE
5-23. INSTALLATION - SPRAG MOUNTS. b. Disconnect cables from engine by removing cable
lugs from starter and handcrank drive mountingstuds
a. Reinstall four mount brackets, if removed, in and eyebolts from aft side of crankcase.
original locations, tightening clamp bolts 30 to 40
inch-pounds. 5-27. INSPECTION - SAFETY CABLES.
b. Install sump adapter on studs of mounting pads a. Inspect cables for security of installation, wear,
at left and aft sides of engine sump, if existing by and corrosion.
removing and reinstalling three studs in left mount-
ing pad. Torque studs 200 to 225 inch-pounds, using b. Inspect for broken wires in cables by passing a
oversize studs (Part No. 61-431-453-1, -3, -5, or -7) cloth along cables, observing for broken wire ends
as necessary for proper torque and extension. Install catching cloth.
nuts and washers, tightened 100 to 140 inch-pounds.
c. Inspect for proper adjustment after engine change
c. Assemble spindle to sump or adapter, if existing or when improper adjustment is indicated by vibra-
and install bolts through thin washer and spindle tion during turns in flight. (Refer to paragraph 5-17.)
flange into sump or adapter collar. Lockwire bolt
heads in pairs. 5-28. REPAIR OR REPLACEMENT - SAFETY
CABLES. Replace any
ABLES. Replace any cable
d. Assembly a link on each corner of swivel plate, cable that
that shows
shows more
more than
than
attached by bolts, with heads up and washer under wires broken in any one inch length. If corroded
head and nut. Tighten nuts withwith wrench to clean or broken
of badly worn,
wires replace cable that
is less than evenspecified umber
though for re-
threads, loosen nuts, retighten finger-tight plus one broken wires is less than that specified for re-
castellation, and install cotter pin.
Note 5-29. INSTALLING - SAFETY CABLES.
a. Install lug of left forward cable on lower studs

of hand crank drive. Carry free end of cable for-
misalignment due to binding in operation. ward and to right, and attach clevis to lug welded
on diagonal structural tube at right of tube cross,
e. Install swivel plate, flat side down, on spindle. securing with clevis bolt, washers, nut, and cotter
Secure with washer and nut. Tighten nut with wrench pin.
to clean threads, loosen nut, retighten finger-tight
plus one castellation, and install cotter pin. b. Install lug of right forward cable on lower starter
f. Place Lord mount in each bracket from outboard mounting studs, with bend pointing in and forward.
side, with longest center core of mount outboard Carry free end of cable forward and left, and attach
(away
(away from engine sump).
sump). Install
Install mounting
from engine mounting bolts
bolts
clevis to welded lug at left of structural tube cross.
through flange and bracket web with heads forward (On -A1A engine only: Attach cable clevis to clamp
or inboard and washers under nut and bolt head. on tube ust above and aft of left forward landing
gear saddle.)
g. Install a nut backward on threaded end of each
brace rod, place standard thick washer on rod c. Attach eyebolt of left aft cable through crankcase
against nut, and insert threaded end of rod through boss aft of No. 5 cylinder, with washers under eyebolt
Lord mount from inboard. Align rod clevis on link head and nut. Turn eyebolt to align with cable pull.
and install bolt. Install large washer and nut on Attach cable clevis to lug on vertical tube above left
outboard end of rod. aft landing gear saddle. (On -A1A engine only: Attach
h. Adjust rods to align engine. (Refer to paragraph cable lug to stud on crankcase boss aft of No. 5
5-17.) cylinder.)
5-24. SAFETY CABLES. (Figure 5-32.) d. Attach right aft cable same as left, except use
spacer between eyebolt head and crackcase boss aft
5-25. DESCRIPTION. Four safety cables are con- of No. 6 cylinder. (On -A1A engine only: Attach
nected between center frame structure and lower cable lug on two aft studs of unused hydraulic pump
end of engine, with sufficient slack to remain in- mounting pad on right side of oil pump housing.)
operative under normal conditions. In event of sprag
mount failure, safety cables would hold engine in e. Adjust cables after adjusting spragmountstoalign
approximate alignment, engine. (Refer to paragraph 5-20.)
5-26. REMOVING - SAFETY CABLES. 5-30. ADJUSTING - SPRAG SAFETY CABLES.

a. Tag or mark cables for reinstallation in same
locations. Disconnect four cable clevises from welded a. Level helicopter and align engine. (Refer to para-
fittings on center frame by removing clevis bolts. graph 5-17.)
5-15
MAINTENANCE
1. Air Intake
2. Support Clamp (On Engine
Mount)
3. Flexible Duct - Cold Air
4. Support Clamp (On Center 22
Frame)
5. Valve Housing 23
6. Valve Actuating Arm
7. Spring
8. Control Cable
9. Cable Support Bracket
10. Filter Housing
11. Flexible Duct - Hot Air
12. Lock-pin
13. Clamp
14. Seal Pan
15. Exhaust Manifold Shroud
16. Support Assembly
17. Temperature Bulb Location
18. Drain Tube
19. Duct Elbow (To Carburetor)
20. Spacers and Capscrews (4)
21. Flexible Duct
22. Adapter
23. Clamps
47615-15
Figure 5-33. Air Induction System

5-16
MAINTENANCE
b. Shorten each cable, by adjusting clevis end, until c. Lugs on adapter stacks or manifolds can be re-
snug without pulling engine out of alignment. Check placed by welding new lugs to either part. The tail
that eyebolts or fittings at engine end of cables are section of manifold may be repaired by welding on
aligned to direction of cable pull-off. Lengthen each a new section of tubing.
cable 6 1/2 turns and tighten lock-nut.
c. During flight, check for bottoming of safety cables d. Cracks in shroud can be stop-drilled and ptched.
as indicated by a characteristic pounding vibration,
present only when executing banking turns. If this e. Burned out parts and damage other thanthatlisted
condition exists, inspect Lord mounts for improper
installation or deterioration. Lengthen safety cables INSTALLING EXHAUST STACKS
as necessary to prevent bottoming.
Note
5-31. EXHAUST STACKS. Note
5-32. DESCRIPTION. The exhaust system consists of Exhaust stacks may be installed with or
six short adapter stacks, mounted by flanges at each
cylinder exhaust port, and right and left manifolds
which collect exhaust gases from eachbank of cylinders a. Install a gasket and short adapter stack on studs
for discharge through tubes extending aft and outboard
from the engine compartment. Manifolds and adapter up on odd-numbered cylinders and down on even-
stacks are made of stainless steel alloy tubing and numbered cylinders. Install washers and nuts on
are connected by bolts through matching lugs at an studs, not fully tightened until manifolds are installed.
expansion joint. A metal shroud is installed on left
manifold to provide heat for the carburetor air intake. b. Check that shroud is clamped securely on mani-
fold. Slip manifold on ends of adapter stacks, align
5-33. REMOVING - EXHAUST STACKS. matching lugs on stacks and manifolds, and install
bolts, washers and nuts. Tighten nuts finger-tight
a. Disconnect heated air intake or flexible duct from and install cotter pins. Tighten nuts on studs at
shroud on manifold. stack flanges. (150 inch-pounds.)
Note c. Connect flexible duct or heated air intake to

exhaust shroud.
Manifold and stack assembly can be re-
moved as a unit from exhaust port studs, 5-37. AIR INDUCTION SYSTEM.
or by the following procedure.
5-38. DESCRIPTION. This installation which con-
b. Remove cotter pins, nuts, washers and bolts from sists of a single ring-shaped filter, located between
lugs on manifolds and adapter stacks. Tap with a soft heat control valve and carburetor, to filter air from
hammer to loosen and pull manifolds aft off adapter intakes located above right-hand forward side of
stacks. engine and at shroud on left-hand exhaust manifold
supplies a variable mixture of heated and unheated
c. Remove nuts and washers from studs at adapter filtered air to the carburetor.
stack flanges and remove adapter stack and gasket
if existing from exhaust port of each cylinder. Cover 5-39. REMOVAL - AIR INDUCTION SYSTEM.
exhaust ports. (Figure 5-33.)
5-34. INSPECTION - EXHAUST STACKS. a. Remove temperature bulb and disconnect drain
line from elbow below carburetor. Disconnect con-
a. Inspect manifolds and adapter stacks for security trol cable from valve arm and bracket.
of installation, dents or cracks.
b. Loosen clamps and remove flexible duct between
b. Inspect shroud for security of attachment and for
cold air intake scoop and heat control valve. Leave
support clamps attached to structure unless removal
is necessary. Remove flexible duct between heat
control valve and shroud on left-hand exhaust mani-
fold. Remove air intake scoop.
a. Replace gaskets at cylinder exhaust ports at Note
engine change.
b. Repair small holes or cracks inexhaust manifolds If removing filter and valve assembly only,
or adapter stacks by accepted welding practices. If remove four nuts attaching flange of filter
exhaust flange is welded, file or machine to provide housing to support and remove assembly
a flat seat against gasket. and gasket. Cover openings.
5-17
MAINTENANCE
c. Cut lockwire and remove bolts attaching flange applying shellac over tape and at least 1/2 inch
of elbow to bottom of carburetor, beyond taped area. Replace duct, if so repaired, as
soon as possible.
d. Cut lockwire and remove bolts attaching support
to engine crankcase. Remove filter and support as-REASSEMBLY - AIR INTAKE ASSEMBLY.
5-43. REASSEMBLY - AIR INTAKE ASSEMBLY.
sembly and spacers. (Figure 5-33.)
(Figure 5-33.)
5-40. DISASSEMBLY - AIR INTAKE ASSEMBLY.
a. Install cotter pin through hole in valve actuating
a. Remove nuts from bolts attaching filter housing rod near armand place washer on rod against
of to
flange
flange to aft end of aft endand
support,
support, remove filter
and remove filter and
and cotter pin. Insert flapper through filter housing to
valve assembly and gasket. position in valve housing, with hinge aligned between
bushings and flapper closed against hot air intake.
b.
b. Remove
Remove lock-pins,
lock-pins, release
release clamps,
clamps, and
and remove
remove Align rod so that arm with larger hole points up and
insert rod
left (45 degrees to flapper) and insert rod through
through
seal pan from filter housing. Remove filter element. housing and flapper
flapper hinge. Install washer and cotter
pin on end of rod.
c. Remove spring from valve arm. Remove cotter
pin
pinand
and washer
washer from
from aft
aft end
end of
of valve
valve actuating
actuating rod
rod b. Assemble adapter, short flexible duct, and elbow,
and pull rod from
fromrod flapper
pull flapper and
and housing.
housing. Remove
Remove and secure clamps at each end of duct. Check security
washer and cotter pin from rod. Remove flapper
washer and cotter pin from rod. Remove flapper of retainers over bolt heads at adapter flange, and
through filter housing. place gasket on flange. Place assembly in support
5-41. CLEANING - AIR FILTER. Clean filter daily with bolt passing through aft end of support.
when operating in dusty conditions, otherwise at
every 25 hours. c. Place gasket and filter housing flange on bolts
at aft end of support and install washers and nuts.
/a. Pull lock-pins, release clamps, and remove seal
pan from housing. d. Place filter element in housing. Install seal pan,
b. Remove filter element and shake off loose dirt engage clamps, and secure clamps with lock-pins.
by rapping on hard surface.
5-44. INSTALLATION - AIR INDUCTION SYSTEM.
(Figure 5-33.)
CAUTION
a. Lift assembled support, adapter, and filter into
Do
not wash filter element in any liquid aft engine compartment. Align support with existing
blow to Doattempt
not off
or soak in oil. Do not attempt to blow off
holes in crankcase cover (On new engine, remove
dirt with compressed airttempt to blow second and fourth studs from bottom) and install
mounting bolts, with spacer on each bolt between
c. Clean out filter housing by wiping with cloth
support and crankcase cover. Lockwire bolts in
moistened with unleaded gasoline. When dry, rein-
stall filter element and seal pan, securing clamps b.Install gasket and
b. Install gasket and secure elbow to
secure elbow to carburetor
carburetor
and lock-pins. with four bolts, lockwired inpairs. Install temperature
5-42. REPAIR OR REPLACEMENT - AIR INDUC- bulb in left side of elbow. Connect drain line to fitting
TiON SYSTEM.
TION SYSTEM. on underside of elbow.
c. Install flexible duct between heat control valve

a. Surface scratches or small dents which might
occur in the system are negligible. Cracks may be and shroud on left exhaust manifold, securing with
repaired by welding.
d. Install cold air intake scoop by bolting to clamps
on upper right forward tubes of engine mount. Install
repaired by drilling the hole to the nearest bolt flexible duct between intake scoop and heat control
size and inserting a shallow head screw in the hole,
with the head on the inside and nut on the outside.withthehead
valve,
ontheinside
secured
andnuton
attheeach
outsideend by clamps and supported
Holes
inch
larger
maythan
be 1/4
repaired
Holes larger than 1/4 inch may be repaired by by clamps on engine mount and center frame tubing.
cutting out the damaged area and installing a patch
of similar material. The patch may be either welded e. Connect control cable clevis to actuating arm of
or riveted in place. heat control valve, using clevis pin and cotter pin.
Clamp cable sleeve to support bracket on housing.
c. Holes or tears in flexible duct may be repaired Install spring between valve arm and bracket. Check
temporarily by wrapping the damaged area with tape, for proper adjustment and operation.
5-18
Model 47G-2 BELL HELICOPTER COMPANY Section V(Part 2)
MAINTENANCE
5-45. CARBURETOR MIXTURE AND HEAT CONTROL. c. Screw clevises on aft ends of control cables,
tighten lock-nuts and connect cables to carburetor
5-46.
5-46.DESCRIPTION.
DESCRIPTION. The
The carburetor air-heat and
carburetor air-heat and mixture lever and heat valve control arm. Install
mixture control quadrant is mounted on left side of
instrument
instrument column. Levers have
column. Levers have sufficient
sufficient friction
friction bends in cable. Check control levers for full travel
loading to remain in any desired position and are
connected to carburetor and heat control valve by and freedom of movement. Adjust cable length at
push-pull cables. Mixture control lever is moved
to top of quadrant for "Full Rich" and downward
With carburetor heat control at OFF position, flapper
valve should be visually checked, to ensure that it is
The heat control lever is moved to top of quadrant
to supply cold air to the carburetor and to bottom seated firmly to close off all hot air. With carburetor heat
of quadrant for
of quadrant heated air.
for heated Intermediate positions
air. Intermediate positions control at FULL HEAT position, flapper valve should be
will supply corresponding mixtures of cold and visually checked, to ensure that is is seated firmly to
heated filtered air to carburetor. closeoff all outsideair
5-47. REMOVING - CARBURETOR MIXTURE AND 549. THROTTLE CONTROLS.
HEAT CONTROLS.
5-50. DESCRIPTION. The carburetor throttle is
a. Disconnect control cable devises from mixture manually controlled through the collective pitch con-
lever on carburetor and heat control valve arm. trol stick, which is geared to a torque tube operating
Remove clip from carburetor bracket. Loosen lock- inside the collective pitch control torque tube. Rotation
nuts and unscrew clevises from control cables. of the control stick grip is transmitted through a
Remove clamps that secure cables to structure. push-pull tube, throttle cam box, and an enclosed
b. Remove access panels from cabin box beam and cable to move the carburetor throttle arm. The
remove clips that secure cables to box beam. Open throttle is synchronized, by cam box action, so that
instrument panel and remove clips holding cables movement of the control stick to increase or de-
to instrument column. crease main rotor pitch also changes throttle setting
to provide more or less power as required.
Note
If altitude compensating carburetor is in-
stalled, remove spring from bracket and
For overhaul procedures on collective
pitch and throttle control assembly, refer
c. Disconnect clevis and rod end from control to Section VII.
levers. Loosen lock-nuts and unscrew clevis and
rod end from cables. Remove bracket holding cables 5-50A. CAMBOX. (Figure 5-35.)
to outside of instrument column.
a. Disassemble Cambox (Model 47G2, serial Nos.
d. Pull cables through grommet in instrument column, 1459 through 2478.)
through cabin box beam and remove from helicopter.
1. Cut lockwire, remove four screws (15, figure 5-35)
5-48. INSTALLING - CARBURETOR HEAT AND and washers (16) which secure cover assembly (11) to
MIXTURE CONTROLS. housing assembly (3), cut lockwire from roll pin (14) at
a. Push forward ends of control cables through shaft assembly (1) and remove roll pin (14).
cabin box beam, up through instrument column and
out through grommet on left side of column. Screw 2. Cut lockwire and remove roll pin (5) from the
clevis on mixture control cable, rod end on heat center of lever assembly (4).
control cable, and secure lock nuts. Connect mixture
control cable clevis to mixture control lever, using 3. Check bearing (10), cam (7), bushings (2) for
clevis pin (with head inboard) through second hole wear and rivets (9) at cam bushing (8) for tightness.
from end of lever. Connect rod end heat control
cable to second hole from end of heat control lever, b. Reassemble cambox.
using clevis bolt (with head outboard) and low castle
nut. 1. Insert throttle cam shaft (6) into arm (4), in-
stall roll pin (5) and lockwire roll pin (5). Insert end
b. Install bracket on left side of instrument column of shaft (6), into housing assembly (3).
and install clips securing cables toinstrument column
and cabin box beam. Close instrument panel and 2. Insert bearing (10) into cam assembly (7). Posi-
install
install access
access panels
panels on box
box beam.
beam. tion arm (4) over the bearing (10) and insert throttle
Note control shaft assembly (1) through housing assembly
(3), arm (4), bearing (10) and cover assembly (11).
If altitude compensating carburetor is in- Install roll pin (14) into shaft assembly (1) and lock-
stalled connect spring to bracket and mix- wire roll pin (14). Install screws (15), washers (16)
ture control lever. and lockwire screws (15).
Rev. 3 5-19
MAINTENANCE
2. Cable Conduit 17. Cam Shaft Lever

3. Swivel Assembly 18. Cam Box
4. Support Bracket 19. Cam Follower Lever
6. Inner Slider 21. Brackets

7. Sliding End Assembly 22.
21. Sliding End Assembly
Brackets
11.
3. Throttle
Swivel Shaft
Assembly 26.
18. Gear
Cam Housing
BoxShaft Lever (Eyebolt) 47631-36
8. Lock Plug 23. Control
9.
4. End
Rod - End
Support
Rod Bracket 24.
24.
20. Lock
Lock Nut
Nut
Seat - Back Structure
10. Throttle Lever 25. Spacer
Spacer
11. Throttle Shaft 26. Gear Housing
12. Stop Arm 27. Pitch Control Tube
13. Idling Stop Screw 28. Throttle Control Shaft
14. Support Bracket 29. Collective Pitch and Throttle Control Stick
15. Swivel Assembly
47631-36
Figure 5-34. Throttle Control Installation

5-20
MAINTENANCE
5-50B. CAMBOX. (Figure 5-36.) (Model 47G-2, 5-51. REMOVING - THROTTLE CONTROL LINK-
Serial Nos. 2556 through 2570.) AGE.
a. Disassemble cambox. a. Remove cotter pin, nuts, washers and bolts that
secure each end of rod connecting jackshaft throttle
1. Remove screws (4), and washers (3), from lever and cam box lever. Remove rod.
cover (5). b. Disconnect control cable from lever on cam box.
2. Remove nuts (22), washers (21), spacers (15), Remove cotter pin and washer from cam box shaft
washers (12) and screws (11). Remove cover half (5), at bracket on center frame. Remove nuts ove
andwashers
plates (13), (18) and cam (16) from bolts attaching cam box to firewall. Remove
cam box. (See figure 5-35 for disassembled view of
3. Remove nut (20) and washers (19), from cam cam box.)
shaft (16). c. Loosen cable retaining lock bolt, unscrew sliding
end assembly from cable end. Remove conduit re-
4. Remove nuts (9), washers (25), from lever cam- taining nut from swivel attached to center frame
box idler (24). bracket.
5. Remove nut (10), and from adapter (31). d. Disconnect control cable from carburetor arm.
Remove nuts and washers from engine studs holding
6. Remove plate (13), cam (16), and assembled bracket and clip. Remove cable assembly.
plate (18). plate (18). 5-52. INSTALLING - THROTTLE CONTROL LINK-
7. Remove nut (26), washer (27), bolt (28), bushing AGE.
(29), cam idler (24), bearing (30), from cam (16).
Note
8. Check bearings in plates (18), (13) and bearing
(30) for freedom of operation, cam (16), adapter (31) Adjustment and installation of throttle
and cam idler (24) for wear. Check rivets (1) in lever control linkage may be accomplished to-
(2), rivets (14) in plate (13) and rivets (17) in cam (16), gether. (Refer to paragraph 5-53.)
for tightness.
b. Reassemble cambox. a. Position cam box assembly to second vertical
tube from right, behind the passenger's seat, with
1. Assemble by inserting bearing (30), into cam end of shaft through bracket welded to structure.
(16), attach bearing with cam lever Idler (24), bolt (Make sure two brackets are in place on bolts be-
(28), clevis (23), bushing (29) washer (27) and nut tween firewall and center frame tubing.) Insert
(26) (adjust clevis (23) and rod end to 2.10" length). four clevis bolts through cabin firewall, brackets,
and cam box lugs and secure with washers and nuts.
2. Insert lever (2) through hole in cover half (5), Install washer and cotter pin on cam box shaft at
assemble plates (18), (13), cam (16) and attach with left side of support bracket. Operate cam shaft
washer (19) and nut (20) lever to check for possible binding, while tightening
attachment bolts.
3. Install lever cambox idler (24) into bearings in
plates (18) (13) and attach with washers (25) and nuts
b. Install push-pull rod, with adjustable end aft,
between cam box shaft lever and jackshaft throttle
4. Install washers (19) and nut (20) onto cam- lever.
shaft (16).
5. Assemble plates (18), (13), cam (16), and cover c. Install control cable support bracket and clip
on engine studs
half (5), attach with screws (11), washers (12), spacers
(15), washers (21) and nuts (22).
d. Insert cable through swivel assembly mounted on
6. Install cover half (5) over other cover half (5) bracket attached to center frame. Tighten conduit
and attach with washers (3), and screws (4). retaining nut. Place sliding end assembly over cable,
insert cable through locking bolt, and screw sliding
Note end on cable at least to depth of witness hole. Tighten
lock plug. Connect clevis of sliding end to cam box
When installing a new cam (16) (camshaft lever.
is undrilled) position cam (16) and lever (2),
as shown on figure 5-36 of assembled, e. Adjust throttle linkage. (Refer to paragraph5-53.)
view A-A. Connect rod end to throttle lever.
5-20A
MAINTENANCE
0-12 1. Camshaft Assembly 9. Rivet

13 11 2. Bushing 10. Bearing
3. Housing Asse 11. Cover Assembly
4. Lever 12. Roll Pin
5. Roll Pin 13. Lever Assembly
6. Shaft 14. Cotter Pin
5 7. Cam Assembly 15. Screw
3 8. Bushing 16. Washer
15-
16
47631-66
Figure 5-35. Throttle Cambox Disassembled
5-53. ADJUSTING THROTTLE LINKAGE. (Fig- e. Move collective pitch control stick to high pitch
ure 5-13.) position (full up) and rotate grip to full open position,
observing for springing of tube or cam shaft lever
a. Disconnect control cable rod end from carburetor at end of travel. If springing occurs, shorten jack-
throttle arm. Adjust idle stop screw to provide 3/16 shaft lever by half-turns to allow free travel to
inch clearance between face on stop arm and face full open position. Tighten lock-nut on jackshaft
of stop on carburetor. Cut lockwire, loosen lock screw throttle lever after adjustment.
and pull carburetor throttle lever from serrated
shaft. Holding stop arm against idle stop screw, f. Return collective pitch stick to low pitch position
position throttle lever on shaft pointing aft and 45 to and rotate grip full closed.
55 degrees above horizontal center line of shaft. g. Hold carburetor throttle arm in full closed posi-
Tighten lock screw. Lock-wire screw across outboard tion, (up, with stop arm against stop screw). Adjust
side of lever to forward stop arm, then from one end fittings on throttle control cable to allow in-
stop arm to the other across end of shaft. (See detail, stallation to throttle arm and lever on cam box.
figure 5-37.) Check through inspection hole above cable locking
bolt for safe position of cable end. Tighten cable
b. Disconnect push-pull tube from throttle lever on locking bolt.
main rotor pitch and throttle control jackshaft. Adjust
length of lever to approximately 1 53/64 inches from h. Check operation of throttle control through full
surface of outer (pitch control) tube to center of bolt range. With throttle full open and collective stick
hole in lever. full up, check sliding end fitting attached to cam box
lever to make sure end of inner slider is not below
c. Place collective pitch control stick in low pitch lower safet hole in outer sleeve. Check sliding end
position (FULL DOWN)and turn grip counterclockwise at carburetor in same manner, with throttle arm in
(looking at grip end) to full closed position. idle position
d. With cam shaft lever held in full aft (closed) i. Start and warm up engine. (Refer to Section I.)
position, adjust length of push-pull tube to allow With collective pitch control stick held in low pitch
installation between cam shaft lever and jackshaft position (full down), open throttle to obtain 3100 rpm.
lever, shorten rod one turn and install. Close throttle rapidly, and observe tachometer for
5-21
Maximum 8 Washers Between A
Shaft End and Lever.
AND
LINK ADJUSTMENT
LEVER SETTING
MAINTENANCE
1. Rivets 17. Rivets

2. Lever 18. Plate
3. Washers 19. Washer
4. Screws 20. Nut
5. Cover 21. Washer
6. Washers 22. Nuts
7. Spacer 23. Clevis
8. Washers 24. Idler
9. Nut 25. Washer
10. Nut 26. Nut
11. Screws 27. Washer
12. Washers 28. Bolt
13. Plate 29. Bushing
14. Rivets 30. Bearing
15. Spacers 31. Lever
16. Cam
Figure 5-36. Throttle Cambox Disassembled (Sheet 2 of 2)
5-22 A
CLOSED
(IDLING)
CABLE END VISIBLE HERE

BEFORE TIGHTENING LOCK PLUG
1 53/64'
INNER SLIDER MUST ALWAYS

BE VISIBLE HERE
6. Lock Plug
7. Rod End
8. Carburetor Throttle Lever
9. Throttle Shaft
10. Stop Arm
11. Idling Stop Screw
12. Push-Pull Tube
13. Cam Shaft Lever
14. Cam Box
15. Cam Lever
16. Control Shaft Lever
1. Control Cable 17. Locknut
2. Conduit 18. Pitch Control Tube
3. Support Bracket 19. Throttle Control Shaft
4. Inner Slider 20. Collective Pitch and Throttle
5. Sliding End Assembly Control Stick
47631-35
Figure 5-37. Adjusting Throttle Control Linkage
engine rpm stabilizing at 1800 to 1850 rpm while hold engine speed at 3100 rpm within plus or minus
freewheeling (before rotor slows enough to place 50 rpm. If engine underspeeds lengthen control
load on engine). Adjust idle stop screw as necessary. cable by adjusting rod end at throttle lever (or
either sliding end on cable) by half-turns. Correct
Note overspeeding by shortening cable in same manner.
Engine will idle at 1500 to 1700 rpm with 5-54. CARBURETOR.
rotor load on engine.
5-55. DESCRIPTION. Lycoming engines may be
j. During test flight, while hovering with 17 to 22 equipped with two types of carburetors. The Marvel
inches Hg manifold pressure, throttle cam should Schebler, MA4-5, (Setting No. 10-3856) is a single-
5-22 B
barrel float type carburetor which incorporates a 5-60. FUEL TANKS AND SUPPORTS. The fuel tanks
manual idle cut-off and mixture control. The Marvel and supports are mounted to the structure above
Schebler, MA4-5AA, (Setting No. 10-3847) is an and at each side of engine. A float-type fuel level
altitude compensating carburetor which provides a indicator is mounted to upper surface of each tank
more satisfactory fuel-air ratio during high atltitude and is electrically connected to fuel gage on instru-
operations and eliminates manual mixture control. ment panel. The system may be serviced from either
An aneroid type bellows is positioned in the fuel or both sides since tanks are interconnected. If fuel
bowl housing to control all fuel passing through the is spilled during refueling operations, excess fuel
main fuel metering jet. The bellows, sensing the drains into a well formed by the firewall, and is
atmospheric pressure change at all altitudes, re- discharged through a drain line. Fuel drains are
positions the main metering needle valve thus pro- provided at each tank and at strainer which serves
ducing the correct fuel-air ratio at the main nozzle both tanks.
outlet. The mixture control, which was previously
used during flight to vary fuel mixture or as an 5-61. REMOVING - FUEL TANKS AND SUPPORTS.
idle cut-off when shutting down the engine, has been
repositioned and with this installation is strictly an a. Disconnect battery. Drain fuel from system.
idle cut-off mechanism.
b. Disconnect vent line from top of tank, loosen
5-56. REMOVING- CARBURETOR. supporting clamps and rotate line out of way. Dis-
connect wire from fuel level transmitter. Disconnect
a. Remove air induction system. (Refer to para- tank drain line from drain valve. Disconnect fuel line
graph 5-37.) from tank outlet.
b. Disconnect throttle control cable from carburetor Note
arm. Remove mixture control cable clip from bracket.
To remove fuel tank only, follow step c. To
c. Disconnect fuel inlet line. Remove nuts and wash- remove tank and support as an assembly,
ers and remove carburetor from engine. omit ste c and proceed to step d.
c. Remove tank drain valve. Disconnect bonding
5-57. INSTALLING - CARBURETOR. jumper between forward end of tank and support.
Cut lockwire and disconnect strap turnbuckles. Lift
a. Install support bracket for mixture control cable tank from support. Remove opposite tank in same
on carburetor cover, pointing to left and secured by manner.
existing screws. Install adapter and elbow (pointing
in right
up and aft) in inlet port.
right inlet port. d. Remove bolts attaching interconnecting firewall
to support. Remove bolts from support brackets
b. Position gasket and carburetor flange on mounting aft of cabin firewall and nut andwasherfrom through-
flange on mounting studs, and secure with washers bolt at engine mount bracket. Lift tank and support
and nuts. assembly from helicopter. Remove opposite tank
and support in same manner.
c. Connect fuel inlet hose from strainer to elbow
in carburetor 5-62. REPAIR OR REPLACEMENT - FUEL TANKS
AND SUPPORT ASSEMBLIES.
d. Connect control cable to carburetor mixture arm
and secure support clip to bracket. Connect throttle
control cable to throttle lever.
Operators in territorial United States make
e. Install air induction system. (Refer to paragraph repairs or replacement in accordance with
5-44.) Civil Aeronautics Manual 18. Helicopters
operated outside Territorial United States
f. Check adjustment of throttle controls. (Refer to should be repaired according to instruc-
paragraph 5-53.) Check adjustment of heat and mix- tions issued the licensing authority.
ture controls. (Refer to paragraph 5-48.) 5-63. INSTALLNG - FUEL TANKS AND SUPPORTS.
5-58. FUEL SYSTEM. (Figure 5-38.) a. Lift support (or tank and support assembly) to
position, inserting forward legs of support between
5-59. DESCRIPTION. The fuel system consists of brackets on structure behind cabin firewall. Align
two interconnected fuel tanks, strainer, shut-off bracket on tank support with aft end of through-bolt
valve, fuel level transmitters, fuel gage, and lines at engine mount bracket and install washer and nut.
and fittings. Fuel flows by gravity from tanks through Place lower end of brace tube against inboard side
shut-off valve and fuel strainer to carburetor. of inboard bracket at cabin firewall and install bolt
5-23
MAINTENANCE
Figure 5-38. Fuel System Diagram _______47680-3
11. Filler
Filler Caps
Caps 7. Fuel Strainer
2. Tank Vent Lines 8. System Drain
3. Fuel Tanks 9. Tank Sump Drains
4. Tank Fuel Strainer 10. Carburetor Air Control Valve Drain Line
5. Fuel Level Indicator 11. Carburetor (Ref.)
6. Fuel Shutoff Valve 12. Fuel Shutoff Control
Figure 5-38. Fuel System Diagram

5-24
MAINTENANCE
through brace, bracket and support leg. (Upper end c. Connect drain line to valve below strainer.
of brace is bolted to tank support structure near
forward end.) Install bolt through outboard bracket d. Open shut-off valve, by pushing in (aft) on control
and support leg. Align holes in interconnecting fire- knob at left of pilot's seat. Check for leaks and flow
wall and support and install bolts (from top), washers to carburetor.
and nuts.
5-67. REMOVING - FUEL STRAINER AND SHUT-
Note OFF VALVE.
If tank was removed from support, follow a. Disconnect battery, drain all fuel from system.
step b.
b. Remove pin and pull valve actuating arm from
b. Lift tank into support, insert drain fitting through shaft.
grommet in support, and install drain valve. Connect
fuel line to tank outlet. Connect, tighten and lockwire d. Disconnect fuel line from elbow on aft side of
tank strap turnbuckles, with pads in place on straps. strainer.
Connect bonding jumper between forward end of sup-
port and bracket on tank. e. Remove bolts attaching strainer and sump-fire
wall to support.
c. Connect drain line to tank drain valve. Connect
vent line to top of tank and tighten support clamps. f. Disconnect fuel lines from interconnecting tee.
Connect wire to fuel level transmitter. Install op- Remove strainer, valve and adapter fittings as an
posite tank and support in same manner. assembly.
g. Remove adapter fittings and separate valve and
5-64. FUEL STRAINER AND SHUT-OFF VALVE. strainer.
A shut-off valve and a fuel strainer, located above
and aft of carburator, are incorporated in the fuel 5-68. INSTALLING - FUEL STRAINER AND SHUT-
line between tanks and carburetor. The shut-off OFF VALVE.
valve is manually controlled by a cable connected
between valve actuating arm and a knob located at a. Assemble strainer, valve and adapter fittings.
the left of pilot's seat. When knob is pulled out full
(forward) b. Position assembly to support with valve shaft
(forward) flow
flow of of fuel
fuel to
to carburetor
carburetor is
is stopped.
stopped. extending up through hole in support. Align mounting
The strainer filters fuel and traps sediment and holes and install bolt through aft holes in support
water. and strainer.
5-65. REMOVING - FUEL STRAINER BOWL AND c. Connect flexible hoses from tank to tee fitting.
SCREEN.
d. Lift aft end of firewall to align mounting holes,
a. Close shut-off valve by pulling out (forward) on and install bolt through firewall brackets and support.
knob at left of pilot's seat.
e. Position actuating arm on valve shaft and install
b. Disconnect drain line from valve at bottom of clevis pin and cotter pin.
strainer.
f. Connect flexible hose from carburetor to aft side
c. Cut lockwire and loosen bowl retaining screw of strainer.
at bottom of strainer.
g. Connect drain line to valve on bottom of strainer.
d. Swing pivoted bowl support forward. Remove
strainer sump bowl, screen and gaskets. h. Check shut-off valve and control for proper
operation. Service fuel tanks and check for leaks.
e. Clean parts by washing in gasoline with soft
bristle brush or blow clean with compressed air. 5-69. COOLING SYSTEM.
5-66. INSTALLING - FUEL STRAINER BOWL AND 5-70. DESCRIPTION. The cooling system consists of
SCREEN. a belt-driven fan, cylinder baffles and cooling shroud,
and supplies cooling air to oil cooler, engine and
a. Assemble bowl and sump, with gasket between electrical junction box.
parts, and place screen in assembly.
5-71. COOLING FAN AND SUPPORT. (Figure 5-39.)
b. Position bowl and screen under strainer top, with The fan assembly consists of fan, hub and bearings,
gaskets in place and drain valve aft. Swing support support, index plate, and shroud support. The index
into place, tighten and lockwire retaining screw. plate provides adjustment of fan belt tension.
5-25
MAINTENANCE
1. Grease Fitting
2. Shaft
3. Retaining Nut
4. Washer 8
5. Pulley
6. Belts
7. Rings (3)
8. Fan
9. Shroud Support
10. Spacer
11. Hub
12. Index Plate 6
13. Fan Support
14. Retainer
15. Locking Pin Handle
16. Locking Pin and Spring
17. Bearing (Shield Aft)
18. Spacer
19. Bushing
20. Bearing (Shield Fwd.)
21. Nut (Lockwired)
Use minimum shims needed to align support.

Maximum on one stud .062".
47661-12
Figure 5-39. Cooling Fan and Support Installation

5-26
5-72. REMOVING - COOLING FAN AND SUPPORT. c. Balance fan after replacement of parts. (Refer
to paragraph 5-78.)
a. Remove fan belts. (Refer to paragraph 5-81.)
5-77. REASSEMBLING - COOLING FAN AND SUP-
b. Remove
b. Remove (Refer to
shroud. (Refer
cooling shroud
cooling to paragraph
paragraph PORT
PORT.
5-86.)
c. Remove nuts and washers (bolts on -A1A engine) a. Place spring on locking pin, insert pin in recess,
which hold fan support to engine. Lift fan and support extending through support casting into handle, and
assembly through left side of engine compartment. install cotter pin through handle and pin.
5-73. DISASSEMBLING - COOLING FAN AND SUP- b. Place retainer in fan support from aft side. Place
PORT. index plate, with shaft forward, and shroud support on
a. Remove grease fitting from end of shaft. Cut plate, with shaft forward, and shroud support on
lockwire, remove nut and washer, and slide fan as- front face of fan support. Align holes and install
sembly from shaft. four bolts, with thin aluminum alloy washers under
heads, through shroud support and index plate into
b. Remove nuts and washers, and remove pulley threaded holes in retainer. Lockwire bolt heads.
from front and bolts and bearing retainer from aft
side of hub. Slide bearings and spacer from hub.
c. Insert single-row bearing, shielded side aft,
seating outer
into hub from aft side, seating against
outer racerace
c. Match-mark parts before disassembling fan from aat
hub. Remove bolts and separate rings, fan, and shoulder in hub bore. Place bearing retainer on aft
bolts and separate rings, fan, and side of hub, align holes, and insert bolts through
spacerRemove
hub. from hub.
retainer and hub. (Do not use washers under bolt
d. Cut lockwire heads.) Lay hub assembly face up. Place spacer
double-row
d. Cut lockwire, remove bolts joining shroud sup-
port, index plate and retainer. Separate parts. in hub on inner race of bearing. Install double-row
bearing, shielded side forward, in hub against spacer.
Install pulley on bolts and secure with washers and
e. Remove cotter pin through handle and remove
locking pin and spring from front of support. nuts.
5-74. CLEANING - COOLING FAN AND SUPPORT. d. Assembly three rings on front of fan and install
Clean parts by wiping with a clean cloth damp with bolts, with heads aft and thick washer under head and
dry cleaning solvent or kerosene. Bearings may be under nut (except as additional washers are required
washed in cleaning solvent and dried with filtered for balancing)
compressed air. Relubricate bearings to prevent
corrosion.
e. Position spacer and fan and ring assembly on
5-75. INSPECTION- COOLING FAN AND SUPPORTS. front of hub and install bolts, with head aft and thin
washer under nut only.
a. Inspect fan for cracks, nicks, alignment and
balance.
f. Balance fan. (Refer to paragraph 5-78.)
b. Inspect hub for cracks or damage.
g. Slide fan assembly on shaft. Install washer and
c. Inspect bolt holes for elongation. Check shaft for nut, torque 75 to 100 inch-pounds, and lockwire nut
cracks, nicks, scratches, or wear. Inspect fan sup- to drilled hole in shaft end. Install grease fitting
port for cracks. in end of shaft and lubricate hub.
d. Inspect bearings for excessive wear, roughness,
and lubrication. 5-78. BALANCING - COOLING FAN. Slide a suit-
5-76. REPAIR OR REPLACEMENT - COOLING FAN able shaft through hub bearings (bearings dry) and
AND SUPPORT. support shaft on a knife-edge stand, in a wind-free
area. Statically balance fan assembly by the addition
a. Repair fan blades by polishing out nicks and of AN960-10, AN960-10L, or AN970-3 washers to
scratches. Replace fan if depth of nicks or scratches the front or back side of AN3-3A bolts. A maximum
exceeds limits. (See figure 5-17.) of two washers may be added to each bolt. Only one
washer may be added to the front of each bolt. If
b. Replace all unserviceable parts. The fan support two washers are added, one must be on the back of
and retainer must both be replaced with current spares bolt. Replace AN3-3A bolt with AN3-4A bolt, if
replacement parts when either part is unserviceable necessary. To obtain fine balance No. 50 (0.070)
on helicopters prior to Serial No. 1459. Helicopters inch diameter holes may be drilled in AN970-3
Serial No. 1459 and subsequent have current parts and washers. Maintain fan blade run-out to 1/32 inch
may be replaced as required. maximum.
5-27
MAINTENANCE
5-79. INSTALLATION - COOLING FAN AND SUP- 5-80. FAN BELTS. A length-matched set of two
PORT. V-type belts transmit power from the transmission
fan pulley to the fan pulley. Each belt is constructed
a. Lift assembly through left side of engine com- of a heat-resistant, static-conducting, mildew-in-
partment. Position support, with adjusting handle at hibited envelope enclosing a molded rubber core with
left, on three studs on front of engine case and in- tension members of synthetic fiber.
stall nuts and washers (bolts on -A1A engine). AID
engines require 2 No.70339 spacers. Check align- REMOVING - FAN BELTS.
ment of fan pulley with drive pulley on transmission.
Adjust pulley alignment as closely as possible, not
to exceed 7/32 (.218) inch maximum misalignment, a. Loosen clamp bolts on each side of fan shroud
by installing minimum necessary amount of shims support ring.
on studs between engine case and support legs,
using not more than one full shim thickness (0.062 b. Unsnap cooling shroud on left side of engine.
inch) under any support leg. Pull aft on handle to disengage locking pin from
index plate. Rotate shroud support ring upward to
b. Install cooling shroud. (Refer to paragraph 5-88.) release belt tension.
c. Install and adjust fan belts. (Refer to paragraphs c. Remove belts.

5-83 and 5-84.)
Note
d. Lubricate fan hub through grease fitting. (See
Lubrication Chart, Section I.) Do NOT force belt over rim of pulley.
5-28
MAINTENANCE
5-82. CLEANING - FAN BELTS. Wipe dirt, grease tension. If pin falls between two holes at proper
or oil from fan belts with a clean cloth. Do not use tension, use hole which provides less tension.
cleaning solvent.
c. If tension of belts is unequal, check alignment of
pulleys, adjusting shims under support legs as nec-
5-83. INSTALLING - FAN BELTS. essary. (Refer to paragrpah 3-79.) In some cases,
unequal tension can be corrected by exchanging
positions of belts. If condition cannot be corrected
by these methods, replace belts with a matched set.
d. After adjustment, tighten shroud clamp ring bolts
not apply preservative oil or com- and secure shroud fasteners to engine.
pounds to fan belts. Replace belts in
matched sets only. Make certain index e. After installation of new fan belts, check belt ten-
plate is in maximum up position before sion every few hours and readjust until tension be-
installation of belts. comes constant. (Refer to figure 5-20.) (Lycoming
Engine.)
a. Place belts over drive and fan pulleys. 5-85. COOLING SHROUD AND BAFFLES. The cool-
ing shroud and baffles enclose the forward side of
b. Adjust belt tension. (Refer to paragraph 5-84.)
c. Snap fasteners securing cooling shroud to engine. around the cylinders and to the oil cooler
Make certain shroud clamp ring is seated in groove REMOVING - COOLING SHROUD AND BAF-
of support. Tighten bolts in clamp ring.
5-84. ADJUSTING FAN BELTS. Check beltsfor equal a. Remove fan belts. (Refer to paragraph 5-81.)
and proper tension by hooking a spring scale between b. Disconnect junction box blast tube from bottom
pulleys and measuring deflection of belt when pre- of shroud. Loosen clamp ring screws at each side
scribed pull is applied. (Figure 5-20.) of shroud support. Slip clamp ring from groove.
a. If adjustment is required, unsnap cooling shroud c. Unsnap fasteners from baffles and remove shroud
fasteners on left side of engine. Loosen clamp ring from engine.
bolts at each side of fan shroud support.
d. If necessary to remove baffles, disconnect springs
b. Pull aft on handle at left side of fan support to and cable from top and bottom baffles at front of
disengage locking pin from index plate. Grasp left engine. Cut lockwire and remove bolts, washers and
side of fan shroud support and rotate downward to spacers that hold baffles to engine. Keep bolts,
tighten, or upward to loosen belts. Allow locking pin washers and spacers together for reinstallation in
to engage index plate hole which provides proper original locations.
5-29
MAINTENANCE
5-87. REPAIR OR REPLACEMENT - COOLING After circulation through engine and transmission, oil
SHROUD AND BAFFLES. returns to sump on bottom of engine. An internal
scavenger pump picks up oil from sump and returns
a. Surface scratches, dents and small irregularities it, through external lines and oil cooler, to supply
in metal baffles to which fabric shroud is attached tank. (On V0-435-A1A engines only: An external
may be considered negligible. Small cracks may be filter is installed in line between pump and cooler.
stopped by drilling a small hole at end of crack. The supply tank is vented by a line from top of
Larger cracks may be repaired by stop-drilling ends tank to right side of accessory case, forward of
of crack and applying a lay-on patch of like material starter mounting pad.) The systemis serviced through
and gage. the supply tank filler cap, accessible from right side
of engine compartment. Tank capacity is 8 US (6.6
b. Small holes or tears in fabric shroud may be Imp.) quarts, capacity of complete system is 14 US
repaired by stitching with cotton thread or by sewing (11.7 Imp.) quarts, including trapped and residual
a patch of like material on outside of shroud. oil. Drain supply tank through drain valve and line,
and by removing cap from tee fitting at outlet. Drain
5-88. INSTALLING - COOLING SHROUD AND engine sump by removing sprag mount swivel plate
BAFFLES. and spindle for access to plug. AIDengines remove
plug and drain sump. Drain cooler and line by re-
a. Place side sections of baffles on rocker box moving cap from tee located at lowest point between
flanges, forward of covers, align with existing holes, pump and cooler.
and install bolts and washers. Place upper sections
of baffle above top cylinders from aft side, remove 5-91. SUPPLY TANK
existing rocker box cover screws which align with
holes in baffle, and install bolts, to pass through 5-92 DESCRIPTION. A welded aluminum alloy oil
washer, baffle, spacer, and washer before entering supply tank, with capacity of 8 US (6.6 Imp.) quarts,
holes in rocker box cover. Install bolt through flange is mounted in a support bracket on center frame
of baffle into right side of engine case, with spacer structure aft of engine. Filler cap is accessible
between baffle and case. Connect two springs across from right side of engine compartment, and has a
front of engine case, hooked to forward inboard ends dip stick for measuring il level. Openings are pro-
vided for connection of inlet, outlet, drain, and vent
b. Install lower sections of baffle in same manner
as for upper section. Install two plates between and
forward of rocker box covers at each side of engine, 5-93. REMOVING- OIL SUPPLY TANK.
with wider ends forward, each attached by four bolts
in rocker box cover holes, (install bolts to pass a. Drain oil from tank by removing cap from tee
through washer, baffle, spacer, and washer before fitting below tank and by opening drain line valve.
entering hole in cover). Lockwire all bolts. Disconnect inlet, outlet, drain, and vent lines from
tank.
c. Install fan belts. (Refer to paragraph 5-83.)
5-94. CLEANING - OIL SUPPLY TANK.
d. Connect blast tube on lower right side of shroud.
Snap shroud fasteners to engine baffles and oil cooler. a. Clean the outside of the supply tank by wiping
Tighten shroud clamp ring. with a cloth damp with cleaning solvent or kerosene.
5-89. OIL SYSTEM. (Figure 5-40.)
b. Flush the inside of tank with any good petroleum
5-90. DESCRIPTION. Oil is supplied from an ex- solvent, and allow to drain thoroughly before rein-
ternal tank to the engine oil pump, located at aft stallation.
right side of engine accessory case. The pump
housing incorporates a full flow filter, a check valve 5-95. REPAIR- OILSUPPLY TANK.
to prevent gravity flow from tank to sump when
engine is not operating, and an adjustable pressure
relief valve to regulate oil pressure within operating
limits (65 to 85 psi under normal operating condi- Note
tions). Oil from pressure pump is distributed through
internal passages to upper end of engine and to ac- Operators in territorial United States
cessory case, and through an external line to the make repairs or replacement in accord-
transmission. The oil pressure gage line is con- ance with Civil Aeronautics Authority
nected to the transmission supply tee fitting on pump Manual 18. Helicopters operated outside
housing. Temperature bulbs installed in pump housing territorial United States of America will
and transmission case are electrically connected to be repaired in accordance withinstructions
oil temperature indicator on cabin instrument panel. authorized by the licensing authority.
5-30
MAINTENANCE
7. Line - Tank to Pump Inlet

8. Return Line - Pump to Cooler
9. Cooler
10. Drain Tee
11. Oil Pressure Gage Line
12. Engine Breather
13. Return Line - Cooler to Tank
14. Line - Transmission Fan
Drive Gear Supply
15. Line - Pump to Transmission
on Detail View of Pump:
16. Sump Drain Plug
17. Engine Sump
18. Temperature Bulb Location
19. Filter Cover Nut
20. Pump Outlet
21. Tee - Transmission Supply
and Pressure Gage Lines
22. Pressure Relief Valve Adjustment
23. Pump Inlet 47670-25
Figure 5-40. Oil System

5-31
MAINTENANCE
5-96. INSTALLING - OIL SUPPLY TANK. 5-99. REMOVING - OIL COOLER.

a. Drain cooler by removing lower section of oil in-
a. Position tank in straps attached to the support let line just below cooler.
bracket. (Makesure strap pads are in place.) Tighten
turnbuckles just enoughto hold tank. b. Remove return oil line from cooler to tank at cool-
er fitting.
b. Turn tank to align fittings and connect inlet, drain
and vent lines. Tighten strap turnbuckles securely c. Unsnap button fasteners from around cooler duct.
and lockwire.
d. Remove nuts and bolts from attaching brackets
c. Close drain valve, install cap on tee fitting below and remove cooler.
tank, and refull supply tank with recommended grade
oil. e. Remove fiberglas shroud from cooler.
5-97. OIL COOLER. 5-100. CLEANING - OIL COOLER.
Note
5-98. DESCRIPTION. The oil cooler consists of a Clean oil cooler at each normal engine
radiator and a thermostatic control valve. During change. Clean immediately after removal
operation, oil enters at cooler inlet and passes di- from engine, to prevent hardening of
rectly to the outlet. When the oil has heated suf- of sludge. Clean thermostatic valve sepa-
ficiently to close the thermostatic valve, oil is rately from cooler, and use care to keep
directed through the core of the radiator to be cooled dirt or grit from entering valve assembly.
by air from the cooling fan, thus regulating oil In case of internal engine failure, cooler
temperature within operating range. (See figure 5-41.) should be replaced.
OUTLET TO OIL TANK
OIL FLOW WITH OIL FLOW WITH

VALVE OPEN VALVE CLOSED
* OIL INLET 47670-24

47670-24
Figure 5-41. Diagram of Oil Cooler Operation

5-32
MAINTENANCE
a. Remove lock-ring from top of thermostatic valve 71.1°C (130°F) and observe valve for being fully
and valve housing, lift thermostatic valve from cooler extended (closed). Replace valve if necessary.
valve housing.
b. Check O-ring on thermostatic valve for proper
b. Immerse cooler (tubes vertical) in a bath of dry condition and seating. Carefully position thermostatic
cleaning solvent, and allow to stand for five minutes. valve in valve housing of oil cooler, install lock-ring
Maintain vertical position, and move cooler up and in groove at top of valve housing.
down to force solvent through tubes to loosen dirt
and sludge. 5-102. INSTALLING - OIL COOLER.
a. Install fiberglas shroud on cooler.

CAUTION
b. Position cooler assembly in place on structure
and install attaching bolts in brackets.
Do not use solvents which are normally
used to clean copper coolers. These sol- c. Install inlet and outlet lines on cooler.
vents are highly corrosive and will cause
deterioration of aluminum coolers. d. Locate and fasten button fasteners.
c. Remove cooler from bath, and drain tubes in

vertical position. Use an air gun and blow between
tubes from face of cooler to remove foreign particles.
d. Check power flushing equipment for being filled
with proper dry cleaning solvent. Wash and thoroughly
flush equipment if it has previously been used with
other cleaning materials. Connect cooler to flushing
equipment so that pressure will enter at outlet port
of cooler.
Note
Power flushing equipment should be equip-

ped with a suitable filter to prevent recir-
culation of foreign particles, and have a
relief valve set to relieve at 75 PSIto pre-
vent damage to cooler.
Pump solvent through cooler for 20 minutes. This

cleans the inside core and warm-up passage.
e. Drain and refill the flushing equipment with clean

solvent. Repeat the preceding step d. Drain cooler
thoroughly and flush with clean, light lubricating oil
(SAE 10) at a temperature of 71.1°C (160°F).
5-101. TESTING-OIL COOLERAND THERMOSTATIC

VALVE.
Note
Operators in territorial United States make

repair or replacement in accordance with
instructions issuedby the Civil Aeronautics
Authority (Manual 18). Helicopters oper-
ating outside Territorial United States will
be repaired in accordance with instructions
authorized by the licensing authority.
a. Submerge thermostatic valve in warm water and
gradually increase heat until temperature reaches
54.4°C (130°F) and observe valve. (If operating prop-
erly the valve will start to expand.) Increase heat to
5-33
MAINTENANCE
5-103. ADJUSTINGOILPRESSURERELIEFVALVE. engine oil temperature bulb, carburetor air temper-

An adjustable oil pressure relief valve is located on ature bulb, thermocouple lead (aft side of No. 2 cyl-
right side of accessory case, above and aftof starter. inder), and ground cables from each side of accessory
Adjust valve, when pressure under normal operating case. Detach cordage where taped to engine mount.
conditions consistently exceeds 85 psi or is less
than 65 psi, as follows: i. Disconnect control cables from carburetor
mixture lever and support bracket and from carbu-
retor
retor heat
heat control
control valve.
valve. Stow
Stow cable
cable ends
ends clear
clear of
of
a. Observe oil pressure gage reading after running
engine until operating temperatures are normal.
Stop engine. Cut lockwire, loosen lock-nut and turn retor throttle arm.
adjusting screw in or out to increase or decrease
tension on valve spring. Tighten lock-nut. Start j.. Remove
Remove air
air induction
induction system.
system. (Refer
(Refer to
to para-
para-
engine and check pressure gage reading. Repeat
adjustment as necessary. k. Remove exhaust manifolds. (Refer to para-
graph 5-33.)
b. When adjustment is satisfactory, tighten lock- graph 5-33.)
nut and lockwire adjustment screw to crankcase..
1. Remove
Remove lateral
lateral cyclic
cyclic torque
torque tube.
tube. Discon-
Discon-
nect push-pull tubes from fore-aft bellcrankontrans-
5-104. POWER PLANT. mission. (Refer to Section VII, Part II.)
(Model 47G-2, 2556 through 2570.)
(Figure 5-25.) m. Disconnect fan shroud from oil cooler.
n. Attach hoist to hoisting ring and take up slack
5-105. DESCRIPTION. to aid in holding engine in alignment. Remove sprag
(Refer to paragraph 5-2.) mount swivel plate and spindle. (Refer to paragraph
5-20. Disconnect safety cables from center frame
5-106. SPECIFICATIONS- ENGINE. fittings.
o. Lift engine slightly to relieve weight on mount
5-107. TROUBLE SHOOTING. bolts. Remove bolts passing through center frame
(Refer to paragraph 5-4.) bracket and Lord mount at each side of engine mount.
Check that no line, linkage, or electrical lead is con-
5-108. REMOVAL - POWER PLANT ASSEMBLY. nected between power plant assembly and helicopter
structure. Lift power plant clear of helicopter and
a. Disconnect battery. place on a stand.
b. Drain fuel and oil systems. 5-109. DISASSEMBLY - STRIPPING ENGINE.
(Figure 5-26.)
c. Remove fuel tank and support assemblies.
(Refer to paragraph 5-61.) a. With engine supported on a stand, remove
d. Remove main rotor. (Refer to Section II, Part transmission. (Refer to Section IV.)
H.)
b. Remove cooling shroud, fan and support, and
e. Remove mast and controls assembly. (Refer baffles. (Refer to paragraphs 5-72 and 5-86.)
to Section III.) Install hoisting ring, T100089, on studs
at top of transmission. c. Remove engine breather tube and fitting from
left front of engine. Plug opening.
f. Remove short forward section of tail rotor
drive shaft. (Refer to Section VI.) d. Remove sprag safety cables. (Refer to para-
graph 5-26.)
g. Disconnect flexible oil lines at engineoilpump
inlet and outlet; fuel feed line from carburetor inlet; e. Remove starter and engine tachometer genera-
manifold pressure gage line at aft end of flexible line tor. Install cover plates on mounting pads.
below engine; oil pressure gage line from tee on oil
pump; and blast tube from electrical junction box. f. Remove carburetor and install cover plate.
Remove hydraulic pump from mounting pad without Remove throttle lever and carburetor inlet fittings
disconnecting hoses from pump, and stow pump out of for installation on new or overhauled carburetor.
way. Cap or cover all lines and openings.
g. Remove spark plugs and replace with dehy-
h. Disconnect electrical leads from following drator plugs.
accessories or locations; generator, rotor tachometer
generator, engine tachometer generator, starter, mag- h. Remove thermocouple fitting from aft side of
neto (groundleads),transmissionoiltemperaturebulb, No. 2 cylinder.
5-34
MAINTENANCE
i. Remove engine oil temperature bulb, oil pump tee fitting in aft upper side of pump housing, and in-
inlet and outlet fittings, and transmission supply line stall external line between right end of tee and oil
and tee. Plug openings. strainer on transmission upper case.
j. Remove ignition harness brackets and clips, m. Remove plug from aft side of intake manifold
and any other fittings needed on replacement engine. above carburetor mounting pad. Install 90 degree
elbow fitting, pointing up, for manifold pressure gage
k. Lift engine from stand and place on shipping line.
case or suitable support, with drive end raised.
n. Install carburetor, with adapter and 45 degree
1. Remove engine mountandadapter plate assem- fitting in right inlet port. Install mixture control sup-
bly and support brackets. (Refer to paragraph 5-11.) port bracket on existing screws at left side of carbu-
retor cover. (Refer to paragraph 5-48.) If priming
m. Remove lockwire, nuts, and washers around system is not to be used, cap tee in primer line at
base of clutch drive coupling and pull coupling from upper aft side of crackcase.
crankshaft.
o. Remove cover plate and install gasket and
5-110. REPAIR OR REPLACEMENT - engine tachometer generator, with electrical plug
POWER PLANT. facing down, on mounting pad aft of magneto on right
(Refer to paragraph 5-7.) side of accessory case.
5-111. REASSEMBLING - ENGINE BUILD-UP.
p. Remove cover plate and install gasket and
a. Support engine in shipping case or other suit- starter, with electrical connection facing forward,
able support, with drive end raised. on mounting pad on right side of accessory case.
b. Install clutch drive coupling on crankshaft q. Remove cover plate and install gasket and
bolts, securing with washers, nuts, and lockwire. hydraulic pump, with inlet port forward, on mounting
Tap coupling with soft mallet to seat on crankshaft pad on left side of accessory case. If pump was left
flange while tightening nuts. attached to hydraulic system, install after engine is
placed in helicopter.
c. Install adapter plate and engine mount assem-
bly and support brackets on engine. (Refer to para- 5-112. DESCRIPTION. The carburetor idle cut-off
graph 5-16.) (VO-435-A1E omit forward bracket.) and air heat control quadrant is mounted on left side
of instrument pedestal. The air heat control lever
d. Lift engine and place on a stand, has sufficient friction loading to remain in any de-
sired position and is connected to heat control valve
e. Install hoisting plateandringT100089, onstuds by a push-pull cable. The mixture control, which was
at top of transmission. Install transmission. (Refer previously used during flight to vary fuel mixture or
to Section IV.) Install fore and aft bellcrank and as an idle cut-off when shutting down the engine,
support, collective pitch bellcrank and support, and has been repositioned and with this installation is
lateral torque tube support. (Refer to Section VII strictly an idle cut-off mechanism. The heat control
Part II.) lever is moved to top of quadrant to supply cold air
and to bottom of quadrant for heated air. Intermediate
f. Install cooling baffles. (Refer to paragraph positions will supply corresponding mixtures of cold
5-88.) and heated air to carburetor.
g. Install spark plugs. (Refer to engine manu- 5-113. REMOVING- CARBURETOR MIXTURE
facturer's instructions.) Connect leads to plugs and AND HEAT CONTROLS.
secure ignition harness to engine. (See figure 5-27.)
a. Disconnect control cable clevises from mix-
h. Remove plug and install fitting and engine ture lever on carburetor and heat control valve arm.
breather line at left front of crankcase. Remove clip from carburetor bracket. Loosen lock-
i. Install cooling fan and support, belts, and nuts and
nuts clevises from
remove clevises
and remove cables. Re-
control cables.
from control Re-
shroud. (Refer to paragraph 5-79.) move clamps that secure cables to structure.
b. Remove access panels from cabin box beam
j. Install thermocouple fitting in threadedrecess and remove clips that secure cables to box beam.
in aft side of No. 2 cylinder. Open instrument panel and remove clips holding cables
k. Install safety cables on engine. (Refer topara- to instrument pedestal.
graph 5-30.)
c. Remove spring from bracket and idle cut-off
1. Remove plugs andinstall inlet and outlet fittings control lever. Disconnect clevis and rod-end from
and oil temperature bulb in oil pump housing. Install control levers. Loosen lock-nuts. Remove clevis and
5-35
MAINTENANCE
rod-end from cables. Remove bracket holding cables Note

to outside of instrument pedestal. If the same carburetor and cambox are to
be reinstalled, scribe mark adapter and
d. Pull cables through grommet in instrument carburetor throttle shaft. Scribe marks
pedestal, through cabin box beam and remove from must be accurate as adapter must be
helicopter. placed on the same serration of carbure-
tor throttle shaft upon reinstallation.
5-114. INSTALLING -- CARBURETOR
INSTALLING HEAT AND
CARBURETOR HEAT AND b. Remove cotter pins, nuts, washers and bolts
which secure two throttle control tube assemblies.
a. Push forward ends of control cables through Remove tube assemblies.
cabin box beam, up through instrument pedestal and
out through grommet on left side of pedestal. Screw
clevis on mixture control cable and rod-end on heat
control cable. Secure with lock-nuts. Connect idle
cut-off control cable clevis to idle cut-off control 5-118.
lever with clevis pin (head inboard) through second THROTTLE CONTROL LINKAGE.
hole from end of lever. Connect rod-end of heat (Figure 5-42.)
control cable to second hole from end of lever with
clevis bolt (head outboard) and low castle nut. Con-
nect spring to bracket and idle cut-off control lever. The collective
collective pitch control must
pitch control be rigged
must be rigged
b. Install bracket on left side in instrument before rigging the throttle control.
pedestal and install clips securing cables. Install rotor pitch andthrottle
clips to secure cables to cabin box beam. Close
jack shaft to approximately 1.82 inches from surface
of outer (pitch control) tube to center of bolt hole in
lever.
c. Screw clevises on aft ends of control cables assembly between collective pitch
and tighten lock-nuts. Connect cables to carburetor bellcrank aft of firewall with
idle cut-off lever and heat valve control arm. Secure
cables to structure with clamps, avoid sharp bends
in cables. Check control levers for full travel and
freedom of movement. Adjust cable length at clevis c. Move collective pitch control
collective pitch control stick full up
stick full up and
and
rotate grip full open. Check for linkage clearance.
Move collective pitch control stick full down and
5-115. THROTTLE CONTROLS. rotate grip full closed. Check for linkage clearance.
(Figure 5-42.) Adjust tube assembly, if necessary, to obtain clear-
ance.
5-116. DESCRIPTION. The carburetor throttle is
manually controlled through the collective pitch con- d. Install forward end of aft tube assembly to
trol stick which is geared to a torque tube operating upper bellcrank aft of firewall with bolt, washer, nut
inside the collective pitch control tube. Rotation of and cotter pin.
control stick grip transmits motion through push-pull
tube and cambox to move carburetor arm. The throttle e. Position cambox on bracket on center frame.
is synchronized by cambox action so that movement Check alignment with tube assembly.
of control stick to increase or decrease main rotor
pitch also changes throttle setting to provide more Note
or less power as required.
Washers may be used as spacers between
Note cambox and center frame bracket, if nec-
For overhaul procedures on collective essary, to align cambox or to obtain di-
pitch and throttle control assembly refer mension betweentwo sections of carburetor
Section VII. to cambox shaft.
5-117. REMOVING- THROTTLE CONTROL f. Install cambox on center frame bracket with
LINKAGE. (Figure 5-42.) bolts, washers and nuts. Operate cam lever and check
for binding. Check clevis assembly in cambox for
a. Move pitch control stick full down and rotate length of 2.13 inches.
grip to full closed. Lock in position. Disconnect
adapter at carburetor, slide from carburetor throttle g. Move collective pitch control stick full up and
shaft and remove. rotate throttle full open. Position cam in wide open
5-36
MAINTENANCE
position 0.050 inch plus or minus 0.030 inch clearance Note

between cam follower and end of slot. Open stop
at carburetor should be off the stop 0.040 inch plus It is suggested the cambox be removed
or minus 0.020 inch. With cam in this position adjust when drilling pilot and final size hole and
and connect control tube to cambox lever. a drill press with a suitable holding fix-
ture be used to ensure accuracy of drilled
h. Move collective stick full down and rotate holes.
throttle closed. Check for clearance at cam follower
and end of slot (0.050 minimum). Adjust idle stop screw
to protrude 0.030 inch. Idle stop should just contact 7. Rivet with a MS20435M3-7 rivet.
screw.
8. Check through inspection hole for safe
i. When the same carburetor and cambox are position of shaft end.
reinstalled use the followingprocedure.
k. When installing a new carburetor use follow-
1. Move pitch control stick full down and ing procedure.
rotate grip full closed. Lock in position. Match
scribe marks on two sections of carburetor to cam- 1. Move pitch control stick full up and rotate
box shaft. Slide two sections together. grip to full open. Lock in position.
2. Match scribe marks on carburetor throttle 2. Disconnect adapter at carburetor. Slide

shaft and adapter. (Refer to paragraph 5-116.) from carburetor shaft and remove.
3. Slide adapter on carburetor throttle shaft. 3. Remove carburetor. (Refer to paragraph

5-121.)
4. Check dimension between two sections of
carburetor to cambox shaft. Check through inspection 4. Install new carburetor. (Refer to para-
hole for safe position of shaft end. Refer to figure 5- graph 5-161.)
42, sheet 1 of 2.
5. Set carburetor throttle shaft at full open
5. Secure adapter with two screws. Lockwire with 0.040 inch plus or minus 0.020 inch clearance
in accordance to figure 5-42, sheet 2 of 2. between open stop and carburetor throttle limit arm.
j. When new cambox is installedusethefollowing 6. Align scribe marks on both sections of

procedure. cambox to carburetor shaft. Check dimensionbetween
Note both sections of cambox to carburetor shaft.
It is unnecessary to remove section of
cambox to carburetor shaft which is con-
to carburetor.
nected to
nected carburetor shaft which is con- 7. Secure adapter to carburetor throttle shaft
with screws and lockwire. (Refer to figure 5-20.)
1. Move pitch control stick full up, rotate
throttle full open.
2. Install cambox with bolts, washers, and -

nuts, check clevis lever assembly in cambox for
length of 2.13 inches. Before operating pitch control stick or
throttle control grip of completely install-
3. Position cam in wide open position 0.050 ed throttle system, check to see that
inch plus or minus 0.030 inch clearance between cam carburetor throttle limit arm does not
follower and end of cam slot. Stop at carburetor over-ride either fully closed or fully open
should be off the stop 0.040 inch plus or minus 0.020 stops by manually actuating throttle con-
inch. trol lever at cambox. This will prevent
shearing rivets in throttle control linkage.
4. Adjust and install control tube to cam
lever. 8. Check throttle system for clearance.
5. Check dimension between section of cam- 1. Start and warm-up engine. (Refer to Section
box to carburetor shaft. I.) With collective pitch control stick held in low
pitch position (full down), open throttle to obtain
6. Hold cam and throttle control shaft in this 3200 rpm. Close throttle rapidly, and observe tachom-
position and using hole in shaft as guide drill a No. eter for engine rpm stabilizing at 1700 to 1800 rpm
41 (0.0960 inch diameter) hole through adapter on while freewheeling (before rotor slows enough to
cambox. place load on engine).
5-37
MAINTENANCE
COLLECTIVE PITCH
CONTROL JACKSHAFT
NOTE: SEE SHEET 2 FOR

SAFETY WIRE
1. Throttle Control Lever
4. Throttle Control Tube

5. Throttle Control Cambox
6. Cambox Lever
7. Cambox Clevis
8. Spacers
9. Cambox to Carburetor Shaft
10. Cambox to Carburetor Shaft Adapter
47631-39
Figure 5-42. Throttle Control Installation (Sheet 1 of 2)

5-38
MAINTENANCE
Note 5-121. REMOVING - CARBURETOR.

Correct idle speed is necessary to ensure
proper clutch
proper clutch engagement technique. Idle
engagement technique. Idle a. Remove air induction system. (Refer to para-
rpm will decrease with rotor load on graph 5-39.)
engine. b. Disconnect throttle control shaft from carbu-
m. If necessary to adjust engine idle speed adjust retor shaft. Remove idle cut-off control cable from
clevis in cambox. Shortening will increase idle rpm. bracket.
n. During test flight, while hovering with 17 to c. Disconnect fuel inlet line. Remove nuts and
22 inches Hg manifold pressure, throttle cam should washers and remove carburetor from engine.
hold engine speed at 3200 rpm within plus or minus
50 rpm.
5-122. INSTALLING - CARBURETOR.
o. If adjustment of rpm is necessary lengthen or
shorten clevis in cambox. a. Install support bracket for idle cut-off con-
trol cable on carburetor cover, pointing to left and
p. If for any reason adjustment is made to the secured by existing screws. Install adapter and elbow
throttle control linkage, recheck idle rpm and speci- (pointing up and aft) in right inlet port.
fied clearance in cam and open and closed stops at
carburetor.
b. Position gasket and carburetor on mounting
5-119. CARBURETOR. flange and secure with washers and nuts.
5-120. DESCRIPTION. Lycomingengines are equip-
ped with a Marvel Schebler, Model MA4-5AA, Part c. Connect fuel inlet hose from strainer to elbow
No. 4025-11 carburetor which is an altitude com- in carburetor.
pensating carburetor which provides a more satis-
factory fuel-air ratio during high altitude operations d Connect control cable to carburetor idle cut-
and eliminates manual mixture control. An aneroid off arm and secure support clip to bracket. (Refer
type bellows is positioned in the fuel bowl housing to paragraph 5-114.) Connect throttle control shaft
to control all fuel passing through the main fuel to throttle shaft. (Refer to paragraph 5-117.)
metering jet. The bellows, sensing the atmospheric
pressure change at all altitudes, repositions the main e. Install air induction system. (Refer to para-
metering needle valve thus producting the correct graph 5-44.)
fuel-air ratio at the main nozzle outlet. The mixture
control, which was previously used during flight to
vary fuel mixture or as an idle-cut-off when shutting f. Check adjustment of throttle controls. (Refer
down the engine, has been repositioned and with this to paragraph 5-117.) Check adjustment of heat and
installation is strictly an idle cut-off mechanism. mixture controls. (Refer to paragraph 5-114.)
5-40
Models 47D-1, 47G & 47G-2 BELL HELICOPTER COMPANY Section VI
MAINTENANCE
Section VI
Tail Rotor System
6-1. TAIL ROTOR SYSTEM. (Figure 6-1.) Indication Probable
of Trouble Cause Remedy
6-2. DESCRIPTION.The tail rotor drive system
consists of a three section drive shaft, universal Worn or dam- Replace link-rod
joint, extension shaft and housing assembly, 90 de- aged pitch
gree gear box, hub and blades. change link-
The drive shaft consists of three tubular sections ro
connected by splined couplings with the universal Misaligned Check shaft in-
joint and the internally splined couplings secured drive shaft stallation
to the shaft by tapered sleeve locknuts and a pin in- or universal
serted through each coupling and shaft for added joint
security.
The extension drive assembly consists of an extension Worn drive Replace worn
shaft and housing and gear box. A tubular housing, shaft bearings parts
enclosing the shaft and bearings, is attached through or universal
a yoke to the upper aft end of the tail boom. The gear joint
box which provides a 90 degree directional change
and speed reduction to the tail rotor is mounted on Worn or im- Replace gear box
the upper end of the extension housing, properly in-
The two-blade, controllable-pitch tail rotor is mounted stalled
stalled parts
parts
at right of extension drive assembly, aft of the tail in gear box
boom, and rotates in a vertical plane parallel to the
longitudinal center line of the helicopter. The tail Inability to
Inability to Improper Check tail rotor
rotor opposes the torque exerted on the helicopter make normal rigging controls rigging
body by the main rotor, thus providing control of turns
attitude around the vertical axis. Pitch of tail rotor
blades is controlled by mechanical linkage from Pedals creep- Incorrect Adjust counter-
pedals in the cabin. The rotor assembly consists of
two matched blades, mounted through anti-friction ing number of
rotor counter weights
and thrust bearings on a forged steel hub yoke in weights
a manner which permits turning of blades on their
long axis by movements of pitch change linkage. The
a. An intermittent high frequency vibration occur-
hub yoke is fitted with two bearings, set slightly
ahead of each blade leading edge for delta-hinge type ring in gusty air conditionsor whenhoveringcross-
mounting by a single bolt passing through bearings wind is probably due to tail rotor hub bumping
and the gear box rotor shaft. This method of attach- fuselage or pedals, should be considered normal and
ment allows flapping action of the rotor to absorb fuselage or pedals,
does not require should be
corrective considered normal and
action.
shock from side loads in sudden gust or maneuvers.
6-3. TROUBLE SHOOTING- TAIL ROTOR SYSTEM. b. High frequency vibration may also originate in
other components rotating at high rpm, such as an
Indication Probable out-of-balance cooling fan or d-c generator.
High frequency Tail rotor out Track and adjust 6-4.

6-4 TRACKING
TRACKINGTAIL ROTOR BLADES.
TAIL ROTOR BLADES (Figure
(Figure
vibration of track
Tail rotor out Balance rotor a. Attach a small piece of soft rubber, 1/8 to 1/4
of balance inch thick, to the end of a 1/2 x 1/2 inch pine stick
(or other suitable material light and fragile enough
Worn or loose Replace bearings to break without damaging rotor or injuring handler
delta-hinge or worn parts as in case it is accidently struck by rotor). Coat rubber
bearings or required with a suitable marking compound,such as Prussian
grip bearings blue or red lead thinned with oil.
6-1
(TYPICAL) 0 i ° - CONTACT ON FIRST HALF OF TAPER <
AFT SECTION
FORWARD SECTION
TORQUE TO 120-140
INCH-POUNDS
zz
9. Coupling-
Transmission
Drive
10. Snap-Rings
1. Transmission Drive Assembly 11. Taper Nut
2. Forward Shaft Section 12. Coupling Pin
3. Splined Coupling 13. Dust Cover
4. Center Shaft Section 14. Lock-Nut
5. Bearing Assembly (7 Places) 15. Sleeve
6. Aft Shaft Section 16. Housing
7. Universal Joint 17. Bearing
8. Extension Drive Assembly 18. Cap
47-640-044) 19. Hanger
e. To check chordwise balance, place rotor cm stand
with center line of blades vertical and fixture shaft
resting on knife edges (or rollers). Observe direction
upper blade tends to move.
Note
Follow step f. for metal blade tail rotor
or step g. for wood blade rotor.
f. On metal blade rotor, achieve proper chordwise
balance of blades by affixing weights P/N 47-742-107-1
weighing approximately 1 gram, or -3 weighing ap-
proximately 2 grams to each blade. (See Detail A,
figure 6-4.) During the balancing procedure attach
weights, along with necessary rivets, to the blades
with tape. Tape weights as “ear as possible to in-
stalling position. If more than one weight is needed
for balance they may be stacked one on top of the
other. Limit two weights per side each location. When
rotor is balanced chordwise drill attaching holesusing
NO.40 (0.096) drill at location shown in Detail A. De-
Figure 6-2. Tracking Tail Rotor Blades burr holes and install weights using rivets. Zinc chro-
mate rivets. If weights are being stacked make certain
rivets are long enough for proper installation.
b. Start and warm-up engine. Run engine at 3000
rpm, apply slight collective pitch to prevent main Note
rotor from taking negative cone. Apply positive pitch
(left pedal forward) to tail rotor until slight indication A maximum of 15 grams may be perma-
of strain is felt in tail boom. nently attached to the nose heavy blade.
If blades do not balance chordwise within
1 gram with a total weight attached they
must be rejected.
If run-up is being performed by other than

an experienced pilot, tie down the heli- one gram, with maximum of 15 grams at-
copter. tached to one blade, the set of blades must
be rejected.
Rest marking device under yoke of extension boom. g. 0” wood blade rotor, if upper blade is nose heavy
Slowly move marking device into disc of tail rotor (moves in direction of leading edge) adjust by adding
just far enough to mark near blade approximately washers in equal amounts on trailing edge grip bolt
two inches from tip.
c. When near blade is marked, stop engine and

allow rotor to stop. Adjust length of pitch control
link in half-turn increments to increase pitch of
marked blade. (Figure 6-3.) Recheck blade track.
6-5. BALANCING TAIL ROTOR (Figure 6-4.)
a. Remove tail rotor. (Refer to paragraph 6-9.)
b. Check knife edges or rollers of balancing stand

for being parallel and level in both directions.
c. Install rotor on mandrel of fixture, T100878,

with pins on arms of fixture engaged in bolt holes
of blade grip pitch horns. (Figure 6-4.) On rotors
with metal blades, check that equal amount of washers
are installed on counterweight arms.
d. Adjust blade angle by aligning machined edge of

hub with index groove on fixture shaft. Figure 6-3. Adjusting Pitch Control Links
6-3
Section VI BELL HELICOPTER COMPANY Models 47D-1, 47G & 47G-2
MAINTENANCE
RAISED
PART NUMBERS
ON THIS SIDE
ADD
WASHERS WASHERS
HERE HERE
DETAIL C (WOOD BLADES)

DETAIL B (WOOD BLADES)
WEIGHTS
1. Balancing Stand Knife Edges
2. T100878 Fixture
3. Index Groove
4. Pitch Change Lug
5. Fixture Arm
C/L OUTBOARD HOLE THIS 6. Balance Weights
WEIGHT TO BE 1/2 INCH (As Req'd. on Metal Blades)
THIS WEIGHT FROM C/L EXISTING RIVET
EQUI-DISTANCE MAINTAINING SAME EDGE
BETWEEN EXISTING DISTANCE AS EXISTING RIVETS
RIVETS DETAIL A
47641-40
Figure 6-4. Balancing Tail Rotor

64
MAINTENANCE
of upper blade and leading edge grip bolts of lower i. Install tail rotor. (Refer to paragraphs 6-17 or
blade. (See detail B, Figure 6-4.) If rotor moves 6-18.)
opposite normal rotation, add washers on opposite
pair of grip bolts. (Detail C.) A maximum of six 6-6. BALANCING TAIL ROTOR WOOD BLADES.
washers are allowed on one bolt, three under head (Alternate method.)
and three under nut, and amounts must be the same
on each grip. Longer bolts to accommodate washers
will provide a slight additional weight. If rotor fails Note
to balance with maximum allowable washers, try a
test weight (modeling clay or other convenient ma- Fixture number 47-794-009-1T210 may
terial) temporarily attached at widest part of trailing be used for balancing woodtail rotors only,
edge of nose heavy blade. If rotor balances with not and is inactive for procurement. It is
more than 7 grams so added, chordwise balance is superseded by T100878.
within tolerances.
h. To check spanwise balance, place rotor on stand
with center line of blades horizontal. Adjust by cutting b. Assemble fixture with balance check weight. (Fig-
off inboard end of brass screw in tip of heavy blade. ure 6-5.) Suspend fixture by cord in anarea sheltered
On metal blades, maintain minimum screw length of from air currents and observe balance as indicated
5/16 inch, to allow installation of retaining rivet. by position of small centering disc on top of mandrel.
When balance is satisfactory, drill through eachblade Adjust balance, as necessary, by taping washers on
tip and screw, 1/4 inch from blade tip, using a No. upper surface of balancing disc. Remove check
51 (0.067 inch) drill. Countersink holes 100 degrees weights.
both sides. Coat an AN426AD2 rivet with zinc chro-
mate and install in each blade tip, flush with both c. Install rotor, with outboard side of hub and blade
sides of blade. On wood blades, rivet is not used. grips up, on mandrel. Secure with two screwsthrough
Coat screw threads lightly with white lead, install delta hinge bearings. Tighten nut to hold rim of disc
and stake in three places. firmly against flat side of blade grips.
2. Compensating Screws 7. Mandrel

3. Balance Check Tool 8. Nut
4. Cord Plug 9. Balancing Disc
5. Lock Screw 10. Sensitivity Adjustment Sleeve 4
Figure 6-5. Balancing Fixture - 47-794-009-1T210

6-5
4. Cord Plug 9. Balancing Disc
Figure 6-5. Balancing Fixture - 47-794-009-1T210
MAINTENANCE
d. Suspend fixture by cord. (Figure 6-6.) Adjust

sensitivity as necessary by loosening lock-screw
near lower end of mandrel, sliding adjustment sleeve
full in, then pull sleeve out in 1/8 inch increments
until centering disc is noticeably displaced by a one
gram weight on one blade tip. Remove weight.
e. Tilt rotor slightly, then allow to come to rest,

observing centering disc.
f. Adjust chordwise balance as necessary by adding
washers on blade grip bolts. Do not exceed six wash-
ers on one bolt (three under head and three under
nut). Use equal number of washers on each grip.
Longer bolts to accommodate washers will also af- Figure 6-7. Chordwise Balance Check
fect balance. If rotor does not balance with maximum
amount of washers, place a small test weight (model-
ing clay or other suitable weight) at edge of balancing a. With engine operating at 3100 rpm, place in neu-
disc on light side. (Figure 6-7.) If disc centers with tral, and observe for pedals creeping when not held
not more than seven grams test weight, chordwise by foot pressure. If right pedal creeps forward,
balance is in tolerance. Remove test weight. counterweights are too light. If left pedal creeps
g. Adjust spanwise balance as necessary be removing forward, counterweights are too heavy.
brass screw from tip of heavy blade, and cutting off
small amount of unthreaded shank and reinstalling washers
as indicated , adjust byadding or removing
screw. Balance is within tolerance when a test weight as indicated, keeping amount of washers and length
of not more than one gram, placed on tip of light
blade, will cause disc to center. When balance is c. Repeat check for pedal creep before flight.
satisfactory, remove screw, apply light coat of white
lead on threads, reinstall and stake at three places. 6-8. TAIL ROTOR.(Figure 6-9.)
h. Install tail rotor. (Refer to paragraphs 6-1 or 6-9. REMOVING- TAIL ROTOR.
6-18.)
6-7. ADJUSTINGCOUNTERWEIGHTS- META L a. Disconnect pitch control links from blade grips.
BLADES. Metal tail rotor blades are equipped with Cut lockwire, slip dust boot inboard off knurled nut,
counterweight brackets mounted on each blade grip, and loosen nut on pitch control head.
providing attachment for standard AN970-4 washers b. Remove delta hinge bolt and cup washers (on hub
as counterweights to compensate aerodynamic blade with needle bearings), control head assembly, and
pitch forces. (Figure 6-8.) New rotor assemblies rotor. If equipped with 47-641-025 hub yoke, use care
are normally furnished with four washers per grip, not to lose shims used between rotor shaft and delta
but actual requirements must be determined for hinge bearings. Remove neoprene washer from rotor
each rotor during ground and flight test. In some shaft.
instances no weights are required. 6-10. DISASSEMBLING - TAIL ROTOR.
a. Cut lockwire and use T101227 wrench to loosen

retaining sleeve at each grip. Remove blade and grip
from hub assembly by pulling outward on grip while
unscrewing sleeve. Wood blades may be removed
from grips before or after removal of grip from hub.
(Refer to paragraph 6-20.) Remove lubrication fitting
and grease seal for Zyglo inspection of grip. Bonded
metal blade and grip assembly may not be disas-
sembled except that inboard grease seal, lubrication
fitting, and counterweight bracket may be removed
for replacement.
b. Remove cotter pins from hub yoke, inboard of
each spindle. Remove bearing retaining bolt, outer
(thrust) bearing, spacer (on 47-641-057 yokes only),
sleeve and inner bearing, and felt washers from each
-47642-19A spindle. (If bolts are to be re-used, identify for
reassembly in same locations.) Push bearings from
Figure 6-6. Wood Blades on 47-794-009-1T210 sleeves.
66
MAINTENANCE
c. Push needle bearings from 47-641-057 hub yoke. c. Refer to Section I for magnetic particle and
On 47-641-025 yoke (using KP5A or K5A bearings), fluorescent penetrant requirements.
insert 47-641-003-3T212, pressing plug from inboard side
and pass a suitable rod through opposite bearing hole to d. Inspect parts dimensionally. (See figure 6-10.)
press bearings from yoke. e. On 47-641-057 hub yoke, inspect delta hinge bolt
for wear, and rotate inner races of needle bearings
6-11. CLEANING - TAIL ROTOR. Clean metal parts to check freedom of operation. If found satisfactory,
with dry cleaning solvent. Dry with filtered com- bolt and bearings may be reused.
pressed air. Do not permit bearings to rotate while
drying. Clean surface of wood blades with warm 6-13. REPAIR OR REPLACEMENT - TAIL ROTOR.
water and a good grade of non-alkaline soap. Dry
and polish with a soft cloth. a. Repair or replace damaged blades. (Refer to para-
graph 6-23 and following:).
6-12. INSPECTION - TAIL ROTOR.
b. Replace all damaged or excessively worn parts. Replace
a. Inspect blades for scratches, dents, and other all parts which have completed specified service life. (Refer
damage or wear. (Refer to paragraph 6-21 or 6-22.) to Mandatory Retirement Schedule, Section I.)
b. Carefully inspect all hub parts for surface condi- c. Replace 47-641-025-1 or 47-641-057-1 hub yoke when
tion, wear, and damage. With a 10-power magnifying corrosion or pitting occurs in fillet radii at inboard ends of
glass, inspect fillet radius at base of each yoke yoke spindles, except when such defects can be entirely
spindle for corrosion or pitting. polished out with fine crocus cloth while maintaining
minimum undercut diameter of 0.845 inch and avoiding
change in contour of the 0.050 to 0.060 inch radius.
Note
0.250INCH Hub yokes, (47-641-025-7 or 47-641-057-7)

AN426A2-10 are nitrided and have increased radii. The
RIVET 47-641-057-9 yoke is nitrided and has
BALANCESCREW increased radii without undercut. These yokes
require two felt washers on each spindle, to
cover the wider radius area.
0.500 INCH
THISWEIGHTEQUI- d. Replace felt washers at 600 hours. Lubricate daily

DISTANTBETWEEN with engine oil.
EXISTINGRIVETS.
MAINTAINSAME 6-14. Deleted
EDGE DISTANCE
AS EXISTING
RIVETS. 6-15. Deleted
Figure 6-11. Deleted
AN970-4WASHER. 6-16. ASSEMBLING - TAIL ROTOR.

MAXIMUM4
WASHERSON
EACHBRACKET. a. Install delta hinge bearings. On 47-641-057 hub yoke,
needle bearings should fit so as to require only thumb
pressure to slip into bore. On 47-641-025 yoke, use
47-641-003-3T212 plug to press KP5A bearings into place.
Note
Install chordwise balance weights in pairs
(back to back) or singly as required.
47642-49B
Figure 6-8. Metal Blade Detail

Rev. 3 6-7
MAINTENANCE
1. Pitch Change Links
2. Pitch Change Head
3. Tail Rotor Hub Yoke
4. Delta Hinge Bolt
5. Counterweights
6. Dust Boot
7. Rotor Shaft
8. Pitch Change Sleeve
9. Knurled Nut
10. Neoprene Washer
11. Bearing
12. Pitch Change Rod
47 640-59
Figure 6-9. Tail Rotor Installation

6-8
MAINTENANCE
TORQUE 160-190 METAL BLADE
TORQUE
150- 200
IN - LBS WOOD BLADE
ITEM
1 Blade Grip-Thrust Bearing Seat ID 1.3773 1.3779 1.3784

2 Bearing-Thrust OD 1.3775 1.3780
3 Bearing-Thrust ID 0.5903 0.5906
** 4 Yoke-Thrust Bearing Seat OD 0.5899 0.5904 0.5896
5 Yoke-Inboard Bearing Seat OD 0.8750 0.8755 0.8745
6 Bearing-Inboard ID 0.8743 0.8757
7 Bearing-Inboard OD 1.3115 1.3125
8 Sleeve-Bearing Seat ID 1.3125 1.3130 1.3140
9 Pitch Change Lug-Bushing Seat ID 0.3130 0.3130 *
10 Bushing OD 0.3135 0.3140 *
11 Bolt Hole ID 0.1895 0.1905 0.1910
**12 Yoke-Bearing Bore ID 0.8125 0.8130 0.8140
13 Bearing-Delta Hinge OD 0.8120 0.8125
**14 Bearing-Delta Hinge (Needle) ID 0.3118 0.3125
***15 Yoke-Thrust Bearing Seat OD 0.5901 0.5904 0.5896
***1.6 Yoke-Bearing Bore ID 0.8115 0.8120 0.8125
***17 Bearing-Delta Hinge ID 0.3120 0.3125
***18 Blade Grip-Bolt Holes ID 0.2495 0.2505 0.2510
* Replace bushings when looseness is noted.

** Dimensions for 47-641-057 hub yokes only.
*** Dimensions for 47-641-025 hub yokes only. 47641-1L
Figure 6-10. Limits Chart - Tail Rotor

All data on pages 6-10 and 6-10A deleted. Rev. 3 6-9
MAINTENANCE
b. If fillet radii at base of yoke spindles are polished against bore shoulders and measure dimension be-
and unplated, apply a light coatof corrosionpreventive tween inner races. Subtract shaft dimension from
compound. Moisten felt washers with engine oil and width between inner races, and add 0.002 to 0.004
place on yoke spindles. (Part Nos. 47-641-025-1 and inch. Make two shims, totalling this thickness and
47-641-057-1 yokes, use one washer on each spindle. equal within 0.002 inch, from standard steel washers,
All others require two washers on each spindle.) filed as necessary.
c. Press inner (B540) bearing into each sleeve, with Note
bearing filling notch toward hub center. Press sleeve
assemblies on spindles, seating bearings on journals. Observe color coding of parts when rein-
On 47-641-057 yoke, install spacer on each spindle stalling rotor. Mark new parts after com-
shoulder. pletion of rigging.
d. Press thrust bearings on spindles, with thrust d. Push bearings slightly outward, away from bore
sides toward hub center. shoulders, so as to pass easily over shaft bosses.
e. Install thrust bearing retaining bolts. Torque bolts Position rotor on
Position rotor shaft, with
on shaft, with machined
machined side of hub
side of hub
160 to 190 inch-pounds, align cotter pin holes in hub
and bolt. If necessary add shims under head of bolt to
align cotter pin holes. If installing new bolt, torque as Insert shims between each bearing and shaft boss,
specified and drill NO. 43 (0.088 to 0.093) hole through guide.install bolt through bearings, shims, shaft, and
and
bolt. Install cotter pins with heads on inboard side of
hub.
e. Tighten and lockwire sleeve nut on control head.
on nut.
f. Thoroughly clean the bearing lip in the grip with Lockwire dust
Lockwire in groove
boot in
dust boot groove on nut.
naphtha, keytone or equivalent. Using A6 adhesive possible, not
f. Torque delta hinge bolt tight as possible, not toto
(Armstrong's) with activator A, lay a bead of ad- exceed 80 inch-pounds, without binding pitch change
hesive around the surface of the bearing lip. Thor- mechanism. (On assemblies having minimum
mechanism. (On assemblies having minimum clear- clear-
oughly clean the cap seal and install. Pushtight against
the bearing lip. Lay a bead of adhesive around the
outer
outer edge
edge ofof the
the cap
cap seal.
seal. Install
Install blade
blade before
before ad-
ad- que may deflect shaft enough to cause binding.) Check
hesive hardens. Position blades blades in sleeve nut and for free flapping action of rotor. Bolt torque should
start nut onto threads at root of blade. Torque nut not affect operation of properly shimmed bearings.
150 to 200 inch-pounds using T101227 spanner wrench.
Lockwire sleeves to counterweight bracket bolt heads g. Turn blades to face normal rotation and connect
(on metal blades) or holes provided in lugs of wood links between pitch control head and lugs on blade
blade grips. grips. Install bolt from inboard side, with standard
thin steel washers under head and nut. If blade grip
g. Install wood blades in grips, if removed. (Refer lugs do not have flanged bushings, also use a thin
to paragraph 6-32.) washer between link bearing and lug.
h. Balance tail rotor assembly. (Refer to paragraph h. Check rigging. (Refer to Section VII.) Checktrack-
6-5 or 6-6.) ing as necessary. (Refer to paragraph 6-4.)
6-17. INSTALLING - TAIL ROTOR WITH 47-641-
025 YOKE. Install rotor by the following procedure 6-18. INSTALLING - TAIL ROTOR WITH 47-641-
when equipped with 47-641-025 series hub yoke. This 057 HUB YOKE. Install rotor by following procedure
type yoke uses KP5A delta hinge bearings, installed when equipped with 47-641-057 series hub yoke, which
in bores which have shoulders at inner ends. Shims is original equipment with metal blades and may also
are required, between bearing inner races and shaft, be used with wood blades at operator's option. This
to provide up to 0.004 inch total clearance between yoke uses needle type delta hinge bearings installed
outer races and shoulders of bores, in order to pre- in bores which pass completely through ring of yoke,
vent preloading of bearing when delta hinge bolt is without shoulders. Bearings are lubricated through
tightened. (See figure 6-12, detail A.) fittings on yoke, connected by drilled passages to
grooves around bearings. Two combinations of delta
a. Install neoprene washer on rotor shaft, against hinge bolt and cup washers are in service with this
flanges which act as flapping stops. yoke. (Figure 6-12.)
b. Check condition and proper installation of dust a. Install neoprene washer on rotor shaft, against
boot, with inboard end of boot lockwired in groove flanges which act as flapping stops.
at outboard end of shaft.
b. Check condition and installation of dust boot,
c. Measure diameter across shaft bosses at delta with inboard end of boot lockwired in groove at out-
hinge bolt hole. Seat delta hinge bearing outer races board end of shaft.
6-11
MAINTENANCE
1. Delta Hinge Bolt (47-641-031)
2. Bearing (KP5A or K5A)

DETAIL A
3. Shim
4. Rotor Shaft
5. Nut (AN320-5)
SHIMS TO PREVENT
BEARING PRELOAD,
EQUAL WITHIN 0.002 5
SHORTEN WASHER LIPS

FOR CLEARANCE
6. Bolt (47-641-056-1)
DETAIL B 7. Washer (47-641-054-1)
8. Nut (47-641-055-1)
9. Needle Bearing
SHIM FOR CLEARANCE
11. Washer (47-641-073-7)

12. Nut (AN320-5)
Note: .075 .124

.032 .077 .120
Bolt Tight as Possible Without
Binding Pitch Change or
Exceeding 80 Inch-Pounds DETAIL D
Fit Washers for Minimum .817 DIA.

Clearance Which Allows 812
Free Flapping Action.
47-641-073-7 WASHER
4764o-43 Maximum Total Clearance 0.004
Figure 6-12. Delta Hinge Bolt Installation

6-12
MAINTENANCE
c. Position rotor on shaft, with machined side of with standard thin steel washers between lug and
hub yoke inboard and bearings aligned with bolt hole. link bearing and under nut. If interference occurs
Insert pitch control head guide in shaft, aligning slots between link bolt head and threaded end of delta
with bolt hole. Install delta hinge bolt, with cup wash- hinge bolt, file hinge bolt to provide 0.020 inch
ers under head and nut. Tighten sleeve nut on control clearance.
head. Torque delta hinge bolt tight as possible with-
out binding pitch change mechanism, but do not ex- f. Check for freedom of operation of pitch change
ceed 80 inch-pounds. Check for free flapping action mechanism. Lockwire knurled nut to one arm of
of rotor. control head. Lockwire dust boot in groove of nut.
Note
g. Check rigging. (Refer to Section VII.) Check
When using special bolt and nut with ma- tracking as necessary. (Refer to paragraph 6-4.)
chined shoulders, check that these
shoulders extend through washers to make 6-19. TAIL ROTOR BLADES. Tail rotor blades are
contact with bearing inner races. (Detail of two types, wood or metal. Both types are serial
B, Figure 6-12.) Current production in- numbered and furnished in sets which are carefully
stallation uses a standard NAS bolt and matched for balance and weight. Wood blades are of
AN320-5 nut, with inner surfaces of cup laminated construction, covered with fiberglas fabric
washers (47-641-073) in contact withbear- protected by a stainless steel cap on leading edge,
ing inner races. (Detail C.) and reinforced by steel plates at butt end for at-
tachment by bolts to blade grips. Airfoil of the metal
blade is formed from aluminum alloy sheet, joined
d. Tap bolt head to seat lip of one washer against at trailing edge by bonding and by rivets near root
yoke. Use feeler gage between lip of opposite washer end, where it is also reinforced by a doubler. The
and yoke to check total clearance. Replace washers tip is closed by a phenolic rib, bonded and flush
if clearance exceeds 0.004 inch. Minimum clearance riveted and provided with a vent hole and a brass
is desirable and need not be a measurable quantity, screw for balancing. A stainless steel cap is bonded
provide rotor can flap freely without binding. On in- on the leading edge, and the blade grip is bonded
stallation with NAS bolt, eliminate binding by in- and riveted in the root end.
stalling equal thickness of shims (Part No. 35Z1-
23-10-20, peeled as necessary) in each cup washer 6-20. REMOVING - TAIL ROTOR BLADES.
against bearing inner race. Washer lip lengths and/or
shims must be equal on both sides of hub within 0.002
inch. a. Remove tail rotor. (Refer to paragraph 6-9.)
Note b. To remove metal blade and grip from hub as-
sembly, loosen sleeve nut. Wood blades may be
Previous instructions have directed fitting separated from grips, before or after removing grip
cup washers by filing lips to obtain clear- from hub, by removing two bolts from each grip.
ance. Part No. 47-641-073-1 washers, for
use with NAS bolt, have an original lip
length of 0.065 to 0.067 inch, measured CAUTION
from inner surface of washer. These wash-
ers are being superseded by the 47-641-
073-7 washers, with a lip length of 0.075 Use care to prevent damage when remov-
to 0.077 inch, for use with shims (35Z1-23- ing or installing blades. If wood blades
10-20) to provide easier fitting and longer are not easily removed from grips, use
washer life. Part No. 47-641-073-1 wash- a pine or spruce block cut to shape of
ers may continue to be used by file-and- blade root. Hold block against blade root
fit method, or may be reworked to dimen- and tap block to loosen blade from grip.
sions of 47-641-073-7. In reworking, use
a 13/16 inch spotface with 5/16 inch pilot 6-21. INSPECTION - WOOD TAIL ROTOR BLADES.
and 0.032 inch radius at outer edge. Keep (Figure 6-13.)
inner and outer faces of washer true and
parallel. Thickness of washer web should a. Examine wood blades for dents, nicks, punctures,
be 0.043 to 0.049 inch after rework. (See tears, blisters, peeling or other surface damage. Dents
Detail D, figure 6-12.) or nicks which do not puncture fabric or leading edge
cap do not require corrective action. Damage to
fabric should be repaired before flight, and damage
e. Turn blades to face normal direction of rotation to wood or to leading edge cap requires immediate
and connect links between pitch control head and corrective action. Warping or contour change which
blade grip lugs. Install bolts with heads inward and does not affect tracking of blades is permissible.
6-13
MAINTENANCE
1. Balance Assembly
2. Stainless Steel Leading Edge
3. Pine Trailing Edge Strip
4. Spruce Leading Edge
5. Blade Grip Plate
6. Balsa Trailing Edge
Figure 6-13. Wood Blade Structure
b. Inspect stainless steel leading edge cap for e. All nicks and scratches, outboard of Station 18
evidence of loosening or lifting. Carefully inspect and not in excess of 0.010 inches in depth, must be
for cracks in reinforcing plates and leading edge cap polished out.
flanges at root area, and at steel radius exposed by
cut-away of fiberglas wrapping on leading edge near f. Sharp dents, outboard of Station 18 which do not
grip. (Figure 6-14.) Replace blades immediately if break the skin or remove metal therefrom and are
any of these conditions exist. not in excess of 0.030 inch in depth and 0.2 square
inch area are permissible.
c. Inspect blade root for elongated bolt holes and Non-sharp dents, outboard of Station 18 and not
wood. Replace blades if
fractures of wood. if such defects ing. excess
Non-sharp
of 0.060 outboard
dents, inch of Station
in depth 18 and not
one squareinch
are found, as no repairs are permissible in this area, are permissible.
area. (See figure 6-15.)
6-22. INSPECTION AND REPAIR OF METAL TAIL

ROTOR BLADES. (Figure 6-16.)
Inspect These
a. All spanwise nicks or scratches within 0 to 15 Areas
degrees of the spanline inboard of Station 18 and not
in excess of 0.006 inch in depth must be polished out.
b. All other nicks and scratches, inboard of Station

18 and not in excess of 0.004 inch in depth and one
inch in length must be polished out.
c. Sharp dents, inboard of Station 18 which do not

break the skin or remove metal therefrom and are
not in excess of 0.010 inch in depth and 0.05 square
inches in area, are permissible. 47642-7A
d. Non-sharp dents, inboard of Station 18 and not in

excess of 0.030 inch in depth 0.2 square inch area, Figure 6-14. Inspection Area - Stainless Steel
are permissible. Leading Edge
6-14
MAINTENANCE
Dents should be inspected closely for nicks,

scratches and cracks. If nicks or scratches
exist in dents and the total depth is in ex-
cess of that permitted in step c. and f.
above, the blade should be replaced. If
cracks exist in a dent, the blade should
NO WOODREPAIRS PERMISSIBLE be replaced. If nicks and/or scratches in
IN WRAPPED AREA excess of that permitted in step a., b.,
and e. exist, the blade should be replaced.
Figure 6-15. Fiberglas Wrapped Area - Wood Blades i. Dents in stainless steel leading edge should be
treated as dents in the skin.
h. Any crack in any location is cause for replace- j. Scratches, nicks and dents in the trailing edge
ment. should be treated the same as skin.
ANY SCRATCH IN EXCESS OF

0.010" IN THIS AREA IS CAUSE
FOR REPLACEMENT OF BLADE
ANY OTHER SCRATCHES IN EXCESS
OF 0.004" OR SPANWISE SCRATCH
ll' IN EXCESS OF 0.006" IN THIS AREA
IS CAUSE FOR REPLACEMENT OF
SPAN LINE BLADE
1/4" CIRCLE EQUALS 0.0491 SQ.
INCH AREA
1/2" CIRCLE EQUALS 0.1964 SQ.
INCH AREA
STA. 18.0
1/4" SQUARE EQUALS 0.0625 SQ.
INCH AREA
CHORD LINE 1/2" SQUARE EQUALS 0.250 SQ.
75 INCH AREA
ANY OTHER SCRATCHES.

ANY SCRATCH WHICH LIES
18 INCHES FROM 0 ° TO 75 ° TO CHORD LINE
SPANWISE SCRATCHES. ANY
SCRATCH WHICH LIES FROM
0° TO 15 ° TO SPANWISE
(EXAMPLE) OTHER TYPE SCRATCH
OF HUB EXAMPLE) SPANWISE SCRATCH
47642-42A
Figure 6-16. Classification of Damage - Metal Blades

6-15
MAINTENANCE
k. Small cracks in paint finish are allowable, "how- Type A. Small abraded areas; scratches, gravel cuts,
ever" if voids in paint finish are present blade must minor burnishes, etc. not through to the
be inspected for cracks in metal, if no cracks are metal.
found, repaint the blade.
Type B. Small areas through the finish with metal
1. Adhesive squeeze out at doublers, leading edge, exposed, no corrosion present.
and grip area, may show small check which are al-
lowable. Voids in adhesive at bonded areas, and indi- Type C. Generally deteriorated top coat finish, pri-
cations of loosening of bonding require immediate mer still fully covering metal.
replacement of blade.
Type D. Finish badly deteriorated, with damaged or
6-23. REPAIRING TAIL ROTOR BLADES. badly eroded primer, some superficial cor-
rosion or no corrosion present.
CAUTION c. Processing - For each type of discrepancy ac-

complish refinishing of blade in accordance with the
processing steps in the order listed below:
No repairs to metal tail rotor blades are
authorized except burnishing out shallow Type A. Steps: 1, 2, 3, & 5.
scratches within specified limits, and
restoring finish. If adequate facilities are Type B. Steps: 1, 2, 3, 9, 4 & 5.
not available for wood blade repairs de-
scribed in following paragraphs, it is Type C. Steps: 1, 6, 7, 4 & 5.
recommended that damaged blades be re-
turned to factory for inspection and re- Type D. Steps: 1, 10, 11, 12, 8, 2, 9, 4 & 5.
pair or replacement.
d. The followingprocedural steps as required under
section "Processing" shall be used to accomplish re-
6-24. REFINISHING METAL TAIL ROTOR work of the above listed types of finish discrepancies.
BLADES.
Step 1. Degrease with Naphtha TT-N-95A Type II.
a. For purpose of identification by personnel re-
pairing metal tail rotor blades, original finish com- Step 2. Wash with detergent MIL-C-18687 and thor-
prises of the following: oughly rinse.
1. Wash primer, MIL-C-8514 to Bell Material Step 3. Sand with 320 or 400 wet or dry sandpaper in
Bulletin FW1148, applied in accordance with Bell Pro- area of finish break to fair-in edges of dam-
cess Specification BPS FW 4356. aged area. Remove sanding residue with
clean rags and naphtha TT-N-95A Type II.
2. One coat 0.5 to 0.8 mil (0.0005" to 0.0008")
dry film thickness of catalyzed epoxy primer to Bell Note
Material Bulletin FW 1047, applied in accordance with
Bell Process Specification BPS FW 4325. Wipe surface dry of solvent, do not per-
mit drying by evaporation.
3. A minimum of two coats of specified acrylic
lacquer by manufacturer and of color configuration Step 4. Apply single coat catalyzed epoxy primer
markings as required by applicable military or com- 0.5 to 0.8 mil (0.0005" to 0.0008") coat dry
mercial finish specification. thickness. Allow primer minimum 30 minu-
tes air dry, maximum four (4) hours.
Note Step 5. Apply three coats of Navy Formula P-95

Acrylic lacquer, allowing minimumforty-five
The inclusion of wash primer was for the (45) minutes air dry between coats. Single
purpose of producing maximum adhesion coat dry film thickness of Acrylic lacquer
of the epoxy to the anadized aluminum 0.4 to 0.5 mil (0.0004" to 0.0005").
blade shell. For refinishing these tail rotor
blades as defined herein, it will not be nec-
essary to use wash primer. Note
Adjustments in drying times in accordance

b. Types of finish discrepancies are listed below and with local conditions will be necessary in
processing methods for accomplishingthe rework shall masking operations for markings or color
be as specified under section entitled "Processing". changes.
6-16
MAINTENANCE
Step 6. Strip acrylic finish, using Lacquer Thinner Note

MIL-T-19544 or Methyl-Ethyl-Ketone (TT-
M-261B). Secure Detergent MIL-C-18687 from
Armour & Company, Chicago, IIL, or from
Note any source included on current issue of
Government Qualified Products list No.
Blades primed with epoxy primer which 18687.
these solvents will remove should have the
primer completely removed and blade re- Note
finished with materials prescribed herein,
as required for Type D discrepancy. Secure Olympic White DuPont No. 2818L
Acrylic Lacquer from any DuPont Auto-
Step 7. Thoroughly sand primer using 240 or 320 motive finishes supplier.
grit wet or dry sandpaper. Remove sanding
residue per Step 3. Note
Step 8. Thoroughly sand stainless steelleading edge. Secure MIL-L-19537 Acrylic Nitrocel-
Use 180 grit wet or dry sandpaper and sand lulose Lacquer from any source included
with a circular motion. on current issue of Government Qualified
Products List No. 19537.
Step 9. After washing, while surfaces are still wet,
·apply brush application of chemical conver- Note
sion coating (MIL-C-5541), rinse thoroughly
and allow to dry. Secure Navy Formula P-95 Acrylic Lac-
quer from DeSoto Chemical Coatings, Inc.,
Step 10. Strip all finish, using Methyl-Ethyl-Ketone Garland, Texas
(TT-M-261B). Primer may be removed by
using cloth pads soaked with Methy-Ethyl- REFINISNG WOOD TAIL ROTOR BLADES.
Ketone. Leave the pads on the surface and
keep
keep soaked with the
soaked with the Methyl-Ethyl-Ketone
Methyl-Ethyl-Ketone a. Thoroughly wash blade surfaces, first with warm
for several minutes. Then with rag pad soak-
ed with MEK, swab
swab surface
surface with water and a good grade of non-alkaline soap, then
with rag
rag pad
padthen with aliphatic naphtha.
follow with a scrubbing wetted surface with
pad of Minnesota Mining Company, Scotch-
pad
brite,oforMinnesota Mining
240 grit wet Company,
or dry sandpaper.Scotch-
Con- b. Sand
with clothlacquered
moistenedblade
with surfaces
aliphatic lightly.
naphtha.Wipe clean
tinue soaking and scrubbing until finish is re-
moved.
Note
Step 11. Remove all corrosion by sanding. Use maxi-
mum grit sandpaper that will result in ac- Use following alternate method of clean-
ceptable surface finish as defined in the ing after sanding, if desired:
maintenance and overhaul instructions hand-
book. Surface depth of sanding to remove 1. Wipe surface with cloth moistened
corrosion shall not exceed allowable limits with commercial grade methanol. If non-
authorized by maintenance and overhaul in- inflammable solvent is required use Vy-
structions handbook. thene (Tect, Inc., Dumont, New Jersey).
Step 12. Thoroughly sand all aluminum surfaces, us- 2. Complete cleaning by wiping with
ing 240 grit followed by 400 grit wet or dry cloth moistened with a five percent solu-
sandpaper. tion of chromic acid.
Note c. Apply one spray coat of clear lacquer adhesive,
C-1404, (Pierce and Stevens Co., Buffalo, N.Y.)
Blades corroded beyond acceptable limits thinned approximately 20 percent with P &S thinner
as defined in the maintenance and overhaul J-5231. Alternate; E.I. Dupont P-1200-U-17060 with
instructions handbook shall be scrapped, thinner Specification No. MIL-T-6094A.
Note
d. Apply two spray coats of aluminized lacquer
Secure Lacquer Thinner MIL-T-19544B made by mixing 12 ounces of aluminum paste (Alcoa
and TT-M-261B Methyl-Ethyl-Ketone from 1571 or equivalent) with one gallon of clear lacquer
any paint manufacturer producing Govern- (see step c.) thinned sufficiently to allow adequate
ment Specification products. mixing of aluminum pigment.
6-16A
MAINTENANCE
e. Apply alternate six-inch bands of yellow and in-

strument black lacquer on both sides of blade. Do not
paint stainless steel leading edge.
Note
When more than minor touch-up is accom-

plished, rotor must be rebalanced. (Refer
to paragraph 6-6.)
6-26. MATCHING ODD TAIL ROTOR BLADES
(WOOD). Serviceable single wood blades from dam-
aged sets may be matched by the following procedure
to form a serviceable set.
a. Remove blades from grips. (Refer to paragraph
6-20.)
b. Place a suitable angle on standard gram scales,
arranged with upper edge of angle parallel to and
28 3/4 inches from a wire stretched level with top
of angle. (Figure 6-17.)
c. Weight butt of each blade with tip supported on

wire and inner edges of bolt holes aligned with
edge of angle. Compare weights. If weights vary
6-16B
MAINTENANCE
more than 6 grams, apply additional wrapping to 6-27. REPAIRING FIBERGLAS BY PATCHING. Small
light blade to match weights within tolerance. (Follow holes or breaks, not more than three inchesin length,
methods for wrapping and finishing as outlined in in fiberglas cloth may be temporarily repaired by
Mandatory Bulletin No. 75.) patching, as follows:
d. Weigh tip of each blade with butt supported on Note
wire. (Insert bolts and align with bolts touching wire
as shown, using same bolts for both blades.) Compare This overlay patch repair should be con-
weights. If tip weights vary more than 2 grams, sidered an emergency repair, and should
apply additional coats of finish to tip area to match be replaced as soon as possible by a per-
weights within tolerance. Do not use balance screws manent repair by insertion.
for matching tip weights. Install balance screws
of equal length in each blade tip for use when balanc- a. Remove aluminized lacquer adhesive with lac-
ing assembled rotor. quer thinner for several inches around break. Apply
five coats of clear lacquer adhesive, thinned ap-
e. After match weighing, rework blade identification proximately 25 percent, to area from which alumi-
plates. Leave actual blade serial number unchanged nized lacquer has been removed. Allow each coat to
but rework space indicating matching blade to show dry thoroughly.
serial number of new mate. Record change in heli-
copter logot. b. Cut a patch of fiberglas cloth of sufficient size
to provide a one inch overlap around break. (To
f. Install blades in grips. (Refer to paragraph 6-32.) prevent cloth from raveling, apply one coat of thinned
Assemble tail rotor. (Refer to paragraph 6-16.) lacquer adhesive before cutting.) Place patchonbreak
Balance tail rotor assembly. (Refer to paragraph and apply one coat of thinned sealer adhesive (one
6-5 or 6-6.) part sealer adhesive and five parts thinner).
28-3/4"
ALIGN EDGES OF
BOLT HOLES
MATCH BUTT WEIGHTS

WITHIN 6 GRAMS
BOLTS TOUCHING WIRE.

USE SAME BOLTS
- FOR BOTH BLADES
Note
Wire and Top of Angle

Approximately Level. 28-3/4"
Position of Angle Same
For All Weighing.
MATCH TIP WEIGHTS

WITHIN 2 GRAMS
47642-36
Figure 6-17. Matching Odd Wood Blades

6-17
Section VI BELL HEUICOFPTER COMPANY Models 47D-1, 47G & 47G-2
MAINTENANCE
c. Apply three coats of lacquer adhesive, thinned c. Measure and lay-out patch on patching material
approximately 25 percent. Sand smooth, and apply (fiberglas). Make patch large enough to be inserted
three coats of aluminized lacquer (12 ounces of under flap at leading edge (within approximately 1/8
aluminum pigment paste to one gallon clear lacquer). inch of butting), and to overlap sides and trailing
edge of cut-out by approximately 1/8 inch. Apply
6-28. REPAIRING FIBERGLAS BY INSERTION. Any one coat of lacquer adhesive to an area 1/4 inch
damage to the fiberglas cloth, including all repairs wide around outer edge of patch to prevent fraying.
of a temporary nature accomplished by patching, by Allow time to dry, then cut patch on lay-out lines.
excluding those classed as negligible, willbe repaired d Remove masking tape, and sand exposed wood
by insertion, as follows: lightly to remove roughness. Apply a minimum of
five coats of unthinned lacquer adhesive to area of
a. Lay out a regular shape (square or rectangular) blade to be patched DO NOT apply lacquer adhesive
large enough to include the damaged area, and in-
clude approximately 3/4 inch at leading edge side to to dry thor-
to flap at leading edge. Allow each coat the
edge side to
leading oughly before applying next coat. When final coat
form a flap to overlap leading edge side of patch. thoroughly dry position patch with leading edge
Mark
(See figure 6-18.)mask with a soft
the using
offarea marked pencil. Carefully
three thicknesses i thoroughly
within dry of
1/8 inch butting
position
butting existing fiberglas under
existing fiberglas under
mask off the marked area using three thicknesses flap and overlapping sides and trailing edge by 1/8
of masking tape. inch. (See figure 6-18.) Brush out all wrinkles with
a dry brush.
b. Using lacquer adhesive thinner, remove lacquer a dry brush.
adhesive in masked-off area. Carefully loosen dam- e. Mix a small quantity (one part lacquer adhesive,
aged area from blade, lift edges, and holding a knife and nine parts of lacquer thinner), and apply a single
nearly parallel to blade, cut away fiberglas on lay- coat to patch. Using the wet brush, brush this coat
out lines. Lift, but DO NOT cut away, 3/4 inch which into patch until all air has been expelled and proper
is intended to overlap leading edge of patch, and DO adhesion assured. Allow to dry thoroughly.
NOT permit point of knife to contact wood.
Note
On small patches, the brushing out proce-

dure can be accomplished by rubbing light-
FOLD BACK LEADING EDGE ly with fingers.
f. Apply one coat of unthinned lacquer adhesive,
and allow to dry thoroughly. Using grade 240, wet
or dry sandpaper, sand entire patch to prevent too
great a build-up of lacquer adhesive, and sand over-
lap edges of patch to remove a small amount of
patch material. DO NOT attempt to feather-in patch
in one sanding operation. Apply three additional coats
of unthinned lacquer adhesive. Allow each coat to
dry thoroughly, and repeat sandingoperations between
each coat.
REMOVE DAMAGE CUT LINE _-l
AREA CAUTION
FLAP LEADING EDGE

3/4 It is mandatory that each coat be thor-
oughly dry before sanding, and that dust
or other foreign material be cleaned off
before applying the next coat. When the
final sanding has been completed, the patch
will be feathered into the contour of the
JSIN1 blade.
g. Apply clear lacquer thinner to flap at leading
edge side of patch, and using a putty knife, work flap
1/8" TYPICAL EDGE into place by sliding putty knife downward from the
OVERLAP leading edge side. Trim frayed (trailing edge) of flap
just prior to making the final strokes with putty
knife. Apply additional thinner, as necessary, while
471-- working into place to assure proper adhesiion. Allow
sufficient time to dry thoroughly. Repeat preceding
Figure 6-18. Fiberglas Repair by Insertion step f., observing "Caution" which follows the step.
6-18
Note b. Glue insert into place, using resorcinol type glue.

Blade and glue must be a room temperature of
A slight indention in flap across leading 23.89°C (75°F) minimum. Prepare glue in accordance
edge of patch is normal, with manufacturer's instructions. Spread glue on both
surfaces. Clamp insert tightly into place using 100
h. When thoroughly dry, apply one brush coat of to 150 pounds pressure for not less than five hours.
surfacer which has been thinned sufficiently with
lacquer thinner for good brushing technique. When c. Shape insert to blade contour. Install new section
thoroughly dry, apply glazing putty to fill all irregu- of fiberglas cloth. (Refer to paragraph 6-28.)
larities. After putty is thoroughly dry, remove ex-
cess glazing putty with dampened, grade 240, wet or 6-31. REPAIRING BALSA TRAILING EDGE BY IN-
dry sandpaper. Finish sanding with grade 320 sand- SERTION. Damaged balsa wood of the trailing edge
paper. Apply one spray coat of surfacer to repaired is repaired as follows:
area, and allow to dry thoroughly. Finish sanding
with grade 320 sandpaper, a. Remove fiberglas cloth in damaged area. (Refer
to paragraph 6-28.) Cut out broken area to form 60
i. Apply two spray coats of aluminized lacquer degree V. If break extends over more than one balsa
adhesive made from 12 ounces of aluminum pigment block, remove section. Prepare new piece of balsa
paste to one gallon of lacquer adhesive. Thin lacquer to replace section removed. Leave sufficient stock
adhesive sufficiently to allow adequate incorporation at trailing edge and on contours for finishingpurposes.
of aluminim pigment with lacquer adhesive thinner.
Rebalance tail rotor. (Refer to paragraph 6-5 or b. Glue insert into place, using resorcinol type glue.
6-6.) Blade and glue must be a room temperature of 23.89 ° C
(75°F) minimum. Prepare glue in accordance with
manufacturer's instructions. Clamp in place by using
Note 15 to 25 pounds pressure for not less than five
hours.
If damage is more extensive than that
described in preceding paragraphs 6-21 c. Shape insert to blade contour. Install new insert
and 6-22, blades should be returned to of fiberglas cloth. (Refer to paragraph 6-28.)
factory for inspection, repair, recovering
or replacement. 6-32. INSTALLING TAIL ROTOR BLADES.
6-29. WOODREPAIRS. a. Check identification plates to see that blades are
matched set.
6-30. REPAIRING SPRUCE LEADING EDGE BY IN-
SERTION. Gouges up to 1/8 inch in depth aft of the b. Assemble wood blade grips, or metal blade and
stainless steel leading edge may be repaired as grip assemblies, on hub. (Refer to paragraph 6-16.)
follows: c. Observing color markings place wood blades in
grips and install bolts from outboard side, with
Note washers under head and nut. (If additional washers
and long bolts were used for balance, reinstall in
Two types of blades are used. On the first original positions.) Tighten bolts 30 to 35 inch-pounds.
type, the leading edge of fiberglas cloth
is covered by an overlapping layer of pink- d. Check balance of rotor. (Refer to paragraph 6-5
ed tape which is held by a spline. No tape or 6-6.)
is used on the second type as the leading 6-33 TAIL ROTOR DRIVE SHAFT.
edge of fiberglas cover is overlapped by
the stainless steel leading edge cap. When
making repairs close to the leading edge
cap on the first type, it is permissible to (Forward Section.)
loosen and raise the pinked tape. On the
second type, it is necessary to leave a a. Remove dust covers from both couplings.
minimum of 1/4 inch of existing cover aft
of the leading edge cap so that the leading b. Remove outer snap-ring from both couplings.
edge of the patch may be covered. Slide shaft forward into coupling, lift aft end of shaft
clear of coupling and pull out of forward coupling.
a. Remove fiberglas cloth in damaged area. (Refer 6-35. REMOVAL - TAIL ROTOR DRIVE SHAFT.
to paragraph 6-28.) Rout out damaged wood to re- (Center Section.)
ceive insert. Prepare insert of spruce with a 15 to 1
scarf on each end. Be sure to leave sufficient stock a. Remove forward section of drive shaft. (Refer
for finishing to contour. Grain must run spanwise. to paragraph 6-34.)
6-19
MAINTENANCE
b. Remove aft section of drive shaft. (Refer to para- a. Assemble bearing assemblies as follows: Press
graph 6-36.) bearing onto sleeve with shielded side of bearing
toward threaded end of sleeve. Install lock-ring and
c. Remove caps from bearing hangers and lift shaft lubrication fitting. Start lock-nut on first threads
and bearing assemblies from hangers. of sleeve. Do not tighten.
6-36. REMOVAL - TAIL ROTOR DRIVE SHAFT.
b. Slide bearing assemblies on shaft with threaded
a. Cut lockwirea. and
Cut loosen sleeve nut on forward
and lockwire
loosen on sleeve
nut forward. (47D1 threaded end of sleeve
end of universal joint. Unscrew nut until pin is ex- end of sleeve foward.
aft.) Install splined couplings and insert pin through
posed. Remove pin. couplings and shaft. Engage wrench T101247 in cou-
b. Remove snap-ring from coupling on aft end of plings and tighten sleeve lock-nuts on coupling 450
center section. Pull shaft out of coupling, raise to 500 inch-pounds. Lockwire nut to screw opposite
forward end and pull shaft from universal joint. grease fitting.
6-37. DISASSEMBLY - TAIL ROTOR DRIVE SHAFT. INSTALLATION - TAIL ROTORDRIVE SHAFT.
6-40. INSTALLATION - TAIL ROTOR DRIVE SHAFT.
Note (Center Section.)
Disassembly of forward and aft sections
of drive shaft is not required except for a. Install inner lock-ring in couplings. Place shaft
removal of dust covers. with bearings in place on hangers. Position caps on
bearing hangers and install bolts and washers.
a. Disassemble center section as follows: Engage
T101247 wrench in coupling, loosen sleeve locknuts b. Adjust shaft to obtain a dimension of 19.75 plus-
on bearing assemblies. Loosen sleeve locknuts on minus 0.030 inch between aft face of coupling on tail
couplings with spanner wrench and push out pin. rotor drive on transmission and forward end of cou-
Remove couplings from shaft. Slide bearing assem- pling on center section of shaft. Hold bearing sleeve
blies from shaft. with wrench and torque lock-nuts on bearing sleeves
b. Disassemble bearing assemblies as follows: Re- 150 to 200 inch-pounds. Recheck 19.75 inch dimension.
move locknut from sleeve. Remove lock-ring and (Figure 6-1.)
lubrication fitting from bearing housing. Press sleeveINSTALLATION - TAIL ROTORDRIVESHAFT.
and bearing from housing. Remove lock-ring and
press bearing from sleeve.
6-38. INSPECTION - TAIL ROTOR DRIVE SHAFT.Note
a. Visually inspect all parts for wear or damage. Before installing forward section check
Check bearings for freedom of operation. engine alignment.
b. Inspect shafts for scratches, nicks, cracks or dents. a. Insert forward end of shaft into coupling on
Replace cracked or dented shafts. Replace scratched transmission. Push
transmission. forward to
Push forward to clear center section.
clear center section.
or nicked shafts if depth of damage is over .002 inch. Lower shat and engage sprocketincenter section
Repair tail rotor drive shafts as follows: Polish off Install lock-rings in both couplings.
cadmium plating around scratch. Measure with a mi- b. Install dust boots over both couplings and lock-
crometer, the diameter of the shaftacrossthescratch wire.
area. Dress out scratch over a substantial area. Mea-
sure shaft again with a micrometer. If amount of 6-42. INSTALLATION - TAIL ROTOR SHAFT. (Aft
material removed does not exceed .002 inch shaft may Section.)
be used. Apply zinc chromate or protective coating
to dressed area. Note
c. Check holes in shaft for elongation, if holes are
elongated new holes may be drilled in the shaft 90 s e holnstalle ror to nstallaton
degrees (plus-minus one degree) from old hole. of aft section.
of aft section.
d. Refer to Section I for Magnaflux and Zyglo re-
requirements. a. Unscrew coupling retaining nut on aft end of
center section. Push pin from shaft and slide cou-
e. Install all parts dimensionally. (Figure 6-19.) pling forward.
6-39. ASSEMBLY - TAIL ROTOR DRIVE SHAFT.
b. Slide aft shaft into universal joint, align pin holes,
Note and insert pin. Tighten coupling nut. Align sprocket
on shaft with coupling on center section. Slide cou-
No assembly of the forward and aft sec- pling aft to engage sprocket. Align hole in coupling
tions is required except slidingdust covers and shaft and install pin. Tighten coupling retaining
on shaft. lock-nut.
6-20
MAINTENANCE
TORQUE 450 to 500 TORQUE 150 to 200

LBS IN LBS
SPLINED COUPLING UNIVERSAL JOINT

To Transmission Drive COUPLING BEARING (Models 47D1, 47G and 47G-2)
Assembly (Typical) (Typical)
USE OF GAGE PINS (Coupling Splines)

ITEM
NO. NOMENCLATURE MIN. MAX REPLACE
1 Transmission Drive Shaft - Spline Width 0.184 0.185

2 Coupling - Spline Space Width 0.186 0.188 0.189
3 Coupling - Spline (Use 0.1680 Dia. Pins) ID 1.2549 1.2585 1.2600
4 Sprocket - Spline (Use 0.1920 Dia. Pins) OD 1.7681 1.7710 1.7670
5 Pin - Coupling OD 0.1875 0.1885
6 Hole - Coupling Pin (For Slip Fit) ID 0.1885 0.1895
7 Coupling - Shaft Bore ID 0.6257 0.6267 0.6270
8 Shaft (Typical) OD 0.6245 0.6255
9 Sleeve - Shaft Bore ID 0.6262 0.6267 0.6270
10 Sleeve - Bearing Seat OD 0.7499 0.7503 0.7498
11 Bearing ID 0.7496 0.7500
12 Bearing OD 1.6245 1.6250
13 Housing - Bearing Seat ID 1.6239 1.6244 1.6245
47640-46 A
Figure 6-19. Limits Chart - Drive Shaft and Universal Joint

6-21
MAINTENANCE
Note c. Check universal joint for side play in trunnions.

Replace unit if side play exceeds 0.020 inch.
Check for 1/16 inch clearance between aft
face of sprocket and forward edge of snap- d. Inspect fit of lock-nuts on tapered ends of uni-
ring groove in splined coupling at aft end versal joint. If point of contact is over halfway up
of center section. on the tapered ends, rework as follows:
c. Insert lock-ring in groove of coupling. Slide dust 1. Dress down the point of contact with fine emery
cover over coupling and lockwire. Torque coupling cloth and finish with crocus cloth until contact is on
nuts 450 to 500 inch-pounds. first half of taper. Obtain as much contact as possible.
6-43. CHECKING RUN-OUT - TAIL ROTOR DRIVE 2. Clean part, as necessary, and apply one coat
SHAFT. of zinc chromate primer to reworked area.
a. Attach a dial indicator to the tail boom structure 6-48. INSTALLATION - UNIVERSAL JOINT.
and check center section of shaft midway between
bearings along entire length. If run-out exceeds 0.010 Note
inch maximum Total Indicator Reading (TIR), check
alignment of bearing hangers. (Refer to Section X.) When universal joint is to be replaced, it is
Correct hanger alignment or replace shaft as neces- usually necessary to replace the aft section
sary. of the drive shaft in order to obtain center-
ing of the sprocket between lock-rings in
b. With a dial indicator, check run-out of shaft just the couplings. (Refer to paragraph 6-42.)
forward of universal joint. Maximum allowable shaft However, old shaft may be used, if serv-
run-out is 0.020 inch. If run-out is in excess of al- iceable, by drilling and reaming a new
lowable, replace shaft or rotate shaft 90 degrees 0.1875 to 0.1880 inch diameter hole 90 de-
and drill new pin hole. (Refer to paragraph 6-48.) grees (plus or minus one degree) to the
old hole.
6-44. UNIVERSAL JOINT.
a. Slide universal joint (with grease fitting aft)
6-45. DESCRIPTION. The universal joint which con- onto extension shaft, align holes in coupling and shaft
nects the aft drive shaft and extension shaft provides and install pin. Hold universal joint to prevent
for an angle change in the tail rotor drive system. turning (with a suitable tool on shoulders) and tor-
que lock-nut 450 to 500 inch-pounds and lockwire.
6-46. REMOVAL - UNIVERSAL JOINT.
Note
a. Remove aft section of drive shaft. (Refer to para-
graph 6-36.) If hole in extension shaft is elongated,
rotate shaft and drill a new hole 90 de-
b. Cut lockwire and loosen sleeve lock-nut just aft grees to the old one as follows:
of universal joint. Push out pin and pull universal
joint from extension shaft. 1. Select correct centering pin as outlined in
paragraph 6-49.
6-47. INSPECTION AND REPAIR- UNIVERSAL
JOINT. 2. Slide universal joint on extension shaft. Press
centering pins inboard so that point enters centering
a. Inspect universal joint for looseness or binding. hole in trunnion.
Check attachment pin holes for elongation. If pin
holes are elongated drill new holes as outlined in 3. Hold universal joint to prevent it moving and
step b. using the hole in universal joint as a pilot, drill a
new 0.156 diameter hole in extension shaft. Ream
b. If pin hole in universal joint is elongated a new hole 0.1875 to 0.1880.
hole may be drilled 90 degrees (plus or minus one
degree) to the existing hole. Center of hole to center 4. If a new shaft is being installed it may be
line of trunnion bearing must be 1.625 inch. (Plus drilled by the same procedure.
or minus 0.005 inch.) Drill a new hole 0.156 inch
in diameter and ream on assembly with shaft 0.1875 5. After alignment and drilling, remove centering
to 0.1880 inch. Spot face drilled holes 1/4 x 1/32 pins and install bolts. Install universal joint as out-
corner radius both sides. Metal thickness to be 0.156 lined in step a.
inch from bottom of spot face. Use 47-644-215-1
pin. When new holes are drilled install a new shaft b. Install aft section of drive shaft. (Refer to para-
or rotate existing shaft 90 degrees and drill and graph 6-42.) If installing new shaft, secure lock-nut
ream a new hole. to shaft with tape to prevent marring of shaft due
6-22
MAINTENANCE
to vibration while drilling. Position sprocket in cou- 1. Pull either pin outboard until only the tapered
pling to obtain 1/16 inch clearance from the inside end is inside the clevis. Press opposite pin through
edge of lock-ring groove to coupling. Holding this mounting bolt hole until points meet and measure
dimension drill and ream a 0.1875 to 0.1880 inch distance between points as in detail C.
diameter hole in shaft, using hole in universal joint
as a pilot. Clean away chips, remove all burrs and
2. Pull fully entered pin to tapered end and push
sharp edges from hole. Insert pin into hole and tor- opposite
opposite pin
pin through
through until
until points
points meet
meet and
and measure
measure
que lock-nut 450 to 500 inch-pounds and lockwire. distance.
c. Install aft lock-ring in splined coupling and lock-
3. Select pin which meets point of opposite pin
wire dust boot to coupling. Lubricate universal joint. exactly, or which aligns within 1/32 inch maximum
exactly, or which aligns within 1/32 inch maximum
6-49. ALIGNMENT - UNIVERSALJOINT. to locate universal joint.
(Figure 6-20.)
4. Slide universal joint on extension shaft and aft
a. Remove bolts that secure yoke to aft section of drive shaft. Press selected centering pin inward so
tail boom. that point enters centering hole in trunnion. Press
b. Insert centering pins, T100169, into each yoke opposite pin inboard against trunnion. Do not try to
attachment bolt hole in the aft end of tail boom. Slide enter point of second pin in trunnion centering hole
pins inboard until points meet, midway between tail unless both pins are used for alignment.
boom members. If points meet exactly as in detail
A, use both pins to locate universal joint. If points c. After alignment, install universal joint as out-
do not meet as in detail B, select the proper pin to lined in paragraph 6-48. Remove centering pins and
locate universal joint as follows: install bolts.
DETAIL A DETAIL B
POINTS ALIGNED POINTS MISALIGNED
Use Both for Best Pin Must

Locating Joint \ \ Be Selected
DETAIL C DETAIL D
EXTENDED PIN ALIGNED

EXTENDED PIN With Opposite Point Within
MISALIGNEDWith 1/32" May Be Used For
V~p~~posite Point Locating Universal Joint
47640-1A
Figure 6-20. AlignmentUniversal Joint

6-23
Section VI BELL HELCOPTER COMPANY Models 47D-1, 47G & 47G-2
MAINTENANCE
6-50. EXTENSIONSHAFTANDHOUSINGASSEMBLY. b. Inspect extension shaft for elongated pin holes,

and for nicks or scratches. Replace shaft is nicked
6-51. DESCRIPTION. The extension shaft and hous- or scratched more than 0.002 inch deep. Polish
ing assembly provides support for the tail rotor gear scratches out if 0.002 inch or less. If holes are
box and transmits power from the drive shafts to the elongated, inspect and replace or repair according
gear box. The shaft is supported in the housing by to procedures for external drive shafts. (Refer to
bearing assemblies. paragraph 6-38.)
6-52. REMOVAL - EXTENSION SHAFT AND HOUS- c. Refer to Inspection Section of Section I for Mag-
ING ASSEMBLY. naflux and Zyglo requirements.
d. Inspect shaft assembly parts dimensionally.
dimensionally. (Fig-
(Fig-
b. Loosen tail rotor control cables at turnbuckles.
Back out cable lock-screw in pitch change drum on
gear box and unwind cable from drum. Remove aft
stalling bushings if holes are elongated. (Refer to
c. Disconnect aft end of tail rotor guard from aft paragraph 6-55.)
side of gear box by removing through-bolts and clamp-
bolts. Disconnect brace straps from eyebolt at fork f. Inspect extension tube where O-rings Part No.
ofguard. 6230B6 which are installed on bearing housings Part
No. 47-644-183-1 and -184-1 fit in tube. The O-rings
d. Support aft end of guard and drive assembly while should provide a good push fit for the housings in
removing two bolts from upper aft end of tail boom. the extension tube. It is possible due to tolerances
Remove guard. Disconnect brace tube from housing on the various parts that a good push fit does not
yoke. Remove dust cover for aft coupling, remove always exist. This condition allows the parts to vibrate
snap-ring and remove drive assembly from tail boom. resulting in wear on the ID of the extension tube. Maxi-
mum depth of grooves allowed in extension tube is
6-53. DISASSEMBLING - EXTENSION SHAFT AND 0.010 inch (0.020 inch on diameter).
HOUSINGASSEMBLY. (Figure 6-21.)
6-55. REPAIR OF HOUSING YOKE BOLT HOLES.
a. Remove drain plug (or plugs) from gear box and
a. Remove drain plug (or plugs) from gear box and Elongated tail boom attachment bolt holes may be
repaired by installation of bushings.
b. Remove nuts, washers, and cable pulley bracket
(if so equipped) from gear box studs at housing tube a. During repair, yoke should be installed on housing
flange. Pull gear box assembly from extension shaft tube, with clamp-bolts normally tightened to align
and housing. bolt holes for line reaming.
c. Remove yoke clamp-bolts and lock-plug. Remove b. Line ream bolt holes (originally 0.375 inch dia-
bearing lubrication fittings from yoke and tube. Pull meter) to 7/16 inch (0.4375) diameter, maintaining
shaft assembly from tube. clean sharp edges.
d. Remove universal joint from shaft by loosening c. Make bushings from 4130 steel, with outside dia-
sleeve nut with spanner wrench and pushing out cou- meter to obtain 0.0005 to 0.001 inch press fit in
pling pin. holes.
e. Remove bearing retaining snap-rings from shaft d. Install bushings flush with both sides of yokelegs.
at each end of forward bearing and support assembly.
Remove bearings and support from shaft, andseparate
bearings from support. Remove O-ring seals from e. Line ream bushings 0.375 to 0.376 inch inside
grooves of support. diameter.
f. Remove bearing retaining snap-ring from center 6-56. ASSEMBLY - EXTENSION SHAFT AND HOUS-
bearing support. Remove support from bearing and ING ASSEMBLY.
shaft. Remove O-ring seals from grooves of support.
Remove snap-rings from shaft and remove bearing. a. Lubricate O-ring seals lightly, with MIL-G-25537
6-54. INSPECTION - EXTENSION DRIVE ASSEM- grease, and install in internal and external grooves
BLY. of aft bearing support.
b. Install snap-ring in aft groove in shaft at aft
a. Inspect all parts for wear or damage. Check all bearing position. Press bearing, shielded side aft,
unserviceable parts. Replace seals at assembly. on shaft against snap-ring. Install snap-ring at for-
6-24
MODEL 47D1
CENTER BEARING HOUSING
CENTER BEARING HOUSING
10. Gear Box (47-640-044-8 on

Models 47G and 47G-2)
11. Guard Attachment Clamp
12. Pitch Change Drum and Rod
13. Oil Level Cock
14. Control Cable Pulley Bracket
16. Grease Fitting
17.Yoke Clamp Bolts
1. Universal Joint *18.Lock-Plug(47-640-047-1)
2. Extension Housing Yoke 19.Bearing
3. Forward Bearing Housing 20.O-Ring Seal-Housing to Bearing
4. Extension Housing Tube 21.O-Ring Seal-Housing to Tube
5. Extension Shaft 22.Snap-Ring
6. Center Bearing Housing 23.Ring
7. O-Ring Seal-Shaft Coupling 24.Gear Box (47-640-044-7 on
8. Rotor Shaft Model 47D1)
AUTION 9. Filler Plug 25. Drain Plug - Pinion Shaft Sleeve
Use 47-640-055-1 tube
on Model 47G-2. Do not
use 47-640-055-3 or -5
*Lock Plug See figure 6-29
MAINTENANCE
MODELS 47D-1 ,47G AND 47G-2
1 Housing - Bearing Support OD 2.5640 2.566 2.5630

2 Housing - Bearing Bore ID 1.6245 1.6250 1.6252
3 Bearing OD 1.6245 1.6250 1.6243
4 Bearing ID 0.7496 0.7500 0.7502
5 Sleeve - Shaft - Bearing Seat OD 0.7499 0.7503 0.7497
6 Shaft OD 0.6245 0.6255 0.6243
7 Coupling Shoulder (Across Splines) OD 0.8110 0.8120
9 Coupling - Spline Width 0.1840 0.1850 0.1835
Figure 6-22. Limits Chart - Extension Shaft Assembly
ward side of bearing. Press support, with open side electrical tape or equivalent the full width
aft, on bearing and install snap-ring. of the groove in complete wraps as re-
quired to obtain the necessary push fit.
c. Lubricate and install O-ring seals in grooves of Where the extension tube is worn andwear
forward bearing support. Press a bearing, shielded does not exceed 0.010 inch in depth (0.020
side out, into each end of support. inch in diameter). Make allowance for
wear by applying additional tape under
d. Install aft snap-ring in shaft groove. Press for- O-rings, otherwise interference fit will
ward bearing and support assembly, with lock-plug be reduced by the amount of wear existing
hole forward, on shaft. Install forward snap-ring. in the extension tube.
e. Place universal joint, with trunnion grease fitting f. Lubricate O-rings with MIL-G-25537grease and
aft and lock-nut started on first threads of universal slide shaft assembly into housing tube, with bearing
joint threaded sleeve. Install pin and tighten lock-nut supports turned to align yoke lock-plug hole and
450 to 500 inch-pounds. Lockwire nut to drilled hole grease fitting holes with corresponding holes in tube.
in yoke shoulder of joint. Insert T100363 sleeve from either end of tube to
engage lugs on supports and turn for exact align-
Note ment.
Note
When assembling the bearing housings in
the extension tube check the ID of the tube The locking plug Part No. 47-640-047-1
by taking two measurements 90 degrees must be a good fit in the 0.250 to 0.252
apart and use the average or mean dimen- inch diameter hole in the housing Part
sion. Check ODof the O-rings after installa- No. 47-644-183-1 (line to line or no more
tion on the bearing housings. Squeeze fit than 0.005 inch loose, hole may be ream-
of the O-rings should be 0.025 inch mini- ed oversize up to the maximum of 0.3125
mum, to 0.040 inch maximum. If less than inch. New oversize locking pin must be
minimum, thoroughly cleanO-ringgrooves made or housing and locking pin replaced.
in the bearing housing and apply scotch (See figures 6-21 and 6-29.)
6-26
MAINTENANCE
g. Install yoke lock-plug, through yoke and tube if e. Install tail rotor. (Refer to paragraphs 6-17 or
oversized locking plug in used ream hole for locking 6-18.)
plug in tube) into lower bearing support, with middle
clamp-bolt passing through head of plug. Install grease f. Rig tail rotor system (Refer to Section VII.)
fitting in aft bearing support.
6-58. TAIL ROTOR GEAR BOX.
Note
6-59. DESCRIPTION. The tail rotor gear box is
If new shaft or universal joint is being in- located on the aft end of the tail boom extension. It
stalled, use centering pins through yoke to has a reduction gear ratio of 2 to 1 and changes the
determine alignment of universal joint. direction of drive 90 degrees. The tail rotor pitch
(Refer to paragraph 6-49.) change mechanism is incorporated in the gear box
assembly.
h. Lubricate internal splines of gear box pinionshaft
with white lead base anti-seize compound or grease 6-60. REMOVAL - TAIL ROTOR GEAR BOX.
MIL-G-25537. Place O-ring seal, lightly lubricated,
in groove on splined end of extension drive shaft. a. Remove tail rotor (Refer to paragraph 6-9.)
b. Remove cables from pitch change drum. (Refer
i. Install gear box on shaft and housing, with pinion to Section VII.) Remove tail rotor guard. (Refer to
shaft splines engaged on extension shaft, and studs Section X.)
through housing flange. Use care to avoid damaging
O-ring seal on extension shaft. Place cable pulley c. Drain oil from gear box. Remove nuts and wash-
bracket (if so equipped) on long studs, and install ers from studs and pull gear box from extension
washers and nuts on all studs, tightened 50 to 70 shaft and housing assembly.
inch-pounds.
6-61. DISASSEMBLY - TAIL ROTOR GEAR BOX.
j. Install drain plug (or plugs) in lower side of gear (Figure 6-23.)
box housing.
a. Remove lock-plate, cable drum, and key from
6-57. INSTALLATION - EXTENSION SHAFT AND pitch change rod. Screw rod into gear box and re-
HOUSING ASSEMBLY. move through end of rotor shaft. Slide guide and
knurled nut from rod. Remove bearing and retaining
a. Install tail rotor gear box on assembly. (Refer nut and washer.
to paragraph 6-64.) Remove aft yoke clamp bolt.
Lift assembly into position. Insert upper end of b. Remove three nuts whichsecure front capto case.
brace tube between aft yoke clamp lugs and install Thread two 5/16-18 x 1 1/4 screws inward and care-
clamp-bolts, torque 160 to 190 inch-pounds. fully pull front cap and shaft assembly from case.
Remove shim and secure to front cap.
Note
c. Cut lockwire and loosen bolts which secure
If a new yoke is installed, hole for brace bearing retaining ring to inside of front cap as-
clamp bolt must be line reamed 0.3741 to sembly. Back bolts out until they contact gear. Con-
0.3751 inches after yoke is installed on tinue to back bolts out to push front cap assembly
extension tube. from bearing.
b. Align yoke legs in tail boom attachment points and d. Straighten tang on lock-washer, and remove lock-
shim as required symmetrically. Position tail rotor guard fork nut, using T101245 spanner wrench. Remove lock-
at outboard sidesof tail boom attachment points, and install washer. Place assembly on T100360support, engaging
bolts, with heads outboard and washers under head and nut inner race of bearing, and press gear, retaining ring
between guard and tail boom. Connect brace straps between and bearing from shaft. Remove cap assembly and
lower brace tube attachment bolt and eyebolt in guard gear key from shaft. Remove seal retaining snap-ring.
fork. Use T100302 plug to press seal from front cap. Re-
move O-ring seal from groove in cap pilot.
c. On Model 47D1, wrap extension tube with at least
two thicknesses of tape (No. 22 Scotch Electric Tape, e. Remove nuts which secure pinion sleeve assem-
Minnesota Mining and Manufacturing Co., or equal) bly to gear case. Thread two 5/16 x 1 1/4 screws
under clamps at upper end of guard. Install clamp- into threaded puller holes in sleeve, turn screws
bolts and spacers, inward and carefully pull sleeve assembly from case.
Keep shims with sleeve assembly, remove O-ring
d. On Models 47G or 47G-2, insert upper end of seal from sleeve bore of case. Cut lockwire and use
guard tube in clamp provided on aft side of gear case. T100306 spanner wrench to remove retaining nut from
Install through bolt and clamp-bolt, torque 20 to 25 sleeve. Press oil seal from nut, using T100314 plug,
inch-pounds. and remove O-ring seal from retaining nut.
Rev.3 6-27
MAINTENANCE
DETAIL DIFFERENCES FOR

MODELS 47G AND 47G-2
1. Pinion Gear Shaft 18. Pitch Control Cable Drum

2. Seal 19. Cable Retaining Screw
3. Forward Pinion Shaft Bearing 20. Lock Plate
4. Aft Pinion Shaft Bearing 21. Lock Plate Retaining Screw
5. Front Cap 22. Woodruff Key
6. Snap-Ring 23. Rear Cap
7. Pitch Control Rod 24. Pinion Gear Retaining Nut
8. Rotor Shaft 25. Pinion Gear
9. Rotor Shaft Gear 26. Pinion Gear Shaft Key
10. Lock-Nut 27. Spacer
11. Lock Washer 28. Pinion Sleeve
12. Front Cap Bearing 29. Sleeve Nut
13. Retaining Ring on Models 47G and 47G-2 (47-640-044-8 Assy.)
14. Shim 30. Flange Washer
15. Bearing Retaining Bolt 31. Duplex Thrust Bearings (face to face)
16. Gear Box Housing 32. Sleeve Liner
17. Rear Cap Bearing 33. Washer
47645-
Figure 6-23. Tail Rotor Gear Box

6-28
MAINTENANCE
f. Engage pinion shaft splines on T100303 holder, d. Replace all unserviceable parts. Replace seals
clamped in a vise, and remove pinion retaining nut at assembly. If replacement of pinion or rotor shaft
and washer. Remove assembly from holder. gear is necessary, replace with a matched set.
g. On Part No. 47-640-044-7 gear box assembly Note

(use on Model 47D1) place T100307 support over
splined end of pinion shaft against inner race of bear- Worm gears on pitch change rod and in rear
ing. On Part No. 47-640-044-8 assembly (used on cap (or bushing) are designed for satis-
Models 47G and 47G-2) use T101239 or T100304 factory operation as long as no end play
modified to same dimensions for this purpose. (Fig- is felt in rod when properly rigged cable
ure 6-24.) Place assemble in an arbor press, with is exerting tension on .drum.
threaded end of shaft up, and place T100223 sleeve
over threaded end of shaft and press shaft from e. Inspect parts dimensionally. (Figure 6-25.)
pinion and bearings. Remove key from shaft.
f. Inspect pitch change shaft for run-out. Maxi-
h. Lift out roller bearing and inner race assembly, mum as noted in figure 6-26.
Remove snap-ring, pull inner bearing race from
sleeve, and remove spacer (and washer on Model g. Inspect tail rotor pitch change control screw, 47-
47G and 47G-2). Insert T100304 or T100239 (see step 641-148-1, with O.D. of spline and diameter of bear-
g.) into sleeve and press out forward bearing (or ing surface to be concentric within 0.010 inch TIR.
duplex bearings).
i. Remove lockwire, bolts, rear cap and shim. Pull 6-63. ASSEMBLY - TAIL ROTOR GEAR BOX.
seal from cap. Remove O-ring seal and snap-ring
and push bearing from case. Note
Note Part No. 47-640-044-7 gear box assembly

is original equipment on Model 47D-1 and
Thread pitch change rod into cap and tap Part No. 47-640-044-8 gear box, modified
lightly on end rod with a soft mallet to for duplex pinion shaft bearings and inte-
break cap loose from case, if necessary. gral housing clamp for guard, is used on
Models 47G and 47G-2.
6-62. INSPECTION - TAIL ROTOR GEAR BOX.
a. Inspect bearings for freedom of operation, cracks, a. Position sleeve on end, place a.heat lamp about 9
brinelling or wear. inches from end of sleeve, apply'heat until sleeve
feels hot to a bare hand. Lubricate forward pinion
b. Inspect gears, shafts, housings and other parts shaft bearing (or bearings) and press on pinion shaft,
for nicks, cracks, chipping, or wear. using T100307support against inner race. On Models
47G and 47G-2, install duplex bearings face to face
c. Refer to Section I for Magnaflux and Zyglo re- (one bearing with thrust side forward next to shaft
quirements. shoulder, other with thrust side aft);
3.38
1.25 1.675
1.00
T101239 4776-87
Figure 6-24. T100304 Modified to T101239 Dimension

6-29
MAINTENANCE
18.62"
17.964"
THIS BEARINGDIAMETER 47-641-148-1 SPLINE

MUSTBE CONCENTRIC CONTROLSCREWASSY
WITHIN0.010TIR
Note
If diameter is not concentric with
tolerances as noted, shaft must be
straightened within this tolerance
47641-39
Figure 6-24A. Inspection - Tail Rotor Pitch Control Screw
3
5 9 MODEL 47G & 47G-2
Note
Dimensions Same For 47-640-044-7
(47D-1) and 47-640-044-8 (47G and
47G-2) Gear Box Assemblies, Except
As Separately Listed Below. 4764-5A
Figure 6-25. Limits Chart - Tail Rotor Gear Box (Sheet 1 of 2)

6-30
Models 47D-1, 47G & 47G-2 BELL HEULCOPTER COMPANY Section VI
MAINTENANCE
ITEM NOMENCLATURE DIMENSION MIN. MAX. REPLACE
1 Pinion Shaft - Spline Space Width

2 Pinion Shaft - Fwd. Bearing Seat
(47D1) OD 1.0000 1.0004 0.9997
3 Pinion Shaft (47G and 47G-2) OD 1.1812 1.1815 1.1809
4 Bearing - Fwd. Pinion Shaft (47D1) ID 0.9996 1.0000
5 Bearings - Duplex (47G and 47G-2) ID 1.1807 1.1811
6 Bearing - Fwd. Pinion Shaft (47D1) OD 1.9995 2.0000
7 Bearings - Duplex (47G and 47G-2) OD 1.8499 1.8504
8 Sleeve - Fwd. Bearing Seat (47D1) ID 2.0000 2.0007 2.0012
9 Sleeve Liner (47G and 47G-2) ID 1.8504 1.8510 1.8513
10 Sleeve - Aft Bearing Seat ID 2.0460 2.0465 2.0467
11 Bearing - Aft Pinion Shaft OD 2.0467 2.0472
12 Bearing - Aft Pinion Shaft ID 0.9839 0.9843
13 Pinion Shaft - Aft Bearing Seat OD 0.9835 0.9840 0.9832
14 Pinion Shaft - Gear Seat (47D1) OD 0.6258 0.6263 0.6257
15 Pinion Shaft - Gear Seat (47G and 47G-2) OD 0.6255 0.6260 0.6254
16 Pinion Gear - Shaft Bore ID 0.6250 0.6255
17 Sleeve - Case Seat (47D1) OD 2.4990 2.5000 2.4985
18 Sleeve - Case Seat (47G and 47G-2) OD 2.4980 2.4990 2.4975
19 Case - Sleeve Bore ID 2.5000 2.5010 2.5015
20 Case - Rear Cap Bore (47D1) ID 1.3772 1.3776 1.3779
21 Case - Rear Cap Bore (47G and 47G-2) ID 1.3772 1.3778 1.3781
22 Rear Cap OD 1.3770 1.3780
23 Rotor Shaft - Rear Bearing Seat OD 0.8040 0.8044 0.8038
24 Bearing - Rear Rotor Shaft ID 0.8050 0.8056
25 Bearing - Rear Rotor Shaft OD 1.3775 1.3780
26 Rotor Shaft - Gear Seat OD 0.9385 0.9390 0.9383
27 Gear - Shaft Bore ID 0.9375 0.9380
28 Rotor Shaft - Front Bearing Seat OD 1.1250 1.1254 1.1248
29 Bearing - Front Rotor Shaft ID 1.1246 1.1250
30 Bearing - Front Rotor Shaft OD 2.1246 2.1250
31 Front Cap - Bearing Bore ID 2.1250 2.1257 2.1260
32 Front Cap - Case Seat OD 3.3740 3.3750 3.3735
33 Case - Front Cap Bore ID 3.3750 3.3760 3.3765
47645-5A
Figure 6-25. Limits Chart - Tail Rotor Gear Box (Sheet 2 of 2)
b. Position sleeve on end, place a heat lamp about 9 washer and nut, torque 160 to 190 inch-pounds and
inches from end of sleeve, apply heat until sleeve secure with cotter pin. Removeassemblyfromholder.
feels hot to a bare hand. Press outer race of roller
bearing into aft end of housing sleeve, using T100309
pressing sleeve, and install snap-ring. Insert shaft and d. Lubricate seal using gear box oil, press seal
bearing assembly through forward end of sleeve and (with part number on seal facing outboard) into bear-
press bearings to seat in liner. (On Model 47D-1 use ing retaining nut, using T100314 plug. Lubricate O-ring
T100304 plug. On 47G and 47G-2 use T101239 or seal lightly and install in groove of nut. On Model
T100304 modified to same dimensions.) (See figure 47G or 47G-2, place washer on inner face of nut,
6-24.) Place washer and spacer on shaft (washer not with lip in bore. Install retaining nut assembly in
used on 47D-1). Place assembly on T100308 shaft sleeve, torque 620 to 960 inch-pounds with T100306
support, and use T100307to press roller bearing and spanner wrench, and lockwire nut tosleeve.
inner race assembly on shaft. Install snap-ring next
to bearing. Install key in shaft and press pinion gear
on shaft, using a suitable pressing sleeve. e. Install snap-ring in rear cap bore of gear case.
on shaft, Lubricate roller bearing with engine oil and press
c. Clamp T100303 holder in vise. Engage pinion into place, using T100307. Lubricate and install
shaft splines on holder. Install pinion retaining O-ring seal in groove of cap bore. Press seal into
6-31
MAINTENANCE
rear cap. Install rear cap with shim, peeled to ob- Lower assembly into place, install washers and nuts
tain 0.002 to 0.004 inch pinch on bearing outer race, onto gear case and tighten nuts. Check backlash on
and secured by two bolts, lockwired together. pinion gear, using a dial indicator. Refer to figure
4-12.
Note
i. Remove rotor shaft assembly, keeping shims in
place. Coat gears with a suitable gear marking corn-
Step f. applies to assemblies using gear pound. Reinstall rotor shaft assembly, engagingmark-
set etched with part number 47-645-013. ed teeth. (See step h.) Holding some friction on pinion
If gear set is numbered 47-645-097 (which shaft to prevent gears chattering, rotate rotor shaft
may be used as spares on all 47-640-044 several turns in each direction. Remove rotor shaft
gear boxes), procedure willbe same except assembly to examine contact markings on both gears.
that T100316 gage cannot be used. For first Adjust shim thickness, between pinion sleeve flange
trails, use original shims, adjusting as and case, as required to obtain correct tooth contact
necessary for proper backlash and tooth markings. (Figure 6-28.) When adjustment is satis-
contact patterns. If parts have been re- factory, clean marking compound from gears, and
placed or original shims lost, trial shims reinstall rotor shaft assembly.
in the following ranges are suggested.
Note
Front Cap Pinion Sleeve If pitch change shaft assembly, part No.
Gear Set Shims Shims 47-641-129, is being installed, make cer-
tain the indexed V on bearings is matched
47-645-013 0.030 to 0.040 0.010 to 0.018 to insure removal of axial play. Installtwo
47-645-097 0.040 to 0.050 0.006 to 0.010 seals, Part No. 71-B-2, into cap, Part No.
47-641-142, with flexible lips facing op-
f. Insert plug gage, T100316, into front cap opening posite.
of gear case and press into place. Insert pinion sleeve
assembly into case until pinion teeth contact gage If IDof shaft, Part No. 47-645-202, is0.8790
lightly. (Figure 6-27.) Measure with feeler gage be- or over, shaft may be reworked and over-
tween case and sleeve flange to determine thickness size sleeve, Part No. 47-641-130-3 may be
of shim required. Remove pinion assembly and gage. installed. (See figure 6-25A.)
Lubricate and install O-ring seal in groove of sleeve
opening in case. Place shim of required thickness
on studs, install pinion assembly and tighten nuts.
CHECKI D.
Note 0.8789" & UNDERUSE 47-640-130-1 SLEEVE
If the 47-645-097-1 gears have been in- 0.8790" OVERUSE 47-640-130-3SLEEVE
stalled as replacement for 47-645-013-5
gears, it will be necessary to install an NOTE:WHEN
BORING
SHAFT
MS20002-17 (Std. 1 inch AN washer)wash- OVERSIZEMAINTAIN
er next to the face of the rotor shaft gear, 0.031RADIUS
ATEND
before the installation of the lock-washer OFBORE
and retaining nut.
g. Lubricate seal using gearbox oil, press seal (with
part number on seal facing outboard) into front cap 0.031"R
using T100302 plug. Press bearing into cap assembly. SEENOTE
Install retaining ring, tighten bolts evenly and lock-
wire in pairs. Slide cap assembly on rotor shaft, 47-645-202-1SHAFT
with seal toward flange end of shaft. Press cap as-
sembly into place on shaft with T100307 support. In- 2.62"
stall lock-washer and lock-nut. Torque nut 960 to
1200 inch-pounds, using T101245 spanner wrench.
Bend tang of lock-washer into nut slot. Lubricate
and install O-ring seal in groove of front cap. NOTE:WHEN
USING
47-640-130-3SLEEVE
GRINDTHISDIMENSION0.001" TO 0.002"
h. Examine pinion gear and note tooth marked X". GREATERTHAN THEO.D. OF THE
GUIDESLEEVETOBE INSTALLED.
Place a mark on end of shaft in line with this mark.
Place shim (14) on gear case. Hold rotor shaft as- 47645-49
sembly above gear box and position shaft so that
tooth marked "X" on pinion will engage between teeth
of bevel gear that are marked "XX". (Gears without
"X and XX" marks may be installed in any position.) Figure 6-25A. Rework 47-645-202 Shaft
6-32
MAINTENANCE
THIS BEARING DIAMETER MUST BE CON-

PLACE THISDIA- CENTRICWITHIN0.060TIR.
METER IN COLLET
47-641-034 SHAFT
47-641-034SHAFT
47-641-045 SHAFT
.PLACETHISDIA- THISBEARINGDIAMETERMUSTBE CON-

METER IN COLLET CENTRIC WITHIN 0.010 TIR
NOTE
If diameters are not concentric within tolerances as noted shaft must be

straightened within this tolerance. 47641-6A
Figure 6-26. Inspection Pitch Change Shaft
j. Press bearing, with seal inboard, on pitch control c. Install control cable on pitch change drum, check
rod and install retaining washer, nut and cotter pin. cable with 10 pound pull for secure locking. Rig tail
Assemble knurled nut on guide sleeve and slide rotor. (Refer to Section VII.)
sleeve on rod. Insert rod through rotor shaft and
thread worm gear into rear cap. Install key in rod
slot and press cable drum into place. Install lock-
plate in shaft slot and install lock-screw.
k. When installing duplex bearings, on pitch control

rod, the indexed "V" must be matched on bearings
with shield inboard. (See figure 6-30.) Complete op-
eration as in paragraph j.
1. Fill gear box with proper oil. Refer to Section I.
6-64. INSTALLATION - TAIL ROTOR GEAR BOX.

a. Position gear box and pinion sleeve into extension
housing, lubricate spline with white lead anti-seize
compound or MIL-G-25537, engaging splines on ex-
tension shaft with splines in pinion shaft. Align studs
in gear box with mounting holes in flange and press
sleeve into extension housing. Install washers and
nuts.
Use with 47-645-013 Gears Only
b. Install tail rotor assembly. (Refer to paragraph 47b-5-7A
6-17 or 6-18.) Replace tail rotor guard. (Refer to
Section X.) Figure 6-27. Gear Setting Gage
6-33
MAINTENANCE
GEAR
HEEL
TOE TOE TOE
TOE
CORRECT *INCORRECT *INCORRECT
MOVE PINION IN MOVE PINION OUT
Note
To correct lash move gear member

To correct pattern move pinion
If pattern is high on pinion move pinion OUT
If pattern is deep on pinion move pinion IN
* Incorrect gear patterns shown are

0.010 out of position.
47-645-232 Gear - No Load Tooth Contact Patterns
GEAR DATA CHART 47645-47A
Figure 6-28. Gear Data Chart

6-34
MAINTENANCE
CHAMFER 0.005 RAD. AS REQUIRED UP TO

45° X 0.030" 0.3125" MAXIMUM
0.156"
0.498"DIA
DRILL 5/16 THRU AXIS DIA.
MUST INTERSECT
WITHIN ± 0.010
NOTE:
.500 Make from 24ST4 bar stock
0.625" 1-1/8" length 1/2" dia. ten-
sile 62,000 P.S.I.
47722-7
Figure 6-29. Oversize Locking Plug
NUT (REF)
MATCH"V" INDEXON BEARINGS GUIDESLEEVE(REF)

DETAIL "A"
DETAIL "A"
SHIELD SIDE OF BEARING CONTROL ROD
47641-36
Figure 6-30. Duplex Bearing Installation

6-35/6-36
Models 47D-1 & 47G BELL HELICOPTER COMPANY Section VII (Part 1)
MAINTENANCE
Section VII
Flight Controls
7-1. FLIGHT CONTROLS. as required, to position bell crank correctly. (Fig-
ure 7-3.)
7-2. DESCRIPTION. Control of the helicopter is ac-
complished through three flight controls systems.
The cyclic control system, through push-pull tubes,
torque tubes, bell cranks, disc assemblies, and If rigging fixture, T100219, is not avail-
swashplate, transmits any movement of the cyclic able, use a protractor across the pivot
control stick to the main rotor hub, which changes and push-pull attachment bolts to position
main rotor attitude, to move the helicopter to either bell crank at 6 degrees, 55 minutes above
side or in a forward or rearward direction. A syn- horizontal. (Figure 7-1.)
chronized elevator (Model 47G) is linked to the cyc-
lic control system in such a manner that the fore d. Set bell crank aft of pilot's seat so that center
and aft movement of the control stick controls the line through pivot point and bolt hole in long arm
angle of incident of the elevator makes an angle of 6 degrees and 35 minutes below
horizontal. Adjust and install push-pull tube from
The collective pitch control system, through push- upper bell crank so that it can be connected without
pull tubes, torque tubes, bell cranks, disc assemblies changing position of either bell crank.
and swashplate, transmits movement of pitch control
lever to pitch change mechanism of main rotor hub. e. Set pitch control lever in cabin to an angle of 56
By means of the collective system, the helicopter and 1/2 degrees above horizontal. (Figure 7-1.)
can be made to ascend or descend vertically or to Adjust and install push-pull tube beneath seat so
hover. that tube can be connected without changing position
of bell crank or pitch control lever.
The tail rotor system, through pedals, cables, pitch
change mechanism, and tail rotor blades, controls f. Place a pencil mark on mast in line with top of
engine torque effect on the tail boom in addition to collective pitch sleeve. Measure up mast 23/64 inch
providing directional control. from top of collective sleeve and place a second
mark on mast. (Figure 7-4.) Remove clamps from
A ventral fin is mounted on the underside of the tail swashplate scissor levers, and place collective pitch
boom structure to provide stability about the longi- control lever in high pitch position. If top of collective
tudinal and horizontal axis of the helicopter. sleeve does not line up with pencil mark, remove
lockwire from collective pitch upper stop, located
7-3. RIGGING- FLIGHTCONTROLS.Rigging is rein collective pitch lever arm, and turn screw to
quired after installation or replacement of component bring sleeve in position. Replace lockwire. Place
parts of the control system. Each system may be pitch control lever in low position, and check for
rigged independently. However, if necessary to rig 23/64 inch travel. If necessary to adjust low pitch
both cyclic and collective systems, it is recommended position, adjust low pitch stop screws and lockwire
that the collective system be rigged first. in position.
7-4. RIGGING - COLLECTIVE PITCH CONTROL g. Disconnect both link-rods from stabilizer bar
SYSTEM. (Figure 7-1.) mixing levers and pitch horns on rotor hub. Adjust
rods to 7 13/16 inches between centers of bolt holes
a. Level helicopter. (Refer to Section I.) Check mast and reinstall in original locations. (Refer to SectionII.)
with spirit level for vertical alignment. If mast is not
perpendicular, align power plant. (Refer to Section V.) Note
b. Disconnect both push-pull tubes from outboard Step g. applies to initial rigging. If per-
bell crank, aft of pilot's seat. Lock swashplate forming rigging check after flight test,
scissor levers in neutral. (Figure 7-2.) and it is known that link-rods were ad-
justed to unequal length in a "hub rolling"
c. Slide rigging fixture, T100219, over ends of bell operation to compensate for a high trim
crank pivot bolt and bolt which attaches vertical tab condition in tracking blades, omit
push-pull tube to bell crank. (If slotted hole at top step g.
of fixture will pass over end of link bolt freely, posi-
tion of bell crank is satisfactory.) Adjust link-rod, h. Check low pitch blade angles, to establish safe
7-1
Section VII (Part 1) BELL HELICOPTER COMPANY Models 47D-1 & 47G
MAINTENANCE
23/64 SLEEVETRAVEL EACH

WAY FROM NEUTRAL
CLAMP SCISSOR
LEVERS IN
NUTRAL
LOWPITCHSTOP
HIGH PITCH STOP
120-046-17-9 SHIMS
SHIM AS REQUIRED EQUALLY
ON EACH SIDE OF BELLCRANK
CLEARANCE
TO PROVIDEBUSHING
OF 0.005 OR LESS.
TORQUE NUT 50-70 INCH POUNDS.
Note
TOLERANCE FOR ALL SETTINGS
± 1/2 ° . CHECK LOW PITCH BLADE
ANGLES BEFORE FLIGHT.
NEUTRAL
84-1/2°
56-1/2°
EXTREMETRAVEL POSITIONS
ARE APPROXIMATE
47727-14A
Figure 7-1. Rigging Collective Pitch Controls

7-2
BELL HELICOPTER COMPANY
Models 47D-1 & 47G & OVERHAULINSTRUCTIONS-
MAINTENANCE Section VII (Part 1)
autorotational rotor RPM on test flight, by following

procedure. Place collective pitch ccntrol stick in
full down position. Place a spirit level chordwise on
flat area of one blade root, just beyond end of grip.
Raise or lower one end of stabilizer bar to obtain
level reading. Keeping this blade level, place pro-
tractor on other blade in same manner and check for
angular measurement of 1/2 to one degree, leading
edge up. Adjust to correct reading by lengthening
or shortening both link-rods, between stabilizer bar
mixing lever and blade pitch horns, keeping length
of rods equal.
Note
Adjust link-rods evenly. This method meas-

ures total of both blade angles, assuming
angle of each blade to be half the total
reading because length of linkage is equal.
i. Check complete system for security and for

freedom of operation. Start and warm-up engine.
(Refer to Section I.) Track main rotor blades. (Re-
fer to Section II.)
7-2A
During first flight after rigging collective
pitch system, check main rotor RPM in
autorotation. Gross weight will effect auto- Tolerance of all angular setting isplus or
rotation RPM so that it should be adjusted minus 1/2 degree.
in the configuration and gross weight at
which the helicopter will be operated. a. Level helicopter. (Refer to Section I.) Check verti-
Make an autorotation descent with the cal alignment of mast with bobble protractor or
collective pitch control full down at an square head. Adjust sprag mount rods and safety
indicated airspeed of 50 MPH and check cables as necessary. (Refer to Section V.)
for a rotor speed of approximately 340
RPM. Then in an autorotation descent at b. Clamp centering fixture, 47-300-001-0-T222,
a” indicated airspeed of 50 MPH execute
a moderate flare. Rotor speed should not
exceed 360 RPM in the flare.
j. If rotor speed was below 340 RPM inautorotation at

50 MPH airspeed, decrease blade angle in low pitch
by shortening both link-rods which connect pitch horns
to stabilizer bar mixing levers. If rotor speed in
flare exceeds 350 RPM in flare, increase blade angle
rods evenly in 1/2 turn increments. Repeat test
flight after adjustment.
k. Ifpilot observes
control stick to creep upward or down tile cruising
at 23 inches HG manifold pressure, correct condition
by changing counterweights. (Refer to Section II.)
MAINTENANCE
ALL MODELS
6 INCHES FOR
FOR MODELS 47D1, 47G AND

ANY MODEL THAT HAS THE
SPLINED FAN DRIVE INSTALLED
THE ANGLE SHOULD BE 1/2 °
BELOW HORIZONTAL
47724-1
Figure 7-5. Rigging Fore and Aft Cyclic Controls

7-4
MAINTENANCE
around bell housing at base of cyclic control stick, protractor or square head to place stick in a verti-
below outer bell. If fixture is not available, use a cal position. Tighten friction, by turning knurled nut,
bubble protractor or square head to place stick in to hold stick firmly in position.
vertical position. Tighten friction, by turning knurled
nut, to hold stick firmly in position. c. Disconnect push-pull tube between control stick
extension and outboard arm of jackshaft. Disconnect
c. Disconnect link rod from control stick and lateral push-pull tube between inboard, arm of jackshaft and
bell crank. Disconnect push-pull tube from lateral bell crank, aft of pilot's seat. Disconnect fore and
bell crank and aft lateral bell crank at station 0. Dis- aft bungee spring. Disconnect push-pull tube between
connect push-pull tube from aft lateral bell crank bell crank, aft of pilot's seat and fore and aft control
and bell crank on lateral cyclic control disc. Remove disc. Disconnect link rod between disc assembly and
lateral control bungee spring. Disconnect lateral swashplate arm.
control disc link rod from swashplate.
d. Set jackshaft located aft of cabin floor bulkhead
d. Set bell crank on cabin box beam so that center so that torque arm in center is in an upward verti-
line through bolt hole in lateral arm and pivot point cal position (Figure 7-6.) Adjust and connect push-
is 90 degrees to center line of helicopter. (Figure pull tube between outboard torque arm and control
degrees
90 andtoinstall
center link
line rod
of helicopter.
7-5.) Adjust between bell(Figure
crank stick
s extension
extension without
without changing
changing position
position of
of jack-
jack-
and control stick without changing position of either.
e. Set bell crank aft of pilot seat so that a line
e. Set aft lateral control bell crank at station 0 so
that center line passes through bolt hole of outboard opposite end is 1/2 degree below horizontal. (Figure
arm and pivot point is 6 degrees, 10 minutes, above 7-6) Ajust length of push-pull tube to connect be-
horizontal. (Figure 7-5.) Adjust and connect push- 7-6.) Adjust length of push-pull tube to connect be-
pull tube between bell crank on box beam and bell t n to bell crank
crank at station 0 without changing position of bell position of bell crank.
cranks. f. Set fore and aft control disc assembly so that a
line passed through the pivot point and bolt hole in
f. Position upper lateral control bell crank so that tube fork is at an angle of 2 degrees above
center line passed through pivot point and bolt hole push-pull tube fork is at an angle of 2 degrees above
is one degree and 15 minutes above horizontal. (Fig- horizontal. Adjust length of push-pull tube so it can
be connected to bell crank without changing position
75. Adjust
ure 7-5.) Adjust push-pull tube (from aft lower bell be connected to bell crank without changing position
of disc assembly.
crank) so that it can be connected to upper bell
crank without changingpositionchanging
crank without of bell cranks. g. Place leveling plate, T100436, on top of swash-
plate. (Figure 7-8.) Set protractor to angle shown
g. Place leveling plate, T100436, on top of swash- in figure 7-7 for swashplate fore and aft tilt of the
plate. (Figure 7-8.) Set protractor to angle shown in helicopter
figure 7-7 for lateral tilt of helicopter being rigged. helicopter being
being rigged.
rigged. Place
Place protractor
protractor on
on leveling
leveling
plate
plate in
in aa fore
fore and
and aft
aft direction
direction. Adjust
Adjust link
link rod
rod
Place the protractor on leveling plate in a lateral
direction and adjust length of the link rod to connect
connecting disc assembly and arm on swashplate
to set swashplate at correct angle. Connect link rod.
between disc assembly and swashplate to set swash- Adjust fore and aft bungee spring to a length of 6
plate at correct angle. Connect lateral control bungee inches and install.
spring. Remove leveling plate from swashplate and
centering fixture from control stick. Move stick h. Remove leveling plate from swashlate and cn-
through entire range of travel and check for freedom
of movement and correct movement of swashplate. through
full range of travel
through full range of travel checking
checking for
for freedom
freedom of
of
movement and proper tilt of swashplate.
7-6. RIGGING - FORE AND AFT CYCLIC CONTROL movement and propertilt of swashplate.
SYSTEM. (Figure 7-6.) 7-7. RIGGING - SYNCHRONIZED ELEVATOR
Note Note MODEL 47G.
a. Level helicopter. (Refer to Section I.) Loosen
Tolerance of all angular settings is plus friction nut on cyclic control stick. Place centering
or minus 1/2 degree. fixture 47-300-001-1-T222, on control stick bell as-
sembly and clamp in place. If centering fixture is
a. Level helicopter. (Refer to Section I.) Check ver- not available, use bubble protractor on side of stick
tical alignment of mast with bubble protractor or to check centering of control stick. Tighten friction
square head. Adjust sprag mount rods and safety nut when stick is centered. Check cables for tension
cables as necessary. (Refer to Section V.) of 24 to 30 pounds. With a bubble protractor held on
the two top rivets of the right end plate of elevator,
b. Clamp centering fixture, 47-300-001-1-T222, which are to be used for protractor readings, check
around bell housing at base of cyclic stick, below for elevator nose down position of 15 1/2 to 16 1/2
outer bell. If fixture is not available, use bubble degrees. This is neutral position for the elevator.
7-5
MAINTENANCE
1° 15'
OF HELICOPTER
NEUTRAL POSITION 90
WHEN RIGGING - 6 ° 10'
UP FROM HORIZONTAL/ 6.60
Figure 7-6. Rigging Lateral Cyclic Controls

7-6
MAINTENANCE
47D1 47G 47D1 47G
FWD RIGHT LEFT
FORE & AFT LATERAL
WITHOUT LITTERS
FORE & AFT LATERAL

Neutral Full Travel Neutral Full Travel
Forward Aft Left Right
47D1 Level 9°±1/2° 9°±1/2° 1/2 ° downto left 7-1/2°±1/2 ° 6-1/2°±1/2 °

° ° ° ° °
47G Level 9°±1/2 9°±1/2 1/2 down to left 7-1/2°+1/2 6-1/2°±1/2
WITH LITTERS
FORE & AFT LATERAL

Neutral Full Travel Neutral Full Travel
Forward Aft Left Right
47D1 1° down fwd. 10°±1/2 ° 8°±1/2 ° 2-1/2 ° down to left 9-1/2°±1/2 °

4-1/2°±1/2 °
47G Level 9°±1/2 ° 9°±1/2 ° 1° down to left 8°±1/2 ° 6°+1/2 °
47150-48
Figure 7-7. Swashplate Rigging Chart
b. Remove cyclic control centering fixture. With Note

control stick full forward the elevator should be nose
up 13 1/2 to 14 1/2 degrees, control stick full aft, When pulley is in correct position, right
elevator should be nose down 24 to 30 degrees. (See arm of lever on upper end of jackshaft is
figure 7-9.) Check for freedom from interference, slightly forward of left arm.
c. Adjust travel of elevator by adjusting control rod
between cyclic control jackshaft and forward cable c. Adjust length of the push-pull tubes from pedal
horn assembly. ratchet shaft lever arms to jackshaft lever so that
center lines of bolt holes in upper end of lever arms
7-8. RIGGING - TAIL ROTOR CONTROL SYSTEM. are 1 41/64 inches forward of center line of forward
ratchet shaft. (Figure 7-10.) Clamp pedals in neutral
a. Remove cabin floor access door and cabin box by placing a straight bar across pedals and secure
beam access doors. Remove lockwire and disconnect with C-clamps.
two turnbuckles which join fore and aft tail rotor
control cables. Remove lockwire andloosen set screw, d. Clamp right end of forward cable to structure
and unwind cable from pitch change drum. so that forward end of cable terminal is 10 to 11
inches aft of center of rivet in top of pulley bracket
b. Remove lockwire and loosen fiber nuts on jack- at aft end of center frame. (Figure 7-10.) Make
shaft pulley stop adjustment screws and turn screws certain forward cable is seated in pulleys and jack-
to left until they are in the out position. Remove shaft pulley. Pull left side of forward cable aft (at
cable locking bolt and nut from pulley. Position jackshaft pulley) to remove slack, force cable into
jackshaft pulley in neutral position (cable locking pulley slot, install and tighten locking bolt. Connect
bolt on center line of helicopter). fore and aft cables at turnbuckles. Do not lockwire.
7-7
Section VII (Part 1) BELL HELICOPTER COMPANY . Models 47D-1 & 47G
MAINTENANCE
until one of its five key-ways slides over the key,

and align Slot at 90 degrees to the center line of the
tail boom extension. If reindexing does not position
drum properly, proceed with step g.
g. Remove tail rotor. (Refer to Section VI.) Remove

cable drum from pitch change rod. Using a 1/16
inch socket and a short extension bar, reach into
guide head and engage nut on pitch change rod.
Carefully unscrew rod, engage second series of
threads and turn rod into place. Repeat step f. and
install screw and locking plate. Install tail rotor.
(Refer to Section VI.)
h. Tighten turnbuckle on right cable sufficiently
to allow later tension adjustment without exposing
terminal threads. Holding pitch change drum in neu-
tral, pull cable tight and place in second groove from
inboard side of underside of drum. (See figure 7-11.)
Keep cable tight, wrap cable up and around drum,
5 1/2 turns for Part NO. 47-640-053-1, 4 1/2 turns
for Pert No. 47-640-024-1, and 3 1/2 turns for Part
No. 47-640-140-l. Cable should fill an equal “umber
of grooves on each side of slot. Install and lockwire
cable lock-screw. Do not pierce cable with lock-
screw. lock-screw, Part No. 47-645-012-5, when
installed in drum, Part No. 47-840-140-1, will not be
flush with surface of drum when cable is secured.
Figure 7-8. Leveling Plate on Swashplate i. Hold cable tight on drum, make certain cable is
properly seated inpulleys, and tighten both turnbuckles
equally until all slack is removed. Tighten turn-
e. Turn pitch change drum to right to limit of buckles equally to obtain 12 to 15 pounds tension on
travel Turn drum to left, one full turn (If drum, cables. Lockwire turnbuckles end remove blocking
part No. 47-641-140. is installed. turn drum only 3/4 from pedals.
of a turn, and check alignment of drum. Slot to be
j. Move left pedal to full throw, end check to see
facing forward and 90 degrees to center line of tail
that there is no linkage interference, and that lug
boom extension. (If pitch change drum, pert No. 47-
on jackshaft pulley is against stop on box beam. Check
640-024-1, is installed, slot must fact aft.) Realign
also to see that the cable does not pile up on drum.
drum if necessary. (Refer to step f.)
Repeat with right pedal at full throw. If cable piles
f. Remove lock Screw and locking plate from drum up, pitch change drum is set incorrectly. Repeat
and pull drum from pitch change rod. Turn drum preceding steps f., g., and h.
\ --
MAINTENANCE
41
Blade Position
1 Neutral
2 Minimum Pitch
3 Maximum Pitch
47722-5
Figure 7-10. Rigging Tail Rotor Controls

7-9
Figure 7-11. Winding Cable on Drum Figure 7-13. Rigging Jig on Extension Tube
k. Clamp pedals in neutral position by placing a

straight bar across pedals and secure with clamps.
To rig wooden tail rotor blades accom- Place blades of tail rotor in a horizontal position
plish following steps k., I., and p., using and block tail rotor hub 90 degrees to drive Shaft.
rigging jig, Part NO. 47-300-001-l-T224. Level rotor shaft (shaft which runs from gear box
Accomplish following steps 1. through p., to tail rotor). Place tail rotor rigging jig, 47-300-
if rigging jig Part NO. T100373, or T101- 001-1-T224, on rotor shaft. (Figure 7-12.) Jig will
316 is being used. When rigging metal lock delta hinge action and also serve as an indi-
tail rotor blades. cator for tail rotor throws. Adjust link to obtain minus
1 to 0 degree reading on indicator with scribe line
on inboard side of blade grip. Adjust opposite blade
in the same manner. Check that both links are ad-
justed equally.
1. Remove blocking from pedals and push left pedal

folly forward. Adjust pulley stop for+6 1/2 to +10 1/2
degrees reading on jig attached to rotor shaft, and
scribed line on grips. Push right pedal folly forward,
and adjust opposite stop on pulley to give a reading of
-10 1/2 to -11 degrees. Lockwire stops and remove
jig from tail rotor. (Figure 7-12.)
m. Place rigging jig, T100373, in position on tail

boom extension tube using outboard hole in jig. With
bead of tool (has graduated sector) extending outward
toward tail rotor. Press jig downward until itcontacts
top of yoke casting and tighten clamp bolt finger
tight. sight across top of jig toward tail rotor shaft.
Rotate jig on tube, as required, to bring upper sur-
faceparallel
of jig to tail rotor shaft. (Figure 7-13.)
Tighten clamp bolt securely.
n. Rotate rotor, bringing one blade into rigging jig.

Hold leading edge of blade into notch provided in
jig, and check angular position of blade on graduated
sector on trailing edge side of jig. (Figure 7-14.)
Adjust pitch control link rod, as required, to obtain
a reading of +l to +2 degrees. Rotate rotor and re-
peat on opposite blade.
o. Remove blocking from tail rotor pedals and push

Figure 7-12. Rigging Jig on Rotor Shaft left pedal folly forward. Hold leading edge of blade
MAINTENANCE
RIGGING TAIL ROTOR BLADES
Neutral Max. Pitch Setting Min. Pitch Setting

Wooden Blades +1° to +2° 10-1/2 ° to 12-1/2 °
8-1/2 °
to 9°
Metal Blades with
47-645-011 or
47-640-024 Drum 0 to +1° +10° to +11-1/2 °
-9 ° to -10 °
Metal Blades with
47-640-053 Drum +1° to +2° +12-1/2 °

to +13-1/2 °
-10-1/2 °
to -11-1/2 °
Figure 7-14. Rigging Dimension - Tail Rotor Blades
against notch in jig and check reading on graduated b. Disconnect linkage from collective pitch crank
sector. Adjust stop screw on control pulley, as re- arm and throttle control lever. Remove copilot's
quired, to obtain a reading of +12 1/2 to +13 1/2 de- control stick (if installed) by removing bolt through
grees. Tighten lock-nut on stop screw. Push right base of stick.
pedal fully forward and adjust opposite stop screw
on control pulley to obtain a reading of -10 1/2 to c. Remove bolts attaching torque tube bearings to
-11 1/2 degrees. Tighten lock-nut on stop screw, and welded brackets on seat structure. Keep shims for
lockwire both screws. reinstallation. Remove assembly from helicopter.
p. Check tail rotor control system for freedom of
operation throughout entire range. Start and warm
up engine. Track tail rotor blades. (Refer to Section
VI.) Install cabin floor access door and cabin box
beam access doors.
7-9. COLLECTIVE PITCH AND THROTTLE CON-
TROL ASSEMBLY. (Figure 7-15.) 5
7-10. DESCRIPTION. The collectivepitchandthrottle
control assembly consists of a collective pitch torque
tube mounted horizontally under seat, a control stick
extending from torque tube gear housing up and for-
ward through left side of seat firewall, and a throttle
control shaft mounted inside the collective pitch
torque tube and operated through gears by rotation
of control stick grip. A friction control rod and
knob are located at the seat firewall convenient to
pilot's right-hand, and allows locking of collective
pitch controls when desired. A knurled knob on the 4)
control stick provides friction control of throttle
setting. Provisions are made for installation of a
copilot's control stick at right end of the torque tube. 1. Friction Adjusting
1. Friction Adjusting Rod
Rod
2. Friction Bearing
7-11. REMOVING - COLLECTIVE PITCH AND 3. Control Tube Arm
THROTTLE CONTROL ASSEMBLY. (Figure 7- 4. Throttle Link
15.) 5. Control Tube
a. Remove cotter pin from lower end of collective 6. Collective Pitch Lever
pitch friction control rod. Unscrew rod tc remove
nut, rod, spacer, and washer. Figure 7-15. Collective Pitch Control Assembly
7-11
7-12. DISASSEMBLY - COLLECTIVE PITCH AND d. Rotate gear segment to lower part of housing.
THROTTLE CONTROL ASSEMBLY. Place washer (and shim, if required) on stick end,
and insert stick through upper bushing of housing.
a. Remove screws, bushing, and shim from right end Place shims and pinion on stick end and insert stick
of assembly. in lower housing bushing. Rotate throttle shaft gear
upward, and engage with pinion so that middle teeth
b. Remove throttle lever from shaft. Slide friction mesh. Holdinggears thus, rotate stick to align screw
bearing from right end of torque tube. hole, and install screw in pinion and stick. Check for
0.002 to 0.004 inch backlash, adjusting pinion shim
c. Remove plug button from end of control stick. as necessary. Lockwire screw. Smear gears with
Remove cotter pin and washer, and screw knurled MIL-G-25537 grease. Install plug buttons in housing.
nut from end of throttle friction control rod. Lower
rod into handle. Remove pin, flanged sleeve, and e. Install throttle lever through torque tube slot into
friction washer from lower end of rod. Remove rod throttle shaft. Adjust to dimension of approximately
through upper end of stick. 1 53/64 inches between center of bolt hole and sur-
face of collective pitch torque tube and tighten lock-
d. Remove plug buttons from end and lower inboard nut. Check operation by rotating control stick grip.
side of gear housing. Remove screw attaching pinion
gear segment to stick. Pull stick from housing, re- f. Insert throttle friction control rod through upper
moving washer and shim from outside and pinion and end of stick. Place friction washer on flanged sleeve,
shims from inside of housing. place sleeve on lower end of rod and install pin. Push
sleeve up into end of stick. Screw knurled nut on
e. Remove screws, bushing, and shim from right end upper end of rod and secure with washer and cotter
of tube and shaft. Pull throttle shaft and gear assem- pin. Snap plug button into top of stick.
bly out through left end of tube and housing. Remove
screws, gear, and shim from shaft. (Keep all shims g. Apply corrosion preventive compound, Specifi-
for reinstallation.) cation MIL-C-16173, to exposed bare steel surfaces
of cross tube.
f. Remove pins, gear housing, spacer, washer, and
bearing from torque tube. 7-14. INSTALLATION- COLLECTIVEPITCH AND
THROTTLE CONTROL ASSEMBLY.
g. Remove pins, loosen clamp-bolt, and remove a. Lift assembly into position under center frame
crank arm from right end of torque tube. seat structure, with control stick extending through
7-13. REASSEMBLY - COLLECTIVE PITCH AND left side of seat firewall. Align bearings with support
THROTTLE CONTROL ASSEMBLY. brackets, using shims as needed for alignment, and
install mounting bolts (countersunk screws at two
a. Lubricate bearings with MIL-G-25537 grease. lower
lower holes
holes of
of friction
friction bearing).
bearing).
Slide bearing, washer, and spacer on end of torque
tube, seating bearing shoulder against riveted collar. b. Place thin washer and long spacer on collective
Insert end of tube into gear housing, align holes and pitch friction control rod and insert through sleeve
press pins through housing into tube. (If new parts in seat firewall. Install thin washer against spacer,
are being assembled, hold parts tight against collar and insert rod through friction lock. Screw rod into
for running fit, and ream holes 0.1855 to 0.1875 inch nut held in place below lock and install cotter pin
for press fit of pins.) Install lockwire, passing through through end of rod.
each pin and completely around housing.
c. Connect linkage to crank arm on torque tube.
b. Slide crank arm on torque tube. Align to point Check rigging of collective pitch control system.
down and forward 21 degrees when raised part (Refer to paragraph 7-4.)
number on gear housing is up, and press pins into
place. Secure pins with lockwire, passing through d. Connect linkage to throttle shaft lever. Check
pins and completely around tube. Slide friction bear- rigging of throttle control system. (Refer to Section V.)
ing on right end of torque tube, past throttle lever
slot. 7-15. CYCLIC CONTROL STICK.
7-16. DESCRIPTION. (Figure 7-16.) The cyclic con-
c. Insert end of throttle shaft into gear and install trol stick, mounted to the cabin floor forward of the
two screws, lockwired together. Place two shims on pilot's seat, is connected to the main rotor cyclic
shaft against gear shoulder and insert shaft in torque control linkage. Trunnion mounting provides for tilt
tube. Install bushing over right end of throttle shaft of the stick in any direction, and non-adjustable stops
and into torque tube, with shims between bushing and limit movement to 15 degrees from vertical (neutral).
tube to eliminate end play of throttle shaft. Install A knurled nut below the offset of the stick provides
and lockwire two screws to secure bushing to throttle adjustment of friction. A push-button microphone
shaft. switch is located on the stick grip.
7-12
7-17. REMOVING - CYCLIC CONTROL STICK.

a. Remove access door under cabin.
b. Disconnect push-pull tubes from extension and

arm on lower end of control stick.
c. Disconnect electrical wiring at nearest quick-

disconnect clips.
d. Remove screws attaching bell to cabin floor and
remove stick assembly.
7-18. DISASSEMBLY - CYCLIC CONTROL STICK.
a. Match-mark bearing caps for reassembly in same
locations. Remove screws, nuts andbearing capsfrom
bell housing.
b. Remove bolt passing through lever assembly
bearings, extension, and stick. Pull lever assembly
off stick extension. Remove nuts and bearings from
lever assembly trunnions. Push bearings out of lever
assembly bores.
c. Pull stick assembly out of inner bell. Remove
extension, outer bell, frictiontube, dust shield washer,
bearing, and friction nut from lower end of stick. Re-
move grip by removing screw (covered by putty),
threading electrical wires up through stick.
7-19. CLEANING - CYCLIC CONTROLSTICK. Wash
metal parts in dry cleaning solvent and dry with
filtered compressed air.
7-20. INSPECTION - CYCLIC CONTROL STICK.
a. Inspect bearings for wear and roughness.

b. Inspect parts for wear, elongated bolt holes,
cracks, nicks and surface damage.
c. Inspect assembly for security and freedom of
operation. Check for excessive play between stick
and extension.
7-21. REPAIR OR REPLACEMENT - CYCLIC CON-
TROL STICK.
a. Replace worn or rough bearings.
b. Replace damaged or worn parts.
7-22. REASSEMBLY - CYCLIC CONTROL STICK.

1. Stick
a. Check connection of electrical wiring to switch. 2 Friction Nut
Install grip, secured by screw and nut. Fill holes 3 Friction Tube
with putty. 4. Bell Assembly
5. Trunnion
b. Assemble friction nut, bearing, dust shield (wash- 6. Fore and Aft Lever
er), friction tube and outer bell on lower end of stick. 47721-6A
Insert stick into extension, aligning bolt holes and
threading electrical wires out through hole above
clevis. Figure 7-16. Cyclic Control Stick
7-13
Section VI (Part 1) BELL HELICOPTER COMPANY Models 47D-1 & 47G
MAINTENANCE
c. Install bearings into bores of lever assembly. 7-27. DISASSEMBLY - CYCLIC CONTROL JACK-
Install bearings and nuts on trunnions of lever as- SHAFT.
sembly, secured by cotter pins.
a. Match-mark parts for reinstallation in same
d. Place inner bell over end of stick. Insert stick position on reassembly. Remove bolts and tapered
extension through lever assembly, with lever aft, bushings and pull torque arms from end of shaft.
align bearings with bolt holes and install bolt through
bearings, extension, and stick. b. Slide bearings and housings from shaft.
e. Observing match-marks made at disassembly, 7-28. CLEANING - CYCLIC CONTROL JACK-

install bearing caps, secured by screws and nuts. SHAFT. Wash parts in dry cleaning solvent or kero-
sene. Dry with filtered compressed air.
7-23. INSTALLATION - CYCLIC CONTROL STICK.
7-29. INSPECTION - CYCLIC CONTROL JACK-
a. Position stick and install screws around flange SHAFT.
of bell.
a. Inspect bearings for wear, rough operation, or
b. Connect fore-aft and lateral control system push- binding.
pull tubes to stick extension and lever.
b. Inspect shaft and arms for cracks, corrosion,
c. Connect electrical wires at quick-disconnect clips. and elongated bolt holes. Inspect tapered bushings
for proper fit, extending not less than 1/32 inch
d. Check rigging of fore-aft and lateral cyclic con- above surface.
trol systems. (Refer to paragraphs 7-5 and 7-6.)
c. Inspect installation for secure mounting and free-
e. Install access door under cabin. dom of operation. Inspect support brackets for cracks.
7-24. CYCLIC CONTROL JACKSHAFT. (Figure 7- 7-30. REASSEMBLY - CYCLIC CONTROL JACK-
17.) SHAFT.
7-25. DESCRIPTION. The jackshaft in the fore-aft a. Lubricate bearings with MIL-G-25537 grease.
cyclic control system is a torque tube mounted Assemble bearings and housings on each end of shaft,
through single-row bearings to brackets on center with original shims (if needed) in place between
frame structure aft of box beam. Jackshaft extends bearing and collar on shaft.
laterally under seat and is equipped with torque
arms which are connected by push-pull tubes to ex- b. Slide torque arms on shaft, install tapered bush-
tension on cyclic control stick and bell crank. With ings and bolts.
dual controls installed the copilot's stick is connected
to arm on right end of jackshaft. 7-31. INSTALLING - CYCLIC CONTROL JACK-
SHAFT.
7-26. REMOVING - CYCLIC CONTROL JACK-
SHAFT. a. Position jackshaft to brackets on structure. In-
stall bolts with heads outboard, through bearings
a. Disconnect push-pull tubes from torque arms of housings and brackets, using washers (as needed)
jackshaft. between housings and brackets to compensate for
misalignment (1/8 inch maximum allowable misalign-
b. Remove bolts through bearing housings andbrack- ment). Check for possible binding while tightening
ets. Remove jackshaft from helicopter. bolts.
47720-7
Figure 7-17. Cyclic Control Jackshaft

7-14
MAINTENANCE
7-32. BELL CRANKS.
7-33. DESCRIPTION.Bell cranks are usedinthe fore

and aft, lateral, and collective pitch control systems
for the purpose of changing direction of movement
and to provide the desired mechanical advantage.
Bell cranks must be set at recommended positions
to provide the desired amount of displacement of the
systems. While bell cranks may differ as to type,
their installation is similar. Therefore, the following
procedures for removal and installation will suffice
for all bell cranks.
7-34. REMOVING - BELL CRANKS.
a. Place controls sticks in neutral position and

tighten friction locks. Match-mark control tubes for
reinstallation in original position.
b. Disconnect control tubes from bell crank. Remove
pivot bolt which secures bell crank to structure and
remove bell crank from helicopter.
7-35. CLEANING - BELL CRANKS. Examine bell

cranks from nicks, scratches, corrosion, elongated
bolt holes, security of attachment, and condition of
bearings. 1. Discs
2. Ring Clamp Bolts
7-36. REPAIR OR REPLACEMENT -BELL CRANKS. 3. Ring
4. Washer
a. Radius minor dents or scratches. Replace bell
cranks with cracks, or deep nicks.
47729-10
b. Replace unsatisfactory bearings and restake at a
new location. Replace bell cranks with excessive stake
marks.
Figure 7-18. Disassembled Control Disc
c. Replace bell cranks with elongated bolt holes or
replace bushings if provided.
b. Disconnect bungee spring in fore-aft control sys-
7-37. INSTALLING - BELL CRANKS. tem. Disconnect control tube from fore-aft control
disc and rod end from swashplate horn. Remove
a. Purge and repack bearings. Do not remove staked pivot bolts and assemblies from support. Remove
bearings to lubricate. support, keeping any shims, washers, or spacers in
sets for use on installation. Support plate on Model
b. Position bell crank to bracket and install pivot 47D1 can be normally left installed on transmission.
bolt. Install only AN or NAS close tolerance bolts
in all pivot points.
7-40. DISASSEMBLY - CONTROL DISC.
c. Identify and install control tubes to bell crank.
Check rigging of control system from which bell a. Take out bolts and remove short arm and shims
crank has been installed. from fore-aft control disc.
7-38. CONTROL DISC. b. Remove clamp bolts, (figure 7-18) and washers
from the rings.
7-39. REMOVING - CONTROL DISC.
c. Remove bolts clamping disc together and separate
a. Disconnect bungee spring in lateral control sys- disc from rings.
tem. Disconnect parallel links from lateral cyclic
control disc and rod end from swashplate horn. Re- 7-41. CLEANING - CONTROL DISC. Wash parts in
move pivot bolt and disc assembly from support. dry cleaning solvent or kerosene and dry withfiltered
Remove support from studs on transmission. compressed air.
7-15
MAINTENANCE
7-42. INSPECTION - CONTROL DISC. e. Disassemble and wash disc and ring to remove
all lapping compound, in dry cleaning solvent or kero-
a. Examine parts for corrosion, nicks, and scratches. sene and dry with filtered compressed air.
Inspect bearings in the ring arms for binding or ex-
cessive wear. 7-45. ASSEMBLING - CONTROL DISC.
b. Refer to Section I for Magnaflux and Zyglo re- a. Place ring (figure 7-18) in disc with "X" mark
quirements. on ring next to 'X" mark on disc and install bolts
that clamp disc together, tightening bolts to 25 inch-
7-43. ADJUSTING FRICTION - CONTROL DISC. pounds torque.
Note b. Install clamp bolt and separating washer in ring
Steps a. through c. are for friction ad- clamp lugs.
justment with a torque wrenchandadapter.
Steps d. through f. are for adjustment c. Install short arm on fore-aft disc, placing shims
without use of torque wrench and adapter. equally on each side of disc under arm bolt holes.
a. Clamp arm of ring in a vise or similar tool and 7-46. INSTALLING - CONTROL DISC.
attach torque wrench adapter to disc. Remove washer
that is between ring clamping bolt lugs. a. Install lateral disc support, with channel section
on aft side, on studs at left side of transmission
b. Tighten ring clamping bolt until a minimum of lower case. Check that spacers are installed through
55 inch-pounds is required to turn disc. pivot and attachment holes in disc. Align disc in
support with grease fitting forward and rod vertical,
c. Peel the laminated washer that goes between the and install pivot bolt through support and lower of
ring lugs so that it will fit tightly with the ring two holes in disc.
clamped as directed in step b. If the clamping lugs
have an AN960 washer between them, grind the b. Connect disc rod-end to swashplate lateral horn,
washer to proper thickness, with bolt finger-tight. Connect inboard ends of parallel
links to disc above pivot, using washers between
d. Clamp disc in a vise or other fixture with the disc and links as needed for alignment. Connect
ring free to turn on the disc. Remove the washer lateral bungee spring.
between clamping bolt lugs.
c. Install fore-aft disc support. When installing 47-
e. Attach a spring scale to the end of the control 729-099 support, use washers as required on fan
arm. Tighten the clamping bolt until a pull of 5 to 6 drive studs to fill counterbored holes slightly beyond
pounds on the scale is required to turn the ring of drive flange surface. Shim between support and trans-
the fore-aft disc, and a pull of 4 to 5 pounds pull re- mission, if gap exceeds 0.004 inch, tighten bolts and
quired to turn ring of lateral disc. A pull of 17 to 18 shim, if necessary, to same gap limit at studs before
pounds is required for correct adjustment of collective tightening nuts.
pitch control disc.
d. Check that spacer is installed through fore-aft
f. Fit washer as outlined in step c. control disc pivot bolt. Align disc in support bearings
and install pivot bolts. Place guard on swashplate
7-44. LAPPINGCONTROLDISC. fore-aft horn and install bolt finger-tight through
a. Disassemble discs and spread No. 600 (fine grit) guard, horn, and disc assembly rod-end. Connect
lapping compound on contact faces of ring and contact control tubes and fore-aft bungee spring.
surfaces of disc.
7-47. TAIL ROTOR CONTROL PEDALS. (Figure 7-
b. Assemble disc and ring, tightening disc bolts to 19.)
25 inch-pounds torque. Tighten ring clamp bolt to
increase friction between disc and ring. 7-48. DESCRIPTION.The pedal assembly, located
in the cabin forward of the cyclic control stick, con-
c. Install assembly in a vise or similar holding sists of two pedals made of welded steel tubing,
fixture with disc held securely and ring free to turn. two shaft assemblies incorporating adjustment ratch-
ets and lever arms, and two bearing housings mounted
d. Work arm of ring back and forth with the "X" on forward corners of box beam instrument column.
mark on the ring at the base of the arm traveling Each pedal has an adjustment pawl which engages
from one "V" mark on the disc to the other. Continue shaft ratchet to allow adjustment of pedals for pilot's
this movement until the ring turns smoothly on the convenience. Push-pull tubes connect to shaft lever
disc and until a minimum of 75 per cent of the con- arms to transmit movement of the pedals to jack-
tact area of the ring has been ground to fit. shaft in box beam.
7-16
MAINTENANCE
1. Stop Pin
2. Adjustment Lever
3. Stop
4. Pawl Rod
5. Pawl
6. Rachets
7. Rachet Shafts
8. Spacer
9. Bearing
10. Support
11. Coupling Tubes
47722-18
Figure 7-19. Tail Rotor Control Pedals
7-49. REMOVING - TAILROTORCONTROLPEDALS. 7-52. INSPECTION - TAIL ROTOR CONTROL

PEDALS.
a. Disconnect push-pull tubes from lever arms on
shaft. a. Inspect bearings for wear or roughness.
b. Remove bolts attaching shaft bearing housings to
box beam and lift assembly from helicopter. b. Inspect parts for cracks, surface damage, corro-
sion, wear and elongated bolt holes.
7-50. DISASSEMBLY - TAIL ROTOR CONTROL
PEDALS. c. Inspect installation for security of attachment
and proper operation.
a. Remove pin attaching adjusting lever to bracket
on forward side of each pedal, lift pawl clear of 7-53. REPAIR OR REPLACEMENT - TAIL ROTOR
ratchet and slide pedal from end of shaft. CONTROL PEDALS.
b. Remove pin through adjusting lever and end of a. Replace all worn or rough bearings.
adjusting rod, and remove lever. Unscrew rod and
remove rod, pawl, and spring. b. Replace an excessively worn or unserviceable
parts.
c. Remove screws and tapered bushings and separate
ratchet shafts, coupling shafts, bearing housings, and 7-54. REASSEMBLY- TAIL ROTOR CONTROL
adapter plugs (use in right end of coupling shaft, ex- PEDALS.
cept when dual controls kit is installed). Push bear-
ings from housings. a. Lubricate bearings with MIL-G-25537 grease
and install bearings in housings.
7-51. CLEANING - TAIL ROTOR CONTROL
PEDALS. Wash parts in dry cleaning solvent or b. Insert spring and pawl in lower end of guide on
kerosene and dry with filtered compressed air. right side of pedal tube. Insert adjusting rod through
7-17
Section VII (Part 1) BE LL HELICOPTER COMPANY Models 47D-1 & 47G
MAINTENANCE
top of guide and screw into pawl (to approximate guards secured to each side of box beam. Adjust-
adjustment length). Check that spacer (or stop) and able stop-screws in each side of pulley acts against
pin are installed in aft end of adjusting lever. Posi- a fixed stop, located forward of pulley, to limit travel.
tion lever, with rod attachment clip to right, on pedal
from aft side, and install pin, with head toward pedal 7-58. REMOVING - TAIL ROTOR CONTROL
tube, attaching to lever. (Omit cotter pin until rod JACKSHAFT.
length is adjusted in later assembly.)
a. Secure pedals in approximately neutral position.
c. Assemble each pedal on a ratchet shaft, raising Remove box beam access plates and access door
pawl to engage in ratchet, with straight side of pawl under cabin.
tooth forward. Insert pin attaching lever to brackets on
forward side of pedal. Check adjusting rod length b. Cut lockwire and loosen turnbuckles on tail rotor
and adjust, by removing lever and rod attachment control cables. Remove push-pull tubes betweenarms
pins and screwing rod into or out of pawl, so that on pedal shafts and jackshaft.
pawl clears highest ratchet tooth by 1/32 inch maxi-
mum when lever is raised against upper stop. Set c. Loosen bolts securing cable guards to box beam,
both pedals in aft notch of ratchet, remove cable locking bolt and slip cable from pulley
under box beam. Stow cable to prevent damage. Re-
d. Insert longest ratchet shaft (left pedal) through move bolt and pulley from shaft.
aft bearing of left-hand housing. Place coupling
shaft with lever arm fartherest right (open side of d. Match-mark, with quick drying paint, upper and
arm forward and arm pointingup) over end of ratchet lower bearing housings and spacers before removal.
shaft against bearing. Align holes and install tapered (Spacers are tapered and match-drilled with bearing
bushings and screws throug coupling shaft and ratchet housings.) Remove bolts and lower bearing housing
shaft. Bushings should protrude 1/32 inch minimum and spacer. Break cement seal between box beam
from surface of shaft. floor and bearing cover, and pull shaft downward
out of upper bearing. Remove shaft through access
e. Insert shortest ratchet shaft (right pedal) through opening in box beam. Remove bearing cover. Remove
forward bearing of left-hand housing. Place coupling bolts and upper bearing housing and spacer.
shaft with lever arm fartherest left (open side of arm
forward and arm pointing up). Lay a straight bar along 7-59. INSPECTION - TAIL ROTOR CONTROL
forward sides of pedals and clamp to each pedal to JACKSHAFT.
hold alignment. Align holes and install tapered bush-
ings and screws through coupling shaft and ratchet a. Examine parts for corrosion, excessive wear,
shaft. (Lever arm bolt holes should now be aligned.) cracks, and other damage.
f. Place right-hand bearing housing on ends of b. Inspect bearings for wear or roughness.
coupling shafts. Insert adapter plug through bearing
into each shaft, align holes, and install tapered c. Inspect installation for security and proper op-
bushings and screws. eration.
7-55. INSTALLING - TAIL ROTOR CONTROL 7-60. REPAIR OR REPLACEMENT - TAIL ROTOR
PEDALS. CONTROL JACKSHAFT.
a. Lift pedal assembly into position, align bearing a. Replace bearings if rough or worn.
housings, on each side of box beam instrument
column, and install bolts. b. Replace any excessively worn or unserviceable
parts.
b. Connect push-pull tubes, with adjustment ends
forward and longest tube at left, between arms on 7-61. INSTALLING
coupling shaft and jackshaft in box beam. - TAIL ROTOR CONTROL
JACKSHAFT.
7-56. TAIL ROTOR CONTROL JACKSHAFT. (Fig- a. Lubricate bearing with MIL-G-25537 grease and
ure 7-20.) install upper bearing housing and spacer (or spacers)
with match-marks aligned (thick end of spacer aft
7-57. DESCRIPTION. The tail rotor control jack- and larger bore up) against doubler at inside top of
shaft is located in the cabin box beam, mounted box beam. Install bolts through top of box beam,
vertically, in upper and lower bearings, and has spacers and bearing housing.
a large pulley installed on shaft end below box beam.
Push-pull tubes connect arms near upper end of b. Place bearing dust cover on lower end of shaft,
shaft to lever arms on pedal assembly. The tail above collar, place shaft in box beam through access
rotor control cable is installed on the pulley, locked opening, and insert end through hole in bottom of
by a bolt and kept in the pulley groove by cable box beam.
7-18
MAINTENANCE
. Upper Spacer
2. Upper Bearing Housing
3. Jackshaft
4. Lower Spacer
5. Lower Bearing Housing
6. Cable Guards
7. Pulley
8. Cable
9. Pulley Retaining Bolt
10. Cable Retaining Bolt
47722-17
Figure 7-20. Tail Rotor Control Jackshaft
c. Lubricate bearing with MIL-G-25537 grease and d. Slip bearing dust cover down on collar of shaft,
assemble spacer (thin end aft) and bearing housing, turning bolt heads to align flats for clearance and
On lower end of shaft. Insert upper end of shaft into positioning cover with a long edge aft. Seal cover to
upper bearing, align lower bearing housing and box beam floor with cement (EC524 Minnesota Mining
spacer, and install bolts through box beam floor, and Mfg. Co.) or equivalent, using care tokeep cement
spacer and bearing housing. Check for free rotation from entering bearing or space between cover and
of shaft and for excessive end play. If necessary, in- shaft collar.
stall or remove spacers (triangular, match-drilled
to tapered spacer, and 0.125 inch thick) between box e. Install pulley, with attachment bolt hole down and
beam doubler and upper bearing spacer. cable locking bolt hole forward whenjackshaft arms
7-19
Section (Part 1) BELL HELICOPTER COMPANY Models 47D-1 & 47G
& OVERHAUL INSIRUCTIONS
MAINTENANCE
(open sides forward) are at right angles (approxi- b. Inspect cables for broken or frayed wires, espe-
mately) to helicopter center line. Position control cially where running over pitch change drum or
cable to pulley and install pulley retaining bolt. pulleys or through fairleads, by wiping cable with a
clean soft cloth, examine cable carefully in area
f. Connect push-pull tubes, with adjustable ends where cloth pulls.
forward and longest tube at left, between jackshaft
arms and lever arms on pedal shafts. Connect con- c. Inspect pulleys for excessive wear, cracks or
trol cable at turnbuckles and check rigging of tail damage. Inspect pulley bearings for excessive wear
rotor control system. and binding. Inspect brackets for cracks. Inspect
system for security and proper operation.
7-62. TAIL ROTOR CONTROL CABLES.
7-63. DESCRIPTION. Two sections of standard(NAS) 7-67. REPAIR OR REPLACEMENT - TAIL

preformed, corrosion resistant, flexible steel aircraft ROTOR CONTROLCABLES.
cable are jointed by turnbuckles located in tail boom
structure near the lower boom attachment to center a. Replace cables that show more than three broken
frame. The tail rotor control cable so formed is a wires in any one inch of length. This is limited to
continuous loop, locked to and actuated by the control two such places on any one cable. Replace cables if
jackshaft pulley at forward end, and locked to and corroded or badly worn even though no broken wires
actuating a spirally-grooved pitch change drum (on are found.
left side of tail rotor gear box) at aft end. A series
of pulleys and fairleads support and guide the cable b. Replace pulleys for excessive wear, damage, or
under and through center frame and tail boom. At for rough or excessively worn bearings.
original installation, pulleys or brackets are color
coded (red and white) and corresponding color code 7-68. INSTALLING - TAIL ROTOR CONTROL
is applied on cable terminals to aid in proper routing CABLES.
in reinstallation. Forward section of cable has righ-
hand threaded turnbuckle terminals, aft section has a. Observing color coding at pulleys and on cable
left-hand threaded terminals. terminals, route aft section of cable through pulleys
and fairleads, installing guard pins. Loop cable
7-64. REMOVING - TAIL ROTOR CONTROL loosely over pitch change drum.
CABLES.
b. Loop forward section of cable on jackshaft pulley,
a. Secure control pedals in neutral by placing a bar adjust guards to retain cable on pulley, and thread
across front side, clamped or taped to both pedals. ends aft through fairleads in bulkhead. Route cable
under pulleys below center frame and over pulleys
b. Disconnect cable turnbuckles. Remove access at lower tail boom attachment point. Install guard pins
door under cabin. Loosen bolts securing cable guards in pulley brackets.
to each side of box beam, remove cable locking bolt
and cable from jackshaft pulley. c. Join ends of cables loosely at turnbuckles. Rig
tail rotor control system. (Refer to paragraph 7-8.)
c. Remove guard pins or pulleys as necessary and
remove forward section of cable. 7-69. VENTRAL FIN.
d. Loosen cable locking screw at pitch change drum 7-70. DESCRIPTION. The ventral fin is secured to
on tail rotor gear box, and disengage cable from the underside of tail boom structure at the aft end.
drum. This installation provides stability about the longi-
tudinal and horizontal axis of the helicopter.
e. Remove guard pins or pulleys as necessary, re-
lease cable from fairleads, in tail boom, and remove 7-71. REMOVAL - VENTRAL FIN.
aft section of cable.
a. Remove bolts attaching assembly to brackets on
7-65. CLEANING - TAIL ROTOR CONTROL tail boom.
CABLES. Wash cables in dry cleaning solvent or
kerosene. Dry with filtered compressed air. Wipe b. Remove bolts attaching tab clamp to tail boom
pulleys and fairleads with cloth dampened with dry and remove assembly from helicopter.
cleaning solvent.
7-72. INSPECTION - VENTRAL FIN.
7-66. INSPECTION - TAIL ROTOR CONTROL
CABLES. a. Inspect fin for security of attachment, scratches,
dents, punctures and structural damage.
a. Inspect control cables for corrosion or excessive
wear. b. Inspect braces and brackets for cracks.
7-20
MAINTENANCE
c. Check condition of chafing pad between braces

and lower tube of tail boom.
7-73. REPAIR OR REPLACEMENT - VENTRAL

FIN.
a. Replace chafing pad when necessary to prevent

chafing of lower tail boom tube by braces of ventral
fin. Make pad from 5/8 ID x 1/16 x 2.0 inch rubber
tubing, (Specification MIL-R-6855, Class II or equiv-
alent) split and bonded to tail boom with EC777 rubber
cement. Pad may also be made by wrapping tail boom
tube with Scotch electrical tape, or equivalent, to a
thickness of 1/16 inch over an area 2.0 inches long.
b. Repair cracks or punctures in skin up to 1/2 inch

in diameter by patching.
c. Repair damage to fin greater than 1/2 inch in

diameter by insertion.
d. Repair damage to edge of fin.
7-74. REPAIR OF VENTRAL FIN BY PATCHING.

(Figure 7-21.) Repair cracks or puncture in skin
up to 1/2 inch diameter as follows:FIN
CLEAN AND
a. Stop-drill cracks or cut-out punctured damage PRIME AREA
and smooth edge of hole in skin.
b. Cut plate patch, large enough for 1/2inchoverlap, 47267-31

from 24S-T3 aluminum alclad sheet, 0.012 inch thick.
c. Use aluminum wool to clean skin area where patch

is to be applied. Wipe clean with dry cloth. Figure 7-21. Repair of Ventral Fin by Patching
d. Apply one coat of primer, Narmco NO. 2105

(Narmco Resins and Coating Co., 600 Victoria St., b. Cut two patch plates of same material as skin
Costa Mesa, California) to patch plate and to fin (aluminum alclad, 24S-T3, 0.012 inch thick) and same
patch area. Allow to dry 24 hours. size as hole. Cut two more patch plates of same
material and large enough to allow one inch overlap
e. Cut a piece of bonding tape NO. 102-45 to size around hole.
of metal patch plate. Use special care in keeping
tape clean to obtain satisfactory bond. c. Apply one coat of primer, Narmco NO. 2105, to
honeycomb core and to both sides of smaller patch
f. Lay bonding tape over damage area. Position plates, and to one side of each overlap plate. Allow
patch on bonding tape and bond at 15 to 25 PSI with primer to dry 24 hours.
heating iron or vacuum blanket for 25 minutes at
350°F. d. Cut two pieces of bonding tap NO. 102-45, same
size as smaller patch plates. Cut two more strips
g. Clean off squeezed-out bonding tape and refinish of bonding tape same size as larger patch plates.
area. Prepare a strip of bonding tape to fit around core
insert. Use special care in keeping tape clean to
7-75. REPAIR OF VENTRAL FIN BY INSERTION. obtain satisfactory bond.
(Figure 7-22.) Repair damage to ventral fin greater
than 1/2 inch in diameter as follows: e. Wrap bonding tape around core insert and posi-
tion in hole. Place smaller pieces of bonding tape
a. Cut a piece of aluminum core to replace damage and smaller patch plates in hole on each side of
section (core specifications are 0.250 thick x 0.250 honeycomb insert. Cover hole, at each side of fin,
hex. 1.5 mil x 3.4 density aluminum honeycomb, with larger pieces of bonding tape and overlap
Hexcil Products Co., 955 Sixty-first St., Oakland 8, patch plates. Apply 15 to 25 PSI with heating irons
California). for 25 minutes at 350°F.
7-21
MAINTENANCE
b. Assemble tab clamp on tail boom brace member

and install bolts.
7-78. HORIZONTAL STABILIZER (MODEL 47D1).

1. Heating Iron 7-79. DESCRIPTION. The horizontal stabilizer con-
2. Patch Plate sists of two triangular-shaped tubular steel frames
3. Bonding Tape covered with cotton airplane fabric, and is attached
4. Filler Plate to the tail boom near the boom extension.
5. Honeycomb Core
Insert
6. Damaged Area 7-80. REMOVAL - HORIZONTAL STABILIZER.
a. Remove bolts securing tube extensioninto sleeves.
b. Remove bolts attaching braces to eyebolts and
remove stabilizer from helicopter by pulling each side
from sleeves.
7-81. INSTALLATION - HORIZONTAL STABILIZER.
a. Push stabilizer tube extension into the sleeves

and install bolts.
b. Install bolts attaching braces to eyebolts.
7-82. SYNCHRONIZED ELEVATOR (MODEL 47G).
7-83. DESCRIPTION. The synchronized elevator is

installed to increase controllability, widen CG range,
and to provide operation within the CG range for all
normal loading conditions without moving the battery
or carrying ballast. The elevator is connected to the
47267-24A cyclic control system.
7-84. REMOVAL - SYNCHRONIZEDELEVATOR.
Figure 7-22. Repair of Ventral Fin by Insertion
a. Remove cotter pins and clevis pins attaching
cable clevis to elevator horn.
f. Clean off squeezed-out bonding tape and refinish b. Remove nuts and bolts attaching elevator to
repaired area. structure and slide elevator out of tailboom structure.
7-76. REPAIRING EDGE OF VENTRAL FIN.
7-85. INSPECTION - SYNCHRONIZED ELEVATOR.
a. Prepare a mixture of Narmco NO. 3119 resin
putty and Narmco NO. 3119-C catalyst (Narmco a. Inspect elevator for security of installation, cracks,
Resins and Coating Co., 600 Victoria St., Costa Mesa, dents, loose rivets, and structural damage. Inspect
California) according to directions on container. support brackets for cracks or elongated holes. In-
(Alternate material: EC1184 Glazing Cement, Min- spect bearings for roughness or excessive wear.
nesota Mining and Mfg., Co.)
b. Inspect cables for security of installation and
b. Apply putty mixture to edge of fin with putty proper routing through pulleys and fairleads. In-
knife, forming a contour slightly larger than that spect daily for broken or frayed cables, especially
of undamaged edge to allow for shrinkage. Let dry where running over pulleys or fairleads.
24 hours.
c. Inspect pulleys for wear and rough bearings,
c. Dress repaired edge with fine mill file to same and brackets for cracks.
contour as undamaged area.
7-86. REPAIR OR REPLACEMENT - SYN-
7-77. INSTALLATION - VENTRAL FIN. CHRONIZED ELEVATOR.
a. Place assembly in brackets under tail boom and a. Repair or replace elevator if structural damage
install bolts. occurs. Replace worn or rough bearings.
7-22
MAINTENANCE
Note two such places on any one cable. Replace cables

Operators in territorial United States if corroded or badly worn even though no broken
make repairs or replacements in accord- wires are found.
ance with Civil Aeronautics Manual 18.
Helicopters operated outside territorial 7-87. INSTALLATION - SYNCHRONIZED
ELE-
United States will be repaired in accord- VATOR.
ance with instructions issued by the li-
censing authority. a. Position elevator in tail boom structure and
secure with bolts, washers and nuts.
b. Replace pulleys for excessive wear or rough
bearings. b. Position control cable clevis to elevator horn and
install clevis pins, washers and cotter pins. Connect
c. Replace cables that show more than three broken fail safe spring. Check rigging of synchronized
wires in any one inch of length. This is limited to elevator.
7-23/7-24
Models 47G & 47G-2 BELL HELICOPTER COMPANY Section VII (Part 2)
MAINTENANCE
Section VII
Section VII - Part 2
7-1. FLIGHT CONTROLS - HYDRAULIC. a. Level helicopter. Check main rotor mast for
vertical alignment, using a bubble protractor or
7-2. DESCRIPTION. Control of the helicopter is ac- square head and adjusting sprag rods and safety
complished through three flight control systems. The cables as necessary. (Refer to Section V.)
cyclic control system, through push-pull tubes, torque
tubes, bellcranks, boost cylinders, and swashplate,
transmits any movement of the cyclic control stick b. Disconnect both push-pull tubes from bellcrank
to the main rotor hub, which changes main rotor located on lower horizontal seat-back structural tube
attitude, to move the helicopter to either side or in near left side.
a forward or rearward direction. A synchronized
elevator is linked to the cyclic control system in
such a manner that the fore and aft movement of c. Clamp swashplate scissor levers in neutral. (Fig-
the cyclic stick controls the angle of incident of the ure 7-24.)
elevator.
The collective pitch control system, through push- d. Set position of bellcrank, mounted to support on
pull tubes, torque tubes, and bellcranks, transmits transmission, by adjusting length of link to allow
movement of pitch control lever to the pitch change rigging fixture, T100219, to be installed over ends
mechanism of the main rotor hub. By means of the of bellcrank pivot bolt, push-pull tube attachment
collective system, the helicopter can be made to bolt, and bolt attaching link to swashplate lever.
ascend or descend vertically or to hover.
The tail rotor system, through pedals, cables, pitch Note
change mechanism, and tail rotor blades, controls
engine torque effect on the tail boom in addition to If rigging fixture, T100219, is not avail-
providing directional control.
providing
control.
directional able, use a bubble protractor across pivot
and push-pull tube attachment bolts to set
A ventral fin is mounted on the underside of the tail forward end of bellcrank 6 degrees, 55
boom structure to provide stability about the longi- minutes above horizontal.
tudinal and horizontal axis of the helicopter.
e. Set bellcrank aft of pilot's seat so that center
7-3. RIGGING FLIGHT CONTROLS. Rigging is re- line through pivot point and bolt hole in long arm
quired after installation or replacement of com- makes an angle of 6 degrees, 35 minutes below hori-
ponent parts of the control system. Each system may zontal. Adjust and install push-pull tube between this
be rigged independently. However, if necessary to rig bellcrank and bellcrank on transmission.
both cyclic and collective systems, it is recommended
that the collective system be rigged first. f. Set collective pitch control stick 56 1/2 degrees
above horizontal and tighten friction knob to hold
position securely. Adjust and install push-pull tube
between arm on collective pitch torque tube and bell-
crank aft of pilot's seat.
Do not apply hydraulic boost to flight con-
trols at any time when rigging tools or g. Place a pencil mark on mast in line with top of
pins are installed. Since movement of the collective pitch sleeve. (See figure 7-25.) Measure
controls could result in serious damage 23/64 inch above top of sleeve and place second
to the control system. mark on mast. Remove clamps from swashplate
scissors levers, release friction lock and move
7-4. RIGGING - COLLECTIVE PITCH CONTROL collective pitch control stick on high pitch position.
SYSTEM. (Figure 7-23.) Adjust stop-screw on collective pitch lever arm to
align top of sleeve with upper mark on mast. With
Note control stick full down, adjust stop-screws on trans-
mission cap to allow 23/64 inch travel of sleeve
Tolerance for all angular settings is plus below neutral position mark. Tighten lock-nuts and
or minus 1/2 degree. lockwire stop-screws.
7-1
Section VII (Part 2) BELL HELICOPTER COMFANY Models 47G & 47G-2
MAINTENANCE
23/64" SLEEVE TRAVEL EACH

WAY FROM NEUTRAL CLAMP SCISSOR
LEVERS
IN NEUTRAL
PITCH
HIGH PITCH
NOTE:
TOLERANCE FOR ALL SETTINGS
1/2 ° . CHECK LOW PITCH BLADE
ANGLES BEFORE FLIGHT
EXTREME TRAVEL POSITIONS

ARE APPROXIMATE
47727-14
Figure 7-23. Rigging Diagram - Collective Pitch Control

7-2
Models 47G & 47G-2 BELL HELICOPTE R COMPANY Section VII (Part 2)
MAINTENANCE
47720-1 47727-1
Figure 7-24. Clamping Scissor Levers in Neutral. Figure 7-25. Measuring Collective Sleeve Travel
h. Disconnect both link-rods from stabilizer bar Note

mixing levers and pitch horns on rotor hub. Adjust
rods 7 13/16 inches between centers of bolt holes During first flight after rigging collective
and reinstall in original locations. pitch system, check main rotor RPM in
autorotation. Gross weight will effect auto-
rotation RPM so that it should be adjusted
Note in the configuration and gross weight at
which the helicopter will be operated.
Step h. above applies to initial rigging. If Make an autorotation descent with the
performing rigging check after flight tests, collective pitch control full down at an
and it is known that link-rods were ad- indicated airspeed of 50 MPH and check
justed to unequal length in a "hub-rolling" for a rotor speed of approximately 340
operation to compensate for a high trim- RPM. Then in an autorotation descent at
tab condition in tracking blades, omit step h. an indicated airspeed of 50 MPH execute
a moderate flare. Rotor speed should not
i. Check low pitch blade angles, to establish safe exceed 360 RPM in the flare.
autorotational rotor RPM on test flight, by following
procedure. Place collective pitch control stick in full k. If rotor speed is below 340 RPM in autorotation
down position. Place a spirit level chordwise on flat at 50 MPH airspeed, decrease blade angle in low
area of one blade root, just beyond end of grip. Raise pitch by shortening both link-rods which connect
or lower one end of stabilizer bar to obtain level pitch horns to stabilizer bar mixing levers. If rotor
reading. Keeping this blade level, place protractor on speed exceeds 360 RPM in flare, increase blade angle
other blade in same manner and check for angular in low pitch by lengthening both link-rods. Adjust
measurement of 1/2 to 1 degree, leading edge up. rods evenly in 1/2 turn increments. Repeat test
Adjust to correct reading by lengtheningor shorten- flight after adjustment.
ing both link-rods, between stabilizer bar mixinglever
and blade pitch horns, keeping length of rods equal.
1. If pilot observes a tendency for collective pitch
control stick to creep upward or downward while
Note cruising at 23 in. Hg manifold pressure, correct
condition by changing counterweights. (Refer to Sec-
Adjust link-rods evenly. This method tion II, Part I.)
measures total of both blade angles, as-
suming angle of each blade to be half the RIGGING - FORE AND AFT CYCLIC
total reading because length of linkage is 7-5. RIGGING - FORE AND AFT CYCLIC CONTROL
CONTROL
SYSTEM. (Figure 7-26.)
equal. SYSTEM. (Figure 7-26.)
equal.
j. Check complete system for security and for free- Note
dom of operation. Start and warm-up engine. (Refer
to Section I.) Track main rotor blades. (Refer to Tolerance for all angular settings is plus
Section II.) or minus 1/2 degree.
7-3
Section VII (Part 2) BELL HELICOPTER COMPANY Models 47G & 47G-2
DAMPER (LYCOMING ENGINE).

SHAFTAT HALF-TRAVEL.
°
30 UP FWD
120-046-17-9 SHIMS USE LEVELING PLATE TO

SHIM AS REQUIRED EQUALLY SET SWASHPLATE 1 2° UP
ON EACH SIDE OF BELLCRANK AT FWD SIDE
2.TO PROVIDEBUSHINGCLEARANCE
OF0.005OR LESS.
TORQUENUT 50-70 INCHPOUNDS.
STICKCENTEREDIN NEUTRAL
SET UPPER ARMVERTICAL,

LOWERARM6° FWD.
+1/2°
TOLERANCEFOR ALL SETTINGS
47724-13F
Figure 7-26. Rigging Diagram - Fore - Aft Cyclic Control

7-4
MAINTENANCE
a. Level helicopter. (Refer to Section I.) Check

vertical alignment of mast with bubble protractor or CAUTION
square head, adjusting sprag mount rods and safety
cables as necessary. (Refer to Section V.) Do not move cylinder shaft or valve with-
out either bolt or T101233 pin in place,
b. Clamp centering fixture, 47-300-001-1-T222, because of possible damage to parts by
around bell housing at base of cyclic control stick. accidentally pulling valve body off end of
below outer bell. If fixture is not available. use shaft. Keep bolt and pin clean and protect
bubble protractor or square head to place stick in machined surfaces. T101233pin is neces-
a vertical position. Tighten friction, by turning sary, for accurate rigging, to eliminate
knurled nut, to hold stick firmly in position. movement between valve body and cylinder
shaft.
c. Remove access door under cabin. Disconnect
push-pull tube between control stick and torque arm f. Set bellcrank, below power cylinder, so that
on left-hand end of jackshaft, located aft of cabin center line through pivot bolt and valve body trunnion
floor bulkhead. Set jackshaft so left torque arm points is 2 degrees down aft. (When rigging with hydraulic
down and 6 degrees forward of vertical center line lines connected to trunnion. use protractor on upper
of shaft (torque arm near middle of shaft points flange of bellcrank and set bellcrank 1 degree up
straight up.) Adjust and reinstall push-pull tube. at aft end.) Adjust and install push-pull tube between
bellcrank and middle arm of cyclic control jackshaft.
d. Disconnect push-pull tubes from bellcrank below
fore-aft hydraulic power cylinder and from clevis g. Disconnect all linkage from fore-aft lever mounted
adapter at top end of cylinder shaft. Disconnect syn- at front of transmission. Set lever with forward bolt
chronized elevator linkage from fore-aft system. 2 degrees above pivot bolt. Adjust and install push-
Adjust clevis adapter to dimension of 1 7/32 inches pull tube between forward end of lever and clevis
between bolt hole center and upper end of cylinder adapter at upper end of cylinder shaft.
shaft, with clevis slot aligned fore and aft.
h. Place leveling plate, T100436, on swashplate.
e. Remove bolt from valve body and insert valve (See figure 7-28.) Using bubble protractor on leveling
centering pin, T101233, with flats of head parallel plate, set swashplate 1/2 degree up forward. Adjust
to cylinder center line and tapered shoulders seated and install push-pull tube between swashplate horn
in elongated bolt hole to hold valve body in neutral and lever on front of transmission. Install washers
position on cylinder shaft. (See figure 7-27.) on bolt through swashplate horn as needed to center
.06R. TYP.
L.100 1.09
25D.
2
R.
.280
.279 DIA.
.45D
1. Bolt - Valve Retaining .15
2. T101233 Valve Centering Pin
3. Valve Body
4. Power Cylinder Shaft
Tapered shoulder and .279 - .280
diameter concentric within .005 T.I.R.
47724-19
Figure 7-27. Valve Centering Pin T101233

7-5
j. Adjust and install link-rod between damper arm

and right (shortest) arm of bellcrank at front of
transmission, keeping bellcrank and damper arm in
neutral position.
In following steps, if hydraulic cylinders

are full of fluid, movement of controls may
be prevented while T101233 pin holds
valve in neutral. Carefully pull pin out
just far enough to allow valve to operate,
move controls to desired position, then
reseat pin in valve body.
k. Remove stick centering fixture or release friction

lock, and move stick to extremes of forward end aft
travel, checking for freedom of operation. To make
sure piston is not bottoming in cylinder, set control
stick full aft and check that bolt connecting push-pull
tube to cylinder bellcrank can be easily slipped in
or out. If adjustment of rod-end is necessary, also
adjust push-pull tube connected to upper end of shaft
Figure 7-28. Leveling plate and protractor in Place an equal amount in opposite direction in order to
maintain swashplate setting. Move stick full forward
and repeat check. Recheck neutral rigging.
rod-end and eliminate clearance between bearing
inner race and sides of horn clevis. (Maximum gap
0.005 inch.) 1. check swashplate travel, using protractor on
leveling plate. (see figure ‘7-29.)
Note
m. check rigging of synchronized elevator. (Refer
to paragraph 7-8.)
steps i, and j., apply to fore-aft damper
used with Lycoming engine installation.
(For damper service and adjustment refer
to paragraphs 7-65 and 7-66.)
Helicopters with Lock and Load valves in- If it is suspected that bolt securing the
Stalled dampers and bungee springs are valve body to the power cylinder shaft has
not required. been previously over-torqued inspect the
bolt by magnetic particle inspection. Upon
Note installation of nut (or nuts) tighten nut snug
(maximum 5 inch pounds torque), then back
off to next castellation and install cotter
Laminated shims, Part No. 120-046-17-9, pi”.
must be used equally on each side of the
bellcrank bushing (as required) to make the n. Remove valve centering pin, T101233, and reinstall
gap of 0.005 or less, between the bellcrank bolt through valve body and shaft, securing with wash-
bushings and support bracket, tighten nut ers, nuts and cotter pi”.
and torque 50-70 inch-pounds, (figure7-26).
7-6. RIGGING - LATERAL CYCLIC CONTROL SYS-
i. check position of fore-aft damper arm, to be 30 TEM - FRANKLIN ENGINE. (Figure 7-30.)
degrees up forward when shaft is midway of travel
(See figure 7-26.) Adjust position, if necessary, as
follows: Choose or mark a reference paint on end of
shaft, move shaft full travel each way, marking case This procedure applies to helicopters
opposite mark o” shaft, then set Shaft midway of tra- equipped with Franklin engine. Tolerance
vel. Remove snap-ring, loosen clamp-bolt, and Pull for all angular settings is plus or minus
arm from shaft. Reinstall in correct position on Shaft 1/2 degree.
splines. Push arm on shaft as far as possible to in-
stall snap-ring, then poll arm firmly against snap-ring a. Level helicopter. (Refer to section I.) check
and tighten clamp-bolt. vertical alignment of mast, adjusting sprag mount
7-6
MAINTENANCE
rods and safety cables as necessary. (Refer to

Section V.)
b. Disconnect bungee spring from bellcrank in left

side of engine mount. Clamp centering fixture, 47-
300-001-1-T222, around bell housing at base of cyclic
control stick, below outer bell. If fixture is not
available, use bubble protractor or square head to
place stick in a vertical position. Tighten friction,
by turning knurled nut, to hold stick firmly in posi-
tion.
Note
Bungee springs not installedonhelicopters

with lock and load valves installed.
c. Disconnect link-rod between control stick horn and

bellcrank mounted on left side of box beam under
cabin floor. Set bellcrank so that center line through
pivot bolt and bolt hole in aft arm is 90 degrees to
side of box beam. Readjust and reinstall link-rod.
7-6A
MAINTENANCE
°
1/2°UP 9-1/2 6-1/2 ° 7-1/2 ° 1/20
RIGHT LEFT
FORE & AFT LATERAL
FORE AND AFT LATERAL
Stick Position Neutral Forward Aft Neutral Right Left

Swashplate Angle 1/2 ° up fwd 8-1/2 °
9-1/2 °
1/2 ° down left 6-1/2 °
7-1/2 °
Note: Tole ance: 1/2 47150-50A

47150-50A
Figure 7-29. Rigging Swashplate
d. Disconnect push-pull tubes between bellcrank on h. Disconnect push-pull tubes between bellcrank
cabin box beam and cylinder shaft lever, at lateral at sprag mount bracket and bellcrank in left side of
sprag mount bracket. Adjust clevis adapter on aft engine mount, and between bell crank and swashplate
end of power cylinder shaft, to dimension of 1 7/32 horn. Set bellcrank in engine mount so that outboard
inches between end of shaft and center of clevis bolt (longer) arm is 10 degrees up from horizontal,
hole. measured on center line between pivot and bolt hole
in outboard end of arm. Adjust and install push-pull
e. Remove bolt and install valve centering pin, tube between upper and lower bellcranks.
T101233, with flats of pin parallel to cylinder center
line and tapered shoulders seated fully in elongated i. Place leveling plate, T100436, on swashplate.
hole to center valve body in neutral on shaft. (See (See figure 7-28.) With bubble protractor on leveling
figure 7-27.) plate, set swashplate tilted 1/2 degree down left.
Adjust and install push-pull tube between swashplate
horn and inboard arm of bellcrank in left side of
CAUTION engine mount. Tighten bolt through swashplate horn
finger-tight only.
Do not move cylinder shaft or valve body Note
without either bolt or T101233pininplace,
because of possible damage to parts by In following steps, if hydraulic cylinders
accidentally pulling valve body off end of are full of fluid, movement of controls
shaft. Keep bolt and pin clean and protect may be prevented while T101233 pin holds
machined surfaces. T101233 pin is neces- valve in neutral. Carefully pull pin partly
sary, for accurate rigging, to eliminate out, just far enough to allow valve to op-
movement between shaft and valve body. erate, move controls to desired position,
then re-seat pin in valve body.
f. Measure travel of cylinder shaft and set in half- j. Check security of installation and proper safety-
travel position. Adjust and install push-pull tube ing throughout system. Remove centering fixture or
between bellcrank on box beam and cylinder shaft release friction from control stick. Move control
lever, keeping shaft in neutral. stick to extreme positions laterally, checking for
freedom of movement and checking with protractor
on leveling plate for swashplate angles of 7 1/2
g. Set outboard arm of bellcrank, mounted between degrees with stick full left, and 6 1/2 degrees with
lateral sprag mount bracket and center frame tube, stick full right. (See figure 7-29.) Remove leveling
up 30 degrees, 12 minutes from horizontal at forward plate. Remove valve centering pin, T101233, and
end. Adjust and install push-pull tube between cylinder reinstall bolt through valve body and power cylinder
shaft clevis and inboard arm of bellcrank. shaft.
7-7
MAINTENANCE
SET SWASHPLATE
1/2° DOWN LEFT
AHD\ INNEUTRAL
CONNECT BUNGEE
SPRING AFTER
RIGGING
SET CYLINDER SHAFT

AT HALF-TRAVEL.
INSTALL T101233 VALVE
ENTERING PIN.
CENTER
STICK IN
NEUTRAL
17/32"
LOOKING
DOWN
47725-8A
Figure 7-30. Rigging Diagram - Lateral Cyclic Controls - Franklin Engine

7-8
MAINTENANCE
7 1/2 UP
VIEW A-A
VIEW B-B
TRAVEL. INSTALL T101233

Figure 7-31. RiggingDiagram - Lateral Cyclic Controls
CYLINDER- Lycoming
SHAFT Engine
AT HALF-
TRAVEL.
VALVE INSTALL
CENTERING PIN. T101233
°TOLER-
VIEW D-D
VIEW D-D ANCE ALL
ANCE ALL ANGLES
ANGLES ± 1/2
1/2
Figure 7-31. RiggingDiagram - Lateral Cyclic Controls - LycomingEngine

7-9
MAINTENANCE
k. Check that grooved spacer and large washer are

installed under bolt head at aft side of inboard arm CAUTION
of bellcrank in engine mount bracket. Check in-
stallation of protective plate and clamps on engine Do not move cylinder shaft or valve with-
mount tube above bellcrank. Move stick full right out either bolt or T101233 pin in place,
and install bungee spring, hooked over protective because of possible damage to parts by
plate between clamps and in groove of spacer, accidentally pulling valve body off end of
(Bungee spring not required when lock and load shaft. Keep bolt and pin clean and protect
valves installed.) machined surfaces. T101233pin is neces-
sary, for accurate rigging, to eliminate
movement between shaft and valve body.
1. Check for freedom of movement of valve body
on cylinder shaft in all control stick positions. Not f. Set bellrank below power cylinder so that center
more than five pounds force should be required to line through pivot bolt and lower cylinder trunnion
move valve body from any position, is 10 1/2 degrees down aft (or measure travel of
cylinder shaft and set in half-travel position). Adjust
7-7. RIGGING - LATERAL CYCLIC CONTROL SYS- and install push-pull tube between bellcrank below
TEM - LYCOMINGENGINE. (Figure 7-31.) cylinder and aft arm of bellcrank on cabin box beam.
Note g. Install push-pull tube between clevis adapter and

forward arm of lateral control torque tube, adjusting
This procedure applies only to helicopters length so that center of bolt hole in aft arm is 5/32
equipped with Lycoming engine. Tolerance inch above center line of torque tube.
for all angular settings is plus or minus
1/2 degree. h. Disconnect push-pull tube between swashplate
horn and aft arm of torque tube. Place leveling plate,
a. Level helicopter. (Refer to Section .) Checkverti- T100436. on swashplate. (See figure 7-28.)With bubble
cal alignment of mast, adjusting sprag mount rods and protractor on leveling plate, set swashplate 1/2 degree
safety cables as necessary.(Refer to Section V, Part II.) down left. Adjust length and install push-pull tube
between swashplate and torque tube, with grease
b.
b. Disconnect
Disconnect bungee
bungee spring
spring and
and lateral
lateral damper fitting in rod-end facing outboard.
damper swashplate horn finger-tight only Tighten bolt through
link-rod from aft end of torque tube. (Bungee spring
not required when lock and load valves installed.)
Clamp centering fixture 47-300-001-1-T222, around
base of cyclic control stick, below outer bell. If Dampers not used if
fixture is not available, use bubble protractor or Dampers not used if lock
lock and
and load
load valves
valves
square head to place stick invertical position. Tighten
friction, by turning knurled nut, to hold stick firmly
i.Check position of lateral damper arm, to be 7 1/2
degrees above horizontal when shaft is midway of
travel. Adjust position of arm on shaft, if necessary,
c. Remove access door under cabin. Disconnect as follows: Choose or mark a reference point on
link-rod between control stick horn and bellcrank end of shaft, move shaft full travel eachway, marking
mounted on left side of box beam under cabin floor. case opposite mark on shaft, then set shaft midway
Set bellcrank so that center line through pivot and of travel. Remove snap-ring, loosen clamp-bolt, and
bolt hole in aft arm is 90 degrees to side of box pull arm from shaft. Reinstall in correct position
beam. Adjust and reinstall link-rod. on shaft splines. Push arm on shaft far as possible
to install snap-ring, then pull arm firmly against
snap-ring and tighten clamp bolt.
d. Disconnect push-pull tube between bellcrank on
cabin box beam and bellcrank below lateral power j. Adjust and install link-rod between damper arm
cylinder. Disconnect push-pull tube between clevis and aft arm of torque tube, keeping damper and torque
adapter at top of cylinder shaft and forward arm of tube in neutral positions.
torque tube. Adjust clevis adapter to dimension of
1 7/32 inches between end of shaft and center of clevis Note
bolt hole.
In following steps, if hydraulic cylinders
are full of fluid, movement of controls
e. Remove bolt and install valve centering pin, may be prevented while T101233 pin holds
T101233, with flats of pin parallel to cylinder center valve in neutral. Carefully pull pin partly
line and tapered shoulders seated fully in elongated out, just far enough to allow valve to op-
hole to center valve body in neutral position on shaft. erate, move controls to desired position,
(See figure 7-27.) then re-seat pin in valve body.
7-10
MAINTENANCE
CAUTION
If it is suspected, that bolt securing the

valve body to the power cylinder shaft has
been previously over-torqued, inspect the
bolt by magnetic particle inspection. Upon
installation of nut (or nuts) tighten nut snug
(maximum 5 inch-pounds torque), then back
off to next castellation and install cotter pin.
k. Check security of installation and proper safetying

throughout lateral control system. Remove centering
fixture or release friction from control stick. Move
control stick to extreme lateral positions, checking
for freedom of movement and checking with bubble
protractor on leveling plate for swashplate angles
of 7 1/2 degrees with stick full leftand 6 1/2 degrees
with stick full right. (See figure 7-29.) Remove leveling
plate. Remove valve centering pin T101233, and re-
install bolt through valve body and power cylinder
shaft.
7-10A
MAINTENANCE
1. Check that grooved spacer and large washer are to 14 1/2 degrees from level position. With stick full
installed under bolt head at forward side of aft arm aft, check elevator position for leading edge down
on torque tube. Check installation of protective plate 24 to 30 degrees from level position.
and clamps on engine mount tube above torque tube.
Move control stick full right and install bungeespring, Note
(bungee spring not required if lock and load valve
installed) hooked over protective plate between clamps If proceeding steps fail to produce proper
and in groove of spacer. neutral setting and travel limits, change
m. Check damper stiffness, adjusting as necessary. lower
lower elevator
elevator control
control horn
horn to
to next
next at-
at-
(Refer to paragraph 7-66.) tachment of cables.
7-8. RIGGING - SYNCHRONIZEDELEVATOR.

(Figure 7-32.)
Note
If it is suspected, that bolt securing the
Rig synchronized
Rig synchronized elevator
elevator after rigging
after rigging valve body to the power cylinder shaft has
been previously over-torqued, inspect the
the fore and aft cyclic system. Tolerance been previously over-torqued, inspect the
for all angular settings is plus or minus bolt by magnetic particle inspection. Upon
1/2 degree installation of nut (or nuts) tighten nut snug
(maximum 5 inch pounds torque), then back
off to next castellation and install cotter pin.
a. Clamp centering fixture, 47-300-001-1-T222, on
bell housing at base of cyclic control stick, below
bell cover. If fixture is not available use bubble e. Remove valve centering pin, T101233, and install
protractor or square head to place stick in vertical bolt through valve body and power cylinder shaft.
position. Tighten friction nut, to hold stick firmly Connect bungee spring (if removed). Lockwire turn-
in position. Install valve centering pin, T101233, to buckles and check system for security and proper
center valve body in neutral on fore and aft cyclic operation.
hydraulic power cylinder shaft. Align flats of pin
parallel to cylinder center line and seat tapered 7-9. RIGGING - TAIL ROTOR CONTROLS. (Figure
shoulders fully in hole. (See figure 7-27.) 7-33.)
a. Cut lockwire and loosen two turnbuckles to pro-

b. Disconnect bungee spring and check link for vide slack in tail rotor cables. Remove lockwire,
length of 3 3/16 to 3 5/16 inches between center of loosen set screw and unwind cable from pitch change
holes. (If installed) set outboard (shortest) arm of drum on tail rotor gear box.
torque tube to point forward and 56 degrees down.
Adjust and install link-rod between inboard (longest) b. Remove cabin box beam access plates and access
arm of torque tube and clevis on lower end of power door under cabin. Check that pedal adjustment pawls
cylinder. Position cable actuating bellcrank so that are in aft notch at each pedal. Clamp pedals in
upper arm is vertical, adjust and connect double neutral, using a suitable straight bar laid across
links to torque tube arm and bellcrank. forward side and secured by C-clamps onboth pedals.
c. Route cables, as shown figure 7-32, connect to
bellcrank and synchronized elevator. Place bubble c. Remove cable locking bolt from jackshaft pulley.
protractor on leveling lugs, located on right elevator Adjust push-pull tubes between jackshaft arms and
fin. Adjust cable turnbuckles to position elevator in pedal coupling shaft lever arms to align jackshaft
neutral, leading edge down 15 1/2 to 16 1/2 degrees. pulley in neutral (cable locking bolt hole onhelicopter
Cable tension should be 24 to 30 pounds. center line).
Note Note
In following step, if hydraulic cylinder is When pulley is in neutral, right arm lever
full of fluid, movement of controls may be on upper end of jackshaft is slightly for-
prevented while T101233 pin holds valve ward of left arm. Push-pull tubes are
in neutral. Carefully pull pin partly out, unequal in length. If adjustment causes
just far enough to allow valve to operate, one tube to be excessively lengthened and
move control stick to desired position, other tube excessively shortened, as shown
then re-seat pin in valve body. by number of exposed threads, remove and
reinstall tubes in correct locations.
d. Remove centering fixture, or release friction,
from cyclic control stick. With stick full forward d. Clamp right-hand cable to structure so as to
check elevator position for leading edge up 13 1/2 locate forward end of cable terminal sleeve 9 to 11
7-11
LEVELING LUGS
MINIMUM DIMENSION
IN NEUTRAL
CABLE TENSION
FORE-AFT POWER 24 TO 30 LBS.
CYLINDER IN NEUTRAL. (IN NEUTRAL)
INSTALL T101233 13-1/2°

VALVE CENTERING PIN
°
14-1/2
15 1/2° o,
|16-1/2
- -1aS4
\
24
3-3/16" TO 3-5/16" PULLEY POSITION ELEVATOR

ADJUST AS REQUIRED POSITION
IN FLIGHT TEST SOLID LINE BOTTOM B - OVER OUTBOARD TOP
(47G-2)
B - UNDER OUTBOARD
C - UNDER OUTBOARD
D- OVER OUTBOARD
BROKEN LINE TOP A - OVER SINGLE BOTTOM
MODEL 47G-2 WITH B - UNDER INBOARD
4 SPRAG SYSTEM C - UNDER INBOARD
D- OVER INBOARD
MAINTENANCE
angle. Adjust stops on jackshaft
DETAIL OF CABLECONTROL C
BEHINDLOCK-BOLT
CABLE LOCK-BOLT
NEUTRAL
POSITION Use T101425 jig to adjust pitch
angle. Adjust stops on jackshaft

STOP quadrant for maximum blade angles.
CONTROLCABLES
ALIGNPEDALSIN NEUTRAL
-47722-49
Figure 7-33. Rigging Diagram - Tail Rotor Controls

7-13
Section VII (Part 2)
inches aft of center line of pulley near lower tail boom

attachment point. Draw cable snug from this point
forward around right side of jackshaft pulley, prop-
erly seated in all pulley grooves, and install cable
locking bolt. (Cable passes behind bolt, with washer
and nut on bolt below cable.) Remove clamp used to
position cable sad.
e. Turn pitch change drum to right to limit of travel.

Turn drum to left, one full tur, (if dram, part No. 47-
641-140, is installed, turn drum only 3/4 of a turn)
and check alignment of drum. Slot to be facing for-
ward and 90 degrees to center line of tail boom ex-
tension. (If pitch change drum, Part No. 47-640-024-1,
is installed, slot must face aft.) Realign drum if nec-
essary. (Refer to Paragraph 7-10.)
f. Tighten turnbuckle on right cable sufficiently to

allow later tension adjustment without exposing ter-
minal threads. Holding pitch change drum in neutral,
pull cable tight and place in second groove from in-
board Side of underside of drum. (See figure l-12.)
Figure 7-35. Tail Rotor Rigging Jig Installed
Note
Tail rotor blade angle settings stated in

steps i. and j., are for metal tail rotor
blades used with part No. 47-640-053-l
pitch change drum. (If equipped with wood-
en tall rotor blades or pitch change drum
of different part number, refer to figure
7-36.)
i. Turn rotor to place one blade in jig. Hold leading

edge against step in jig, and check angular position of
blade on graduated sector at trailing edge approxi-
mately 1 1/2 inches from tip. Adjust pitch control
link-rod to obtain neutral setting of plus 1 degree to
plus two degrees. Adjust opposite blade in same
manner.
j. Remove clamps and bar used to hold pedals in

neutral. Adjust stop-screws on jackshaft pulley to
obtain blade settings of plus 12 1/2 to plus 13 1/2
degrees when left pedal is full forward, and minus
10 1/2 to minus 11 1/2 degrees with right pedal full
forward. Tighten lock-nuts and lockwire stop-screws.
Check freedom of operation through full range. If
cable piles up on pitch change drum, recheck align-
ment of drum. Remove rigging fixture.
check that quadrant hits stops instead of

pitch change sleeve bottoming out at delta
hinge bolt.
MAINTENANCE
TOP OF JIG T101425

TO BE PARALLEL TO
UPPERSURFACEOF
ROTORSHAFT
LEADINGEDGE
AGAINSTSTEP
IN JIG
NEUTRAL MAXIMUM PITCH SETTING MINIMUM PITCH SETTING

+1° to +2° +12 1/2 ° to +13 1/2 ° -10 1/2 ° to -11 1/2 °
47640-90
Figure 7-36. Rigging Tail Rotor Blades
k. Check security and safetying of entire system. b. If adjustment is necessary, remove lever pivot
Install access door under cabin and access plates pin, and rod attachment pin, and raise lever clear
on cabin box beam. Check track of tail rotor blades of rod. With pawl engaged in ratchet, screw rod in
during ground run. (Refer to Section VI.) or out to adjust length. Reinstall rod attachment
pin and lever pivot pin. Recheck adjustment.
7-10. ALIGNING TAIL ROTOR PITCH CHANGE
DRUM.
DRUM. Accomplish
Accomplish following
following procedure
procedure when
when pitch
pitch main rotor collective pitch control system below the
change drum is not in correct position in neutral. swashplate consists of the collective pitchandthrottle
control assembly (also called torque tube or jackshaft
assembly), a bellcrank (or lever) and support mounted
a. Cut lockwire, remove screw and locking plate, on left forward side of transmission upper case, two
and pull pitch change drum from shaft. Keeping shaft push-pull tubes, and a short link-rod connecting the
in neutral position, turn drum so that slot faces transmission bellcrank to the swashplate pitch con-
forward (aft if drum is part No. 47-640-024-1) with trollever.
base of slot 90 degrees to center line of tail boom
extension tube and one of five keyways aligns with
key in shaft. Install drum, locking-plate, screw and
lockwire. If alignment cannot be obtained by this
procedure, proceed with following step b.
Use care to prevent damage to parts by accidental
movement of linkage while disconnected.
b. Remove pitch change drum. Remove two cap screws

a. Disconnect and remove push-pull tubes and link-
from gear box cap, unscrew cap from threads to pitch
change shaft. Engage second series of threads in cap b. Remove bellcrank and support from transmission
and screw cap on shaft. Reinstall cap screws. Re- by removing bolt through plate and support and bolt
peat step a. to reinstall pitch change drum. through support and transmission case. Note position
of any washers used for alignment. Cut lockwire,
7-11. ADJUSTINGRATCHET PAWL - TAIL ROTOR remove two shear nuts and remove support plate from
PEDALS. Adjust ratchet pawl after replacement of transmission studs.
parts, or when pawl fails to disengage and engage c. Remove bellcrank from welded brackets on
securely in ratchet. structural tubes behind pilot's seat by removing
bolt and spacer.
a. Raise adjusting lever until stop contacts lug on
pedal. Check pawl for clearing highest tooth on ratchet d. Remove collective pitch and throttle control as-
by 1/32 inch maximum. sembly. (Refer to paragraph 7-15.)
7-15
MAINTENANCE
SECTION A-A &
INSTALL WASHERS
AS REQUIRED FOR
ALIGNMENT WITHIN
1/8 INCH
SHIM AS REQUIRED
FOR .002" TO .004" C
A I BACKLASH IN GEARS
SECTION B-B SECTION C-C 47631-31
Figure 7-37. Collective Pitch and Throttle Control Assembly (Sheet 1 of 2)

7-16
MAINTENANCE
1. Lever - Throttle Control 23. Pins

2. Locknut 24. Housing
3. Spacer 25. Shims (2)
4. Bushing 26. Gear - Throttle Control
5. Screw 27. Pinion Gear
6. Shaft - Throttle Control 28. Pins
7. Plug 29. Pin
8. Shim 30. Control Stick
9. Tube - Pitch Control 31. Rod - Throttle Friction
10. Bearing- Friction Lock 32. Grip
11. Shim 33. Nut- Throttle Friction
12. Washer (Complete) 34. Plug
13. Rod - Friction Control 35. Cotter Pin
14. Spacer 36. Washer
15. Knob - Friction Control 37. Washer
16. Nut 38. Screw - Pinion Retaining
17. Crank Arm - Pitch Control 39. Plug Button
18. Pins 40. Washer (Leather)
19. Clamp Bolt 41. Rod End
20. Bearing 42. Pin
21. Washer 43. Plug Button
22. Spacer 44. Screws - Gear Retaining
7-14. COLLECTIVE PITCH AND THROTTLE CON- 7-16. DISASSEMBLING - COLLECTIVE PITCH AND
TROL ASSEMBLY. (Figure 7-37.) The collective THROTTLE CONTROL ASSEMBLY.
pitch and throttle control assembly consists of a
collective pitch torque tube mounted horizontally a. Remove screws, bushing, and shim from right
under seat, a control stick extending from torque end of assembly.
tube gear housing up and forward through left side
of seat firewall, and a throttle control shaft mounted b. Remove throttle lever from shaft. Slide friction
inside the collective pitch torque tube and operated bearing from right end of torque tube.
through gears by rotation of control stick grip. A
friction control rod and knob are located at the seat c. Remove plug button from end of control stick. Re-
firewall convenient to pilot's right-hand, and allow move cotter pin and washer, and screw knurled nut
locking of collective pitch controls when desired. A from end of throttle friction control rod. Lower rod
knurled knob on the control stick provides friction into handle. Remove pin, flanged sleeve, and friction
control of the throttle setting. Provision is made washer from lower end of rod. Remove rod through
for installation of a copilot's control stick at right upper end of stick.
end of the torque tube.
d. Remove plug buttons from end and lower inboard
7-15. REMOVING - COLLECTIVE PITCH AND side of gear housing. Remove screw attaching pinion
THROTTLE CONTROL ASSEMBLY. (Figure gear segment to stick. Pull stick from housing, re-
7-37.) moving washer and shim from outside and pinion and
a. Remove cotter pin from lower end of collective shims from inside of housing.
pitch friction control rod. Unscrew rod to remove
nut, rod, spacer and washers. e. Remove screws, bushing, and shims from right
end of tube and shaft. Pull throttle shaft and gear
b. Disconnect linkage from collective pitch crank assembly out through left end of tube and housing.
arm and throttle control lever. Remove copilot's Remove screws gear, and shim from shaft. (Keep
control stick (if installed) by removing bolt through all shims for rinstallation.)
base of stick.
*~ baseof
f. stick.
Remove pins, gear housing, spacer, washer, and
bearing from torque tube.
c. Remove bolts attaching torque tube bearings to
welded brackets on seat structure. Keep shims for g. Remove pins, loosen clamp-bolt, and remove
reinstallation. Remove assembly from helicopter. crank arm from right end of torque tube.
7-17
MAINTENANCE
7-17. REASSEMBLING - COLLECTIVE PITCH AND center frame seat structure, with control stick ex-
THROTTLE CONTROL ASSEMBLY. tending through left side of seat firewall. Align bear-
ings with support brackets, using shims as needed
a. Slide bearing, washer, and spacer on endof torque for alignment, and install mounting bolts (counter-
tube, seating bearing shoulder against riveted collar. sunk screws at two lower holes of friction bearing).
Insert end of tube into gear housing, align holes and
press pins through housing into tube. (If new parts b. Place thin washer and long spacer on collective
are being assembled, hold parts tight against collar pitch friction control rod and insert through sleeve
for running fit, and ream holes to 0.1855 - 0.1875 in seat firewall. Install thin washer against spacer,
inch for press fit of pins.) Install lockwire, passing and insert rod through frictionlock. Screw rodinto nut
through each pin and completely around housing. held in place below lock, and install cotter pin through
end of rod.
b. Slide crank arm on torque tube. Align to point
down and forward 21 degrees when raised part c. Connect linkage to crank arm on torque tube. Check
number on gear housing is up, and press pins into rigging of collective pitch control system. (Refer to
place. Secure pins with lockwire, passing through paragraph 7-4.)
pins and completely around tube. Slide friction bear-
ing on right end of torque tube, past throttle lever d. Connect linkage to throttle shaft lever. Check
slot. rigging of throttle control system. (Refer to Section
V.)
c. Insert end of throttle shaft into gear and install .)
two screws, lockwired together. Place two shims on 7-19 CLEANING - PITCH CONTROL LINKAGE
shaft against gear shoulder and insert shaft in torque
tube. Install bushing over right end of throttle shaft or kerosene
and into torque tube, with shims between bushing
and tube to eliminate end play of throttle shaft. In- INSPECTION - PITCH CONTROL LINKAGE.
stall and lockwire two screws to secure bushing to
throttle shaft.
a. Inspect push-pull tubes for worn or rough rod-
d. Rotate gear segment to lower part of housing. end bearings, loose rivets, cracks, dents, nicks or
Place washer (and shim, if required) on stick end, scratches.
and insert stick through upper bushing of housing.
Place shims and pinion on stick end and insert stick b. Inspect bellcranks and supports for cracks,
in lower housing bushing. Rotate throttle shaft gear nicks, scratches, elongated bolt holes, and worn or
upward, and engage with pinion so that middle teeth rough bearings.
mesh. Holding gears thus, rotate stick to align screw
hole, and install screw in pinion and stick. Check for c. Inspect collective pitch and throttle control as-
0.002 to 0.004 inch backlash, adjusting pinion shim sembly for worn or damaged parts and for proper
as necessary. Lockwire screw. Install plug buttons operation.
in housing.
d. Inspect all parts of linkage for security of in-
e. Install throttle lever through torque tube slot stallation, proper rigging and operation.
into throttle shaft. Adjust to dimension of approxi-
mately 1 53/64 inches between center of bolt hole 7-21. REPAIR OR REPLACEMENT - PITCH CON-
and surface of collective pitch torque tube and TROL LINKAGE
tighten lock-nut. Check operation by rotating control
stick grip. a. Replace worn or rough bearings or rod-ends.
f. Insert throttle friction control rod through upper b. Replace bushings in collective pitch and throttle
end of stick. Place friction washer on flanged sleeve, assembly when excessively worn
place sleeve on lower end of rod and install pin.
Push sleeve up into end of stick. Screw knurled nut
on upper end of rod and secure with washer and
cotter pin. Snap plug button into top of stick. 7-22. INSTALLING - PITCH CONTROL LINKAGE.
g. Apply corrosion preventive compound, Specifica-

tion MIL-C-16173, to exposed bare steel surfaces of Note
cross tube.
Perform a rigging procedure or check after
7-18. INSTALLING - COLLECTIVE PITCH AND removal and reinstallation of any part of
THROTTLE CONTROL ASSEMBLY. system.
a. Lubricate bearings before installation with MIL- a. Install collective pitch and throttle control as-
G-25537 grease. Lift assembly into position under sembly. (Refer to paragraph 7-18.)
7-18
MAINTENANCE
b. Check that spacer is in place through needle

bearings and position bellcrank, with shortest arm
down, between outboard pair of brackets welded on
lower tube of seat-back structure. Install bolt. Install
push-pull tube, with adjustable end attached to shortest
arm of bellcrank, and fixed end of crank arm on
collective pitch control torque tube.
c. Position bellcrank support on left forward upper

case of transmission, under swashplate collective
pitch lever, aligning bolt hole with first transmission
case through-bolt hole left of center. Support rests on
fore and aft bellcrank support already installed.
Install bolt through both supports and transmission
case. Install support plate on two studs below swash-
plate lever, using low castle nuts. Install bolts, with
heads up, through plate and support, using washers
between plate and support or under lower end of
support as needed.
d. Install bellcrank (raised lettering designates

TOP) between bearings of support. Install link, with
large rod-end up and grease fitting forward, between
middle of bellcrank and forward end of collective
pitch sleeve lever.
e. Install fork end of push-pull tube to forward end

of bellcrank, with clearance cut at base of fork on
aft side (note arrow and FWD rubber-stamped on
sides of fork). Connect lower end of tube to bell-
crank behind pilot's seat.
f. Rig collective pitch system. (Refer to paragraph

7-4.)
7-23. CYCLIC CONTROL SYSTEMS. Two systems
of linkage transmit control movements from the
cyclic control stick in the cabin to the swashplate
horns, controlling the attitude of the swashplate and
thus, through rotating control linkage, controlling
the main rotor and direction of movement of the
helicopter. These two non-rotating control linkage
systems, designated as the fore-aft and the lateral
cyclic, controls from the direction of their effects
on the swashplate, interact to produce corresponding
positions of swashplate and rotor for all control stick
positions within its range of travel. A hydraulic boost
cylinder incorporated in each linkage system mini-
mizes effort required for control and prevents feed-
back of forces from the rotor.
1. Grip 8. Outer Bell
7-24. CYCLIC CONTROL STICK. (Figure 7-38.) The 2. Stick 9. Inner Bell
cyclic control stick, mounted to the cabin floor for- 3. Sleeve 10. Bearing Caps
ward of the pilot's seat, is connected to the main rotor 4. Friction Control Nut 11. Bearings
cyclic control linkage. Trunnion mounting provides 5. Bearing 12. Lever Assembly
for tilt of the stick in any direction, and non-adjustable 6. Shield 13. Stick Extension
stops limit movement to 15 degrees from vertical 7. Friction Tube
(neutral). A knurled nut below the offset of the stick
provides adjustment of friction. A push-button micro-
phone switch is located on the stick grip. Figure 7-38. Cyclic Control Stick
7-19
Section VII (Part 2) BELL HELICOTER COMPANY Models 47G & 47G-2
MAINTENANCE
7-25. REMOVING - CYCLIC CONTROL STICK. c. Lubricate bearings with MIL-G-25537 grease and
install bearings into bores of lever assembly. Install
a. Remove access door under cabin. bearings and nuts on trunnions of lever assembly,
secured by cotter pins.
b. Disconnect push-pull tubes from extension and
arm on lower end of control stick. d. Place inner bell over end of stick. Insert stick
extension through lever assembly, with lever aft,
c. Disconnect electrical wiring at nearest quick- align bearings with bolt holes and install bolt through
disconnect clips. bearings, extension, and stick.
d. Remove screws attaching bell to cabin floor and e. Observing match-marks made at disassembly,
remove stick assembly. install bearing caps, secured by screws and nuts.
7-26. DISASSEMBLING - CYCLIC CONTROLSTICK. 7-31. INSTALLING - CYCLIC CONTROL STICK.
a. Match-mark bearing caps for reassembly in same a. Position stick and install screws around flange
locations. Remove screws, nuts and bearing caps of bell.
from bell housing.
b. Connect fore-aft and lateral control system push-
b. Remove bolt passing through lever assembly pull tubes to stick extension and lever.
bearings, extension, and stick. Pull lever assembly
off stick extension. Remove nuts and bearings from c. Connect electrical wires at quick-disconnect clips.
lever assembly trunnions. Push bearings out of lever
assembly bores. d. Check rigging of fore-aft and lateral cyclic con-
c. Pull stick assembly out of inner bell. Remove trol systems. (Refer to paragraphs 7-5 and 7-6 or
extension, outer bell, friction tube, dust shield wash- 7-7.)
er, bearing, and friction nut from lower end of stick.
Remove grip by removing screw (covered by putty), e. Install access door under cabin.
threading electrical wires up through stick.
7-32. HYDRAULIC BOOST SYSTEM - CYCLIC CON-
7-27. CLEANING - CYCLIC CONTROLSTICK. Wash TROLS. (Figures 7-39 and 7-40.) The hydraulic sys-
metal parts in dry cleaning solvent and dry with tem serving the power cylinders in the main rotor
filtered compressed air. cyclic controls consists of the followingunits.
7-28. INSPECTION - CYCLIC CONTROL STICK.
A cylindrical 1 1/2 pint reservoir, clamped to seat
a. Inspect bearings for wear and roughness. back structural tubing at left aft side of cabin fire-
wall, is serviced through a filler neck equipped with
b. Inspect parts for wear, elongated bolt holes, cracks, a strainer and a cap with attached dip stick. Suction
nicks and surface damage. and return lines connect at marked ports in bottom
of reservoir. An internal baffle at return port prevents
c. Inspect assembly for security and freedom of excessive swirling of fluid. A vent line, equipped with
operation. Check for excessive play between stick filter using a replaceable micronic elementtoprevent
and extension. entry of dust, connects at a marked boss on reservoir
top to equalize pressure between reservoir and
7-29. REPAIR OR REPLACEMENT - CYCLIC CON- atmosphere.
TROL STICK.
An engine-driven hydraulic pump, mounted to ac-
a. Replace worn or rough bearings. cessory case at lower end of engine, can deliver a
flow of one gallon per minute at normal operating
b. Replace damaged or worn parts. speed. A short drain line is installed near the gear
end of the pump case to allow drainage overboard of
7-30. REASSEMBLING - CYCLIC CONTROL STICK. any oil leaking past oil seal between engine and pump.
a. Check connection of electrical wiring to switch.

Install grip, secured by screw and nut. Fill holes A filter, in pressure line near pump outlet, contains
with putty. a replaceable micronic element which screens out
any dirt from hydraulic fluid. An arrow indicates
b. Assembly friction nut, bearing, dust shield, (wash- direction of flow and ports are marked for proper
er), friction tube and outer bell on lower end of stick. installation. A pressure relief valve, adjustable to
Insert stick into extension, aligning bolt holes and regulate system pressure to 225 PSI, is located
threading electrical wires out through hole above below reservoir and connects between pressure and
clevis. return lines.
7-20
Models 47G & 47G-2 BELL HELICOPTER Section VII (Part 2)
1. Reservoir
2. Vent Line
3. Filler Cap
4. Pump Seal Drain
5. Pump - Engine Driven
6. Pump Met - Suction
7. Pump Outlet - Pressure
8. Filter - Reservoir Vent
9. Filter - Pressure Line
10. Tee - Pressure Line
11. Pressure Relief Valve
12. Return Line
13. Pressure Line - Lateral Cylinder
14. Return Line - Lateral Cylinder
15. Valve Inlet - Pressure Line
16. Plug (Pressure Test Gage Connection)
17. Valve Outlet - Pressure Line
18. By-Pass Outlet - Return Line
19. By-Pass Control Valve (See Detail)
20. Control Rod and Knob
21. Valve shaft
22. Spacer
23. Control Arm
24. Return Line - Fore - Aft Cylinder
25. Pressure Line - Fore - Aft Cylinder
Figure 7-39. Hydraulic Boost System - Franklin (Sheet 1 of 2)

7-21
1. Reservoir
2. Vent Line
3. Filler Cap
4. Filter - Reservoir Vent
5. Pump Inlet - Suction
6. Pump - Engine Driven
7. Pump outlet - Pressure
8. Cap (Pressure Test Gage Connection
9. Pump seal Drain
10. Filter- Pressure Line
11. Tee - Pressure Line
12. Pressure Relief Valve
13. Pressure Line - Lateral Cylinder
14. Return Line - Lateral Cylinder
15. Pressure Line - Fore - Aft Cylinder
16. Return Line - Fore - Aft Cylinder
17. Valve Inlet - Pressure Line
18. Valve Outlet - Pressure Line
19. By-Pass outlet - Return Line
20. By-Pass Control Valve (See Detail)
21. Control Rod and Knob
22. valve shaft
23. Spacer
24. Control Arm
25. Return Line 47690-11
Figure 7-39. Hydraulic Boost system - Lycoming (sheet 2 of 2)

7-22
MAINTENANCE
Seal drain line

for any leakage
past pump seals
RESERVOIR FILTER
OVERBOARD
RETURN
FILTER LATERAL FORE & AFT

POWER POWER
CYLINDER CYLINDER
PRESSURE
RELIEF VALVE
(SET AT 225PSI)
PRESSURE
BULKHEAD
t -- PRESSURE
BY-PASS CONDITION
CONTROL
VALVE "BOOST ON" CONDITION
PRESSURE
47690-8
Figure 7-40. Schematic Diagram - Hydraulic Boost System
A control valve, mounted on right side of cabin box The upper (or aft) cylinder head is trunnion-mounted
beam allows manual setting, by pushing a rod and knob in fixed supports attached to center frame structure
down to direct fluid under pressure to power cylinder and has no movement except to swing slightly in one
valves, or pulling knob up to by-pass fluid through plane to maintain alignment with shaft.
return line to reservoir when hydraulic boost control
is not required. A valve body, located at lower (or forward) end of
the shaft and having marked ports for connection of
Each power cylinder consists of a piston shaft op- hydraulic pressure and return lines, is trunnion-
erating through a cylinder barrel and head assembly. mounted to a bellcrank or lever linked to the cyclic
7-23
MAINTENANCE
control stick. The valve body is retained on the No. 1 at the pressure line, check valve No. 2 and re-
cylinder shaft by a special bolt, and the retaining lief valve No. 4 on the return side the fluid cannot
bolt hole in the body is elongated to allow a short escape because there is no pressure to operate re-
movement of the body, relative to the shaft, which lief valve No. 3. For other than stabilized flight condi-
opens or closes valve ports to actuate piston shaft tions the pilot must resist flight loads when moving
movement. the cyclic control. With boost pressure on, flight loads
In normal operation, hydraulic fluid from reservoir are resisted the boost pressure. After the pressure
feeds by gravity and suction to pump inlet, leaves has failed the servo valve directs the fluid flow to the
pump outlet under pressure to pass through the filter piston as dictated by the cyclic stick movement. The
and the control valve (in normal operating position) fluid is forced the movement of the piston around
to fill pressure lines to the cylinder valves. Cylinder the closed circuit throughthelowpressurecheckvalve
ports whenever
closed
valve are control stick is No. 2 to the servo valve. The locking feature of the
stationary, and there is no flow into or away from irreversible
irreversible flow
flow check
check valve
valve No.
No. 11 and
and check
check valve
valve
the cylinder. Pressure in line overcomes spring ten- No. 2 is safe guarded against excessive load build
sion to open the pressure relief valve, allowing up by the installation of relief valve No. 4. This
circulation through return line to reservoir. feature additionally serves as a warning to the pilot
if control leads become excessive for any reason,
When control stick is moved, linkage moves the cyl- boost on as well as boost off. This clearly indicates
how the installation of lock and load valves is an
inder valve body a short distance on the shaft (limited the hydraulic boost control system
by elongated retaining bolt hole), opening valve ports the pressureshould
fail oc and loadvalvesprovde
to apply fluid under pressure to one end of cylinder
and to release trapped fluid from other end, causing a function that prevent excessive feedback forces to
movement of piston, shaft and attached control linkage cyclic control system.
When movement of control stick is stopped, shaft 7-34. TROUBLE SHOOTING - HYDRAULIC BOOST
movement is arrested as valve ports close, andswash- SYSTEM. The most common trouble in hydraulic
plate linkage is held securely in new position by boost system installations is "chattering" due to mis-
fluid trapped in cylinder. alignment of power cylinders. Alignmentprocedures
should be performed with extreme care and precision
When control valve in cabin is manually set in the to avoid this source of trouble.
BY-PASS position, fluid flows from pump through
filter and control valve to return line to reservoir,
by-passing power cylinders. Misalignment resulting in binding may occur in
mounting of brackets to structure or in assembling
The system is self-purging, eliminating any air in support or bellcrank on cylinder head and valve
system during a few cycles of normal operation. trunnions. Misalignment may also result from a side
load applied to power cylinders by attached linkage
Systems used with Franklin and Lycoming engines or by hydraulic lines connected to cylinder.
are alike except for location of pump, location and
mounting of power cylinder in lateral cyclic control Possible misalignment as a cause of "motoring"
system, and consequent differences in length of some may be detected by the following rapid check. With
lines and hoses. boost system in operation, using a hydraulic test
7-33. HYDRAULIC IRREVERSIBLE VALVE. (Figure stand or operating the helicopter engine, lightly grasp
7-41.) The hydraulic irreversible valve, when in- valve
valve body,
body (keeping hands
hands clear
keeping clear of
of moving parts)
moving parts)
stalled, prevents excessive feed-back forces of the and twist first in one direction, then the opposite.
rotor from entering the cyclic stick, should there Next apply slight loads upward and downward on
be a failure of the hydraulic pump. The valve also valve body. If any of applied loads reduces or aggra-
"shuts-off" the existing system should there be a vates the "motoring" condition, misalignment is almost
failure of the hose between the pump and the ir- certainly causing or greatly contributing to the mal-
reversible valve, so the helicopter may be controlled function, and reactions to the check will aid in finding
without excessive feed-back into the cyclic control the specific misalignment.
stick.
"Motoring", a condition in which cylinder shaft tends
Should the boost pressure fail the fluid between check to move persistently in one direction even after stick
valve No. 1 and relief valve No. 3 is trapped because movement stops, has been known to occur due to
there is no pressure to open relief valve No. 3. This servo valve sticking.
creates a closed circuit for the flow of the trapped
hydraulic fluid. Rare instances have occurred of defective power
Irreversibility is obtained independentof boost pres- cylinder, damaged O-rings, pistons scored by grit,
sure for all fixed stick conditions of flight. The hy- and paint overspray on operating parts, but most
draulic fluid being incompressable is hydraulically cases of boost system trouble have been caused by
locked between the cylinder piston and check valve misalignment.
7-24
MAINTENANCE
SWASHPLATE (REF.)
HYDRAULIC POWER CYLINDER (REF.)
CYLINDER CONTROL HEAD (REF.)
RETURN LINE PRESSURE LINE
ACCUMULATOR
IRREVERSIBLE
LOCK LOAD VALVE
P/N 4010A
CHECK VALVE NO. 2.

1-3 PSI (CRACK)
RELIEF VALVE NO. 3 CHECK VALVE NO. 1.

35-40 PSI (CRACK) 8-15 PSI (CRACK)
SYSTEM SYSTEM
RETURN PRESSURE
RELIEF VALVE NO. 4

350 PSI (CRACK)
47690-26
Figure 7-41. Schematic Diagram - Irreversible Valve

7-25
MAINTENANCE
Indication Probable Indication Probable

of Trouble Cause Remedy of Trouble Cause Remedy
Chattering Loss of hydrau- Check fluid level, Air introduced Suction line re-
lic fluid check system for into system stricted.
leaks, refill sys- at pump drive Reservoir suc-
tem seal shaft tion port restric-
ted. Pump drive
Air in system Purge by opera- shaft seal defec-
tion tive. Replace
pump
Cylinder bot- Check rigging
toming at ex- Fluid flows Air in hydrau- See "Air in hy-
treme travel out reservoir lic system draulic system"
vent line
Defective cyl- Replace cylinder
inder Pump does not Reservoir oil Refill reservoir
deliver rated level low
Clogged vent Clean or replace flow
line or filter filter. Clean or Suction line Remove restric-
replace line restricted tion or replace
line
Motoring Sticking valves Check cylinder
alignment Pump de- Replace pump
Excessive Low system
control pressure due
feedback to: High pressure Relief valve Adjust relief
a. Low oil a. Refill system not properly valve
supply adjusted
b. Open by- b. Check valve Relief valve Replace valve
pass valve position not functioning
properly
c. Improper c. Adjust pres-
relief valve sure relief valve Low pressure By-pass valve Close by-pass
setting open valve
d. Pump mal- d. Replace pump
function Relief valve Adjust relief
not adjusted valve
e. Cylinder e. Replace cyl- properly
malfunction inder
Hydraulic See "Pump does
f. Improper f. Check rigging pump does not not deliver rated
adjusted rotor of rotor deliver rated flow"
flow
Hydraulic Loose con- Tighten connec-
oil leaks nections tions Relief valve Replace valve
not functioning
Worn gaskets Replace gaskets properly
or seals or seals
Engine oil Pump vent line Remove obstruc-
Defective tub- Replace tube or in hydraulic obstructed tion
ing flare or fitting system
fitting Engine seal Replace seal
leaking
Air in hydrau- Air not bled Purge system
lic system from system System in- By-pass valve Repair or replace
foam in reser- operative (By- inoperative valve
voir Air introduced Check fittings for pass valve
into system security and suc- does not affect Hydraulic line Remove restric-
through suction hose for the system) restricted tions and clean
tion line small holes hydraulic system
7-26
MAINTENANCE
Indication Probable air. Use care to protect polished or mating surfaces

of Trouble Cause Remedy from damage while cleaning and protect any disas-
System in- Hydraulic Repair or replace sembled parts from dust and dirt.
operative (By- pump inopera- pump b. Flush lines and hoses with clean hydraulic fluid.
pass valve tive Clean or replace elements in line and vent filters
does not affect as required. (Refer to paragraphs 7-41 and 7-42.)
the system)
in cylinders Bleedair.
Air controls
Spongy Wipe exposed polished surfaces of power cylinder
shaft with clean cloth moistened with hydraulic fluid.
Power cylinders Bulkhead hy- Install fitting Wipe exterior of cylinder with cloth moistened with
move too slow draulic fitting correctly dry cleaning solvent.
installed in re-
turn port of 7-37. INSPECTION - HYDRAULIC BOOST SYSTEM.
cylinder too far
a. Inspect all components for security of mounting
Low pressure Refer to "Low and evidence of leakage.
pressure"
b. Inspect tubing and hoses for nicks, dents, exces-
7-35. REMOVING - HYDRAULIC BOOST SYSTEM. sively sharp bends, and security of connections.
Any unit of system may be removed for overhaul or
replacement, or entire system may be removed in c. Inspect power cylinder shaft for scoring, exces-
the following order or in any practical sequence. It sive radial play, binding and leakage at seals. In-
is recommended that support clamps and connecting spect valve body for leakage and for free movement
lines be left in place, when possible, to speed rein- on shaft within normal operating limits. (Servo valve
stallation and aid in determining location of units, should move without sticking or binding 0.015 to0.035
Cap or cover all openings and use care to keep dust inch either direction with respect to center line of
and dirt out of system. retaining bolt.)
d. Inspect cylinder support and bellcrank assembly
a. Drain reservoir by removing cap from tee fitting and mounting brackets for security, cracks, surface
at "SUCTION"port under reservoir, or by discon- damage, elongated bolt holes, worn trunnion bushings,
necting suction and return lines. Disconnect vent line and worn or rough bearings
from top of reservoir. Loosen clamp and remove
reservoir. e. Check for proper operation without and with hy-
draulic boost in operation. (Refer to paragraph
b. Remove vent filter by disconnecting lines. 7-40.)
7-38. REPAIR OR REPLACEMENT - HYDRAULIC
c. Remove pump by disconnecting flexible hoses and BOOST SYSTEM.
removing nuts from mounting pad studs.
a. Replace any worn, damaged, or malfunctioning
d. Remove filter from main pressure line near pump parts.
by disconnecting inlet and outlet lines and removing b. Replace seals, lines or fittings as necessary to
bolts through clamps and filter head. prevent leakage.
c. Replace filter elements as necessary. (Refer to
e. Remove pressure relief valve by disconnecting paragraphs 7-41 and 7-42.)
lines and removing mounting bolts.
d. Replace power cylinder for malfunctionor leakage.
f. Remove manual control "BY-PASS" valve by Overhaul and bench testing of cylinders should be
removing access door under cabin and box beam attempted only byqualified personnel andin accordance
access plates, disconnecting lines, removing bolt, with instructions issued by manufacturer (Conair, Inc.,
arm and spacer from valve shaft, and removing 731 West Wilson Ave., Glendale 3, California).
mounting bolts through side of box beam to remove
control rod, remove arm, clevis, andlock-nutandpull e. Replace worn or rough bellcrank bearings. Re-
rod up through guide. place worn bushings. (Refer to paragraphs 7-46 and
7-71.) If one-half of support or bellcrank is un-
g. Remove power cylinders. (Refer to paragraphs serviceable replace both halves with matched set.
7-57 and 7-83.) 7-57 7-39. INSTALLING - HYDRAULIC BOOST SYSTEM.
7-36. CLEANING - HYDRAULIC BOOST SYSTEM. (Figure 7-39.) Parts of system may be reinstalled
in any practical sequence. Therefore, installation of
a. Wash metal parts in a cleaning solvent which each unit is treated as through rest of system were
will not damage seals. Dry with filtered compressed already installed. (Refer to Parts Catalog for details
7-27
MAINTENANCE
of attaching parts required.) Lubricate straight- nect tube from right end of tee to tee in return line
thread fittings with hydraulic fluid. Apply a small from power cylinders. Connect tube from "VENT"
amount of anti-seize compound to threads of tapered nipple to upper end of vent filter. Tighten and lock-
pipe-thread fittings, using care to prevent compound wire reservoir mounting clamp.
entering system.
d. Check installation of reducer nipples in reservoir
Note vent line filter. Position filter at left of reservoir,
with end marked "RES" up. Connect vent line from
Step a. applies to installation with Frank- reservoir to upper end of filter, and line to atmos-
lin Engine. phere to lower end.
a. Check that neoprene plug (Aircooled Motors, Part e. Position pressure line filter at inboard side of
No. 19607) is installed up past internal splines of lower left center frame tube which extends fore and
hydraulic pump drive, located at mounting pad aft aft, 7 1/4 inches forward of vertical tube on line
of starter on underside of accessory case. Engines with mast, with "IN" port of filter aft and direction-
Serial No. 26776 and subsequent have redesigned gear of-flow arrow pointing forward. Check installation of
shafts and do not require neoprene stopper. Position fittings as follows: Reducer nipple in filter "OUT"
pump with gasket in place, on mounting pad studs port; bushing and 45 degree elbow pointing toward
with name plate to right. Check fittings as follows: pump in "IN" port. Install two clamps, with open ends
90 degree elbow, for seal drain line, at forward side up, on structural tube and install bolts through clamps
of flange and pointing down; 45 degree elbow at inlet and filter head. Connect hose from filter "IN" elbow
port (middle of case, left side) pointing to left and to hydraulic pump outlet. Connect tube from filter
forward; 90 degree elbow in outlet port at bottom end "OUT" nipple to pressure line tee which is connected
of pump, pointing to left. Install nuts on mounting to lower nipple on left side of pressure relief valve.
studs. Connect hose from reservoir "SUCTION"port
to pump inlet fitting, hose from pump outlet to filter f. Install two reducer nipples in ports of pressure
inlet, and drain line to seal drain fitting. Proceed relief valve. Install two clamps, with open ends left
to step c. and a bolt inserted in each clamp with head forward,
on left vertical seat-back structural tube below res-
Note ervoir. Place valve, with two reducer nipples pointing
left and adjustment cover nut up, against clamps with
Step b. applies to installation with Ly- bolts extending through body of valve. Start nuts on
coming Engine. bolt. Determine position of valve on structure by
connecting tube from left end of reservoir "RETURN"
b. Remove cover from mounting pad (originally tee to upper nipple on valve, and by connecting tube
designated as vacuum pump pad) located on engine from lower valve nipple to upper end of pressure line
accessory case at left side, aft of hand-crank jaw. tee below valve. Tighten nuts on clamp bolts.
Position hydraulic pump, with name plate aft and
gasket in place, on studs of mounting pad and check g. Hold by-pass control valve in mounting position,
installation of pump fittings as follows: Nipple for with shaft pointing left and side which has no port
seal drain line in flange port at underside; 45 degree up. Check installation of fittings as follows: Reducer
elbow in pump inlet (middle of case on forward side) nipple in forward (by-pass return) port; bushing and
pointing forward and to left; tee fitting in pump outlet elbow pointing right at aft (pressure inlet) port; union
in outboard end, pointing forward and aft. Install nuts and tee point down and forward in lower (pressure
on mounting studs. Connect hose from lower end of outlet) port, with plug in lower end of tee and re-
tee fitting in reservoir "SUCTION" port to elbow in ducer nipple in forward end. Remove box beam ac-
pump inlet, hose from forward end of pump outlet cess plates and access door under cabin. Place
tee to inlet port of filter, and seal drain line to nipple valve in position on right side of box beam under
below pump flange. Install cap on aft end of pump cabin floor, with valve shaft extending through hole
outlet tee. into box beam. Install four mounting bolts from inside
of box beam into valve flange. Lockwire bolt heads.
c. Position reservoir in clamp, located on upper Connect tube from forward (by-pass return) port of
left seat-back structure aft of firewall, so that valve to right bulkhead fitting (of three located aft
center line through filler cap and "VENT" port is of valve). Connect tube from elbow at aft (pressure
45 degrees to firewall (with filler cap aft and left). inlet) valve port to left bulkhead fitting. Connect tube
Check installation of fittings as follows: Reducer from forward end of tee at lower (pressure outlet)
nipple in "VENT" port; bushing and tee in "RETURN" port to middle bulkhead fitting. Insert control rod
port, with ends of tee pointing right and left; bushing down through guide on right upper side of box beam
and tee in "SUCTION"port, with ends of tee pointing and install lock-nut and clevis on rod. Install arm
down and aft. Cap aft end of "SUCTION" tee, and and spacer on valve shaft, with arm forward, and
connect hose from lower end of tee to pump inlet. secure with bolt installed in end of shaft and lock-
Connect tube from left end of "RETURN" tee to upper wired. Align rod clevis on forward end of arm and
nipple on left side of pressure relief valve, and con- install and safety clevis pin.
7-28
MAINTENANCE
h. Install power cylinder and support in fore and the cyclic control stick to the forward horn of the
aft cyclic control system. (Refer to paragraph 7-59.) swashplate, tilting the swashplate and controlling
main rotor attitude through rotating linkage on the
i. Install power cylinder and support in lateral cy- mast. Fore-aft linkage consists of push-pull tube,
clic control system. (Refer to paragraph 7-85 for cyclic control jackshaft, a bellcrank on front of
installation with Franklin engine.) (Refer to para- transmission and a hydraulic power cylinder, support,
graph 7-86 for installation with Lycoming engine.) and bellcrank assembly. A damper (with Lycoming
engine only) and a bungee spring reduce feed-back of
j. Check system for security of connections and at- forces from rotor to control stick. The synchronized
tachments. Fill system with hydraulic fluid and check elevator control linkage is connected to and actuated
operation. (Refer to paragraph 7-40.) by the fore-aft cyclic control linkage.
7-40. SERVICING AND TESTING - HYDRAULIC Note
BOOST SYSTEM.
Lock and load valves are installed on some
Note Models, thereby eliminating the necessity
of damper and bungee spring.
An auxiliary pump or test stand of 1 GPM
flow can be used for hanger check of leak- 7-44. REMOVING - FORE-AFT CYCLIC CONTROLS.
age and control function. Checking and Parts of system may be removed in any practical
setting system pressure must be done by sequence. Take precautions to prevent damage to
operating engine at cruising RPM. parts by accidental movement of linkage while dis-
connected.
a. Install pressure gage. On installations with Frank- a. Disconnect bungee spring. If installed, disconnect
lin engine, remove plug and install gage in lower end and remove push-pull tubes from forward horn of
of tee fitting below by-pass valve on cabin box beam. swashplate, bellcrank on front of transmission, and
On installations with Lycoming engine, remove cap upper end of power cylinder shaft. Disconnect and
and install gage on aft end of tee fitting on pump. remove push-pull tubes from bellcrank on cylinder
support cyclic control jackshaft, and control stick
b. Fill reservoir to full mark on cap dip stick with extension. Disconnect link-rod or push-pull tube
hydraulic oil, Specification No. MIL-0-5606. between fore-aft controls and synchronized elevator
linkage. (Refer to paragraph 7-94.) On Lycoming-
c. Start engine. Purge system by operating cyclic powered helicopter, disconnect link-rod.
control stick in circular motion at least ten times.
Check for leakage. Noexternal leakage is permissible. b. Remove bellcrank and support assembly from
front of transmission as an assembly or as separate
d. Check pressure gage for system pressure read- parts, keeping support alignment shims and washers
ing of 215 to 235 PSI while operating engine at i place for reinstallation.
cruising RPM. To adjust pressure relief valve, re-
move cover nut, loosen lock-nut, adjust screw to c. Remove power cylinder support, and bellcrank
increase (turn clockwise) or decrease (turn counter- as an assembly or as separate parts. (Refer to
clockwise) plunger spring tension, tighten lock-nut paragraph 7-57.)
reinstall cover nut and lockwire.
With engine
e.e. With engine stopped, remove pressure
stopped, remove pressure gage
gage and
and d. Remove cyclic control jackshaft. (Refer to para-
replace plug or cap. Check level of hydraulic oil in graph 7-49.)
reservoir. Purge system by operating control stick
Remove cyclic control stick. (Refer to para-
graph
in a circular motion at least ten times. graph 7-25.)
7-25.)
7-41. CLEANING FILTER - HYDRAULIC BOOST
SYSTEM. Inspect filter installed in hydraulic pres- 7-45. INSPECTION-FORE-AFT CYCLIC CONTROLS.
sure line between pump and relief valve after each
25 hours when operating in dusty conditions, other- a. Inspect push-pull tubes and link-rods for cracks,
wise after each 125 hours of operation. Wash filter nicks or other surface damage, loose rivets, worn or
element in clean hydraulic fluid, or replace element. rough rod-end bearings, security of attachment,
alignment, and possible interference with other parts.
7-42. REPLACING FILTER - HYDRAULIC RESER-
VOIR VENT LINE. Inspect filter installed in reser- b. Inspect bellcranks and supports for security of
voir vent line after each 25 hours when operating in attachment, cracks, nicks or other surface damage,
dusty conditions, otherwise after each 125 hours of elongated bolt holes, worn or rough bearings, and
operation. Replace filter element as necessary. possible interference with other parts.
7-43. FORE-AFT CYCLIC CONTROL SYSTEM. A c. Refer to Inspection Section of Section If or Magna-
system of linkage transmits fore-aft movement of flux or Zyglo requirements.
7-29
MAINTENANCE
d. Inspect entire installation for security and proper a. Install cyclic control stick. (Refer to paragraph
operation. Inspect cyclic control stick, jackshaft, 7-31.)
damper (if installed), and power cylinder and support.
(Refer to paragraphs 7-28, 7-52, and 7-58.) b. Install cyclic control jackshaft. (Refer to para-
graph 7-55.)
7-46. REPAIR OR REPLACEMENT - FORE-AFT
CYCLIC CONTROLS. c. Install fore-aft bellcrank support on two upper
fan drive studs and forward pair of transmission
a. Replace any damaged or unserviceable parts. through-bolts, using washers as required on studs
Replace bearings for excessive wear or roughness. to fill counterbored holes slightly beyond drive
flange surface. Shim between support and upper
b. Replace leaking or malfunctioningpower cylinder. case if gap exceeds 0.004 inch, tighten bolts, and
(Refer to paragraph 7-59.) shim if necessary to same gap limit at studs before
tightening nuts. Position bellcrank, with longest clevis
c. With Lycoming engine installation replace leaking at left, between support bearings and install pivot bolt.
or malfunctioning damper. (Refer to paragraph 7-63.)
d. Install power cylinder and support assembly.
d. Replace, worn bushings in Fore-Aft cyclic sup- (Refer to paragraph 7-59.)
port and cylinder assembly, as follows:
e. Rig fore and aft cyclic control system while in-
(1) Replace worn bushings in upper and lower stalling push-pull tubes. (Refer to paragraph 7-5.)
plates. Connect and check rigging of synchronized elevator
control system. (Refer to paragraph 7-8.)
(2) Assemble upper and lower plates onto sup-
port. f. Check operation of system.
(3) Line ream bushings, in plates for upper end 7-48. FORE-AFT CYCLIC CONTROL JACKSHAFT.
of hydraulic cylinder to, 0.4995/0.5005 inch. (Figure 7-42.) The jackshaft in the fore-aft cyclic
control system is a torque tube mounted through
(4) Ream bushing in one plate for lower end of single-row ball bearings to brackets on center-frame
hydraulic cylinder to, 0.813/0.814 inch. Ream bush- structure aft of box beam. Jackshaft extends laterally
ing in opposite plate to, 0.819/0.821 inch. The inside under seat and is equipped with torque arms which
diameter of the two bushings must be concentric are connected by push-pull tubes to extension on cyclic
within 0.002 inch after reaming and coat I.D. of control stick and to bellcrank which actuates the
bushings with DRY film lube. power cylinder. With dual controls copilot's stick is
connected to arm on right end of jackshaft.
Vendors of DRY Film Lube
7-49. REMOVING - FORE-AFT CYCLIC CONTROL
LUBRI-BOND "A" Electrofilm Incorporated JACKSHAFT.
P.O. Box 106 a. Disconnect push-pull tubes from torque arms of
7116 Laurel Canyon Blvd jackshaft.
North Hollywood, Calif.
b. Remove bolts through bearing housings and
SURF-KATE Hohman Plating & Mfg. Co. brackets and remove jackshaft.
A-1625 814 Hillrose Avenue
Dayton 4, Ohio 7-50. DISASSEMBLY - FORE-AFT CYCLIC CON-
TROL JACKSHAFT.
DRY LUBE FILM Alpha-Molykote Corp.
65 Harvard Avenue a. Match mark parts for reinstallation in same
Stamford, Conn. positions. Remove bolts and tapered bushings and
pull torque arms from each end of shaft.
e. If hydraulic power cylinder No. 1450 is installed
on Model 47G-2 helicopter, lockwire spring Part No.
47-691-078-1, between clevis and control valve using
0.030 lockwire to prevent spring from interfering 7-51. CLEANING - FORE-AFT CYCLIC CONTROLS
with proper function when bellcrank is in extreme JACKSHAFT. Wash parts with dry cleaning solvent
position. or kerosene and dry with filtered compressed air.
7-52. INSPECTION - FORE-AFT CYCLIC CONTROL
7-47. INSTALLING - FORE-AFT CYCLIC CONTROLS. JACKSHAFT.
Parts of system may be installed in any practical
sequence. Rigging check must be performed after a. Inspect bearings for wear, rough operation, or
installation of any parts in system. binding.
7-30
MAINTENANCE
b. Inspect shaft and arms for cracks, corrosion,

and elongated bolt holes. Inspect tapered bushings
for proper fit, extending not less than 1/32 inch
above surface.
c. Inspect installation for secure mounting and free-
dom of operation. Inspect support brackets for cracks.
7-53. REPAIR OR REPLACEMENT - FORE-AFT
CYCLIC CONTROL JACKSHAFT.
a. Inspect bearings for excessive wear or roughness.

b. Replace any damaged or unserviceable parts.
7-54. REASSEMBLING - FORE-AFT CYCLIC CON-

TROL JACKSHAFT.
a. Lubricate bearings with MIL-G-25537 grease.

Assemble bearings and housings on each end of shaft,
with original shims (if needed) in place between
bearing and collar on shaft.
7-30A
MAINTENANCE
b. Install torque arm for synchronized elevator c. Connect and check rigging of synchronized eleva-
linkage (not used when elevator linkage is connected tor. (Refer to paragraph 7-8.)
to lower end of fore-aft power cylinder) on right
end of shaft, 5 7/16 inches from center of shaft, d. When dual controls are installed, place both sticks
with arm pointing 59 degrees aft and up when center full forward or full aft, adjust and install push-pull
arm is pointing straight up. Install tapered bushings tube between copilot's cyclic control stick extension
and bolt. and right-hand torque arm on jackshaft. Move both
sticks to opposite extreme of travel, checking and
c. Install torque arm on each end of shaft, pointing readjusting as necessary so that sticks reach end of
down and 6 degrees forward when center arm is travel each direction at same time.
pointing straight up. Install tapered bushings and
bolts, with heads aft. 7-56. HYDRAULIC POWER CYLINDER AND SUP-
PORT - FORE-AFT CYCLIC CONTROLS. (Figures
7-55. INSTALLING - FORE-AFT CYCLIC CONTROL 7-43 and 7-44.) The fore-aft cyclic controlpower cyl-
JACKSHAFT. inder is mounted vertically in a support attached to
the seatback structure, aft of the firewall. The cylinder
a. Position jackshaft to brackets welded on vertical head trunnions are mounted in bushings in the sup-
seat-structure tubes just aft of box beam and fire- port. The valve body, on lower end of cylinder shaft,
wall. (Forward lugs of bearing housings are trimmed is attached through trunnions and bushings to a bell-
off to clear firewall.) Install bolts with heads out- crank pivoted on lower end of support and actuated
board, through bearing housings and brackets, using by a push-pull tube from the cyclic control jackshaft.
washers as needed between housings and brackets to A clevis adapter on upper end of cylinder shaft pro-
compensate for misalignment (1/8 inch maximum al- vides attachment for linkage to the swashplate. A
lowable misalignment). Check for possible binding clevis adapter on upper end of cylinder shaft pro-
while tightening bolts, vides attachment for synchronized elevator linkage
(except on kit installations of early design). Support
b. Rig fore-aft system in neutral while connecting and bellcrank are made of stamped sheet metal halves
push-pull tube between cyclic control stick extension assembled with bolts and spacers or, in later design,
and left-hand torque arm of jackshaft, and push-pull of aluminum alloy castings. Hydraulic pressure and
tube between center torque arm and bellcrank on return lines connect to fittings in the valve body
power cylinder support. (Refer to paragraph 7-5.) trunnions.
1. Torque Arm (To Cyclic Control Stick)

2. Shaft
3. Torque Arm (See Note)
4. Bracket
5. Torque Arm (To Fore - Aft Linkage)
6. Bearing Housing
7. Bearing
NOTE:
Arm (3) used for synchronized elevator linkage
on Model 47G without hydraulic boost controls.
47724-15
Figure 7-42. Fore and Aft Cyclic Control Jackshaft

7-31
MAINTENANCE
SHIMTO ALIGNCYLINDER
VERTICAL IN NEUTRAL
SHIMTO GAPOF 0.003MAX.
BEFORETIGHTENING
If sheet metal support or bell-

crank must be replaced, install
complete assembly of cast parts
(bellcrank, support and channel).
See item 16
1. Fore - Aft Cyclic Control 10. Bellcrank (47G with 47-267-138

Jackshaft Elevator Installation)
2. Push-Pull Tube 11. Push-Pull Tube (to Swashplate)
3. Seat - Back Structure 12. Link Rod (To Damper)
4. Welded Brackets (With spacer) 13. Lever Assembly
5. Support 14. Hydraulic Cylinder
6. Clamp (and Bushing) 15. Valve Body (Pressure Port to Left)
7. Channel 16. Cylinder Support and Bellcrank -
8. Spacer Assembly (Aluminum Alloy Castings)
9. Push-Pull Tube
47724-45
Figure 7-43. Power Cylinder Installation -Fore and Aft - Cyclic

7-32
MAINTENANCE
1. Cylinder Assembly 11. O-Ring Packing (AN6227-12)

2. Cotter Pin 12. O-Ring Packing (AN6227-14)
3. Nut 13. Front Head
4. Washer 14. O-Ring Packing (AN6227-12)
5. Bolt 15. O-Ring Packing (AN6227-14)
6. O-Ring Packing (AN6227-12) 16. Bushing
7. Valve Body 17. Rear Head
8. O-Ring Packing (AN6227-7) 18. Piston Rings
9. Plug 19. Shaft
10. Clamp 20. Barrel
4 7 69 0- 9
Figure 7-44. Power Cylinder Assembly - Typical

7-33
MAINTENANCE
7-57. REMOVING - POWER CYLINDER AND SUP- seat-back tube member. Install bolt through support
PORT - FORE-AFT CYCLIC CONTROLS. and brackets, with spacer between brackets. Place
two clamps, with bushings, between firewall and
Note vertical tubes to align with bolt holes in channel.
Place original shims between tubes and channel,
With cast support and bellcrank, removal insert bolts, place spacer on each bolt, and start
of power cylinder may be accomplished by bolts into clamps. Shim to maximum gap of 0.003
removing plates at trunnions. With support inch between clamp and forward end of each spacer
and bellcrank of sheet metal construction, before tightening bolts. Proceed with step e.
remove power cylinder by removing one-
half of support and bellcrank to free cyl- Note
inder trunnions, or remove support, bell-
crank, and cylinder as an assembly for Steps c. and d., apply to 47-724-131 in-
bench disassembly. stallation, with support and bellcrank of
cast construction.
a. Disconnect control linkage from cylinder shaft
and from bellcrank. Remove any other parts neces- c. Position support between brackets welded near
sary for access. center of lower seat-back horizontal tube member
and install bolt. Place channel across vertical tubes,
b. Disconnect hydraulic lines at valve body trunnions, align bolt holes and install bolt attaching right side
allow hydraulic oil to drain into a container, remove of support to channel. Place clamps, with bushings,
elbow fittings from trunnions, and plug or cap all between firewall and vertical tubes to align with bolt
openings. Use extreme care to prevent entry of dirt holes in channel. Place original shims between tubes
into system. and channel, insert bolts, place spacer on each bolt,
and start bolts into clamps. Shim to maximum gap
c. Remove bolts attaching support to brackets, and of 0.003 inch between clamp and forward end of each
remove support, cylinder and bellcrank as an as- spacer before tightening bolts.
sembly. Leave brackets in place on structure unless
removal is necessary for inspection or replacement, d. Assemble support plates on power cylinder head
or for repair of center frame. If brackets are re- trunnions, position plates on each side of support
moved, mark locations and keep parts and shims at upper end, and install three bolts. Install bellcrank
together for reinstallation. on lower end of support. Assemble bellcrank onlower
end of support. Assemble bellcrank plates on valve
d. Separate support and bellcrank halves by re- body trunnions and bellcrank, and install two bolts.
moving bolts and spacers. Remove power cylinder. (Valve pressure port toward left.)
7-58. INSPECTION - POWER CYLINDER AND SUP- Note

PORT - FORE-AFT CYCLIC CONTROLS. (Refer to
paragraphs 7-36, 7-37, and 7-38 for cleaning, in- Following steps apply to either installa-
spection and repair or replacement.) tion.
7-59. INSTALLING - POWER CYLINDER AND SUP- e. Determine neutral position of cylinder shaft by
PORT - FORE-AFT CYCLIC CONTROLS. measuring from upper end of cylinder to upper end
of shaft with shaft full up, then full down. Position
Note shaft at exactly half-travel. Remove bolt through
valve body and shaft, and install valve centering pin,
Steps a., and b., apply to 47-724-063 in- T101233, to center valve body in neutral position
stallation, with support and bellcrank com- on shaft.
posed of stamped sheet metal halves as-
sembled with spacers. f. With ship level, suspend a plumb-line from left
end of a long close-tolerance bolt inserted through
a. Assemble halves of support on power cylinder forward holes in bellcrank on front of transmission.
head trunnions, and install spacers and bolts. As- Check alignment of cylinder by positioning bellcrank
semble halves of bellcrank on valve body trunnions 2 degrees up forward (neutral position). Plumb line
(with pressure port toward left) and support, and should cross centers of cylinder head trunnion and
install spacers and bolts. Assemble channel to sup- valve body trunnion when cylinder shaft is in half-
port, with long flange of channel on forward ends travel position. Adjust amount of shims between
of upper support flanges, and install bolts. Place support channel and vertical tubes as necessary to
spacers between channel and forward support flanges obtain alignment. After alignment, lockwire clamp
and install bolts, with heads forward. bolts in pairs.
b. Position assembly to align bottom of support in g. Connect control linkage to cylinder shaft and
brackets welded near center of lower horizontal bellcrank. Reinstall any parts removed for access.
7-34
Models 47G & 47G-2 BELL HELICOTER COMPANY Section VII (Part 2)
MAINTENANCE
h. Install elbow fittings in valve body trunnions, and valve centering pin, T101233, and reinstall bolt
connect hydraulic pressure and return lines. through valve body and cylinder shaft.
i CAUTION j. Fill and purge hydraulic system and check opera-

After bottoming elbow, back out two turns, 7-60. CYCLIC CONTROL DAMPERS. (Figure 7-45.)
align and tighten nut. With Lycoming engine only, two hydraulic dampers,
interchangeable with stabilizer bar dampers except
i. Check rigging of fore-aft cyclic control system. for arms and supports, are used to aid in smooth
(Refer to paragraph 7-5.) Check rigging of synchro- operation of main rotor cyclic control systems. Both
nized elevator. (Refer to paragraph 7-8.) Remove dampers are mounted in supports attached to the
Note transmission upper case, the fore and aft damper
arm being connected by a link-rod to a bellcrank
On helicopters with irreversible valves below the forward swashplate horn, and the lateral
installed hold check valve No. 1 (figure damper connected to similar manner to the lateral
7-41) while tightening hose to keep it from cyclic torque tube. Some models have lock and load
turning. valves and dampers are not installed.
1. Link Rod 6. Damper Support

2. Snap Ring 7. Transmission Upper Case
3. Lever Assembly 8. Support Plates
4. Damper 9. Shims (for .003 max. gap)
5. Dowel Retainer 10. Damper Assembly
47725-16
Figure 7-45. Cyclic Control Dampers

7-35
MAINTENANCE
7-61. REMOVING - CYCLIC CONTROL DAMPERS. 7-65. FILLING CYCLIC CONTROL DAMPERS (LY-
COMING ENGINE INSTALLATION).
a. Disconnect link-rod from damper arm. Remove
bolts at damper case lugs and lift damper from sup- a. Disconnect link-rod from damper arm. Remove
port. (On lateral damper keep shims with support.) filler plug.
b. Cut lockwire, remove mounting bolts and dowel b. Fill damper to inside edge of filler hole with
retainers, and remove fore and aft damper support petroleum base hydraulic fluid (red color), Specifi-
from transmission case. Remove mounting bolts cation No. MIL-O-5606. Move damper arm up and
and lateral damper support plates. down slowly through full travel while filling to expel
air from working chamber.
c. When replacing damper, loosen clamp bolt, re-
move snap-ring, and pull arm from damper shaft. c. Install filler plug. Connectlink-rodto damper arm.
7-62. INSPECTION - CYCLIC CONTROL DAMPERS. 7-66. ADJUSTING CYCLIC CONTROL DAMPERS
(LYCOMING ENGINE INSTALLATION). Stiffness of
a. Inspect dampers for security of installation, evi- damper action is regulated by setting of a needle
dence of leakage, and wear at shaft splines or bolt valve, which has an external pointer at end of damper
holes. Inspect damper case and support for cracks shaft
and damage.
a. Disconnect link-rod from damper arm. Remove
b. With link-rod disconnected, move damper arm damper from transmission upper case, and clamp
through full travel, checking for smooth operation assembly in vise in a convenient position.
and for evidence of air in damper. (Refer to para-
graphs 7-65 and 7-66 for filling and adjustment.)
b. Attach a suitable extension to damper arm. Sus-
pend a 7 1/2 pound weight on arm extension 10 inches
7-63. REPAIR OR REPLACEMENT - CYCLIC CON- from center of shaft. Raise arm to upper limit, re-
TROL DAMPERS. lease and check for travel time of 2 1/2 seconds
(plus or minus 1/2 second) to lower limit.
a. Replace dampers when leakage or malfunction
cannot be corrected by proper servicing and ad-
justment. (Refer to Section III.) c. Adjust as necessary by turning needle valve
pointer clockwise for slower travel or counterclock-
b. Replace worn or damaged parts. wise for faster travel rate.
7-64. INSTALLING - CYCLIC CONTROL DAMPERS. d. Reinstall damper. Test movement of control stick
manually, without hydraulic boost, to see that opera-
a. Install fore-aft damper support over dowels on tion is not excessively limited by damper action.
mounting boss at right front of transmission upper 7-67. LATERAL CYCLICCONTROLSYSTEM. Asys-
case. Align dowel retainers with bolt holes and in- tem of linkage transmits lateral movement of the
stall bolts, lockwired in pairs. Position damper on cyclic control stick to horn on left side of swashplate,
support, with filler plug up and shaft pointing left, tilting the swashplate and controlling main rotor
and install mounting bolts with heads inboard. attitude through rotating linkage on the mast. Lateral
system linkage used with Franklin engine installation
b. Check position of arm on shaft and adjust and consists of a link-rod connecting control stick horn
connect link-rod. (Refer to paragraph 7-5.) to a bellcrank on the cabin box beam, push-pull tubes,
a hydraulic power cylinder assembly, bellcranks at
c. Place lateral damper support plates, with longer lateral sprag mount bracket and in left side of engine
leg down, on each side of mounting boss on left side mount frame, and a bungee spring. Lateral cystem
of transmission upper case. Align holes and install linkage used with Lycoming engine installation con-
bolts with heads forward. Position damper, with sists of a link-rod from control stick to bellcrank
filler plug up and shaft pointing aft, between support on cabin box beam, push-pull tubes, a hydraulic
plates. Install and tighten bolts through forward power cylinder assembly, a torque tube on upper
support plate and lugs of damper case. Measure left of center frame, a hydraulic damper and link-
gaps between aft support plate and damper case lugs. rod and a bungee spring.
Install laminated shims to reduce gaps to maximum
of 0.003 inch and install bolts. 7-68. REMOVING- LATERAL CYCLIC CONTROLS-
WITH FRANKLIN ENGINE. Parts of system may be
d. Check to make sure dampers do not bottom out removed in any practical sequence. Take precautions
at extreme travel of controls, before operating with to prevent damage to parts by accidental movement
hydraulic boost "ON". of linkage while disconnected.
7-36
MAINTENANCE
Note c. With Lycoming engine, inspect torque tube and

supports. (Refer to paragraph 7-78.) Inspect cyclic
Procedure below applies to installation control damper. (Refer to paragraph 7-62.)
in Franklin-powered helicopters only. (For
control system used with Lycoming en-
gine, refer to paragraph 7-69.) d. Inspect cyclic control stick. (Refer to paragraph
7-28.) Inspect power cylinder and support. (Refer to
a. Disconnect bungee spring (if installed). Discon- paragraph 7-84.)
nect and remove push-pull tubes from horn on left
side of swashplate, from bellcranks in left side of e. Refer to Section I, for Magnaflux and Zyglo re-
engine mount frame and at lateral sprag mount quirements.
bracket, and from bellcrank on left side of cabin
box beam under floor. Remove bellcranks. f Inspect entire installation for security and proper
operation.
b. Remove power cylinder and support assembly.
(Refer to paragraph 7-83.) 7-71. REPAIR OR REPLACEMENT - LATERAL CY-
CLIC CONTROLS.
c. Remove cyclic control stick. (Refer to paragraph
7-25.) a. Replace any damaged or unserviceable parts.
Replace bearings for excessive wear or roughness.
7-69. REMOVING- LATERAL CYCLIC CONTROLS-
WITH LYCOMING ENGINE. Parts of system may be
removed in any practical sequence. Take precautions b. Replace leaking or malfunctioning power cylinder.
to prevent damage to parts by accidental movement (Refer to paragraph 7-84.)
of linkage while disconnected.
c. With Lycoming engine, replace leaking or mal-
functioning damper. (Refer to paragraph 7-64.)
Procedure below applies only to Lycoming-
powered helicopters. (Refer to paragraph d. Replace, worn bushings in Lateral Cyclic Support
7-68 for installation with Franklin engine.) and Cylinder Assembly, as follows:
a. Disconnect bungee spring. Disconnect push-pull (1) Replace worn bushings in upper and lower
tubes from horn on left side of swashplate, from plates.
both arms of torque tube, from power cylinder and
bellcrank, and from bellcrank on left side of cabin (2) Assemble upper and lower plates onto sup-
box beam under floor. Remove bellcrank from box port.
beam.
(3) Line ream bushings, in plates for upper end
b. Remove torque tube and supports. (Refer to of hydraulic cylinder to, 0.4995/0.5005 inch.
paragraph 7-75.)
(4) Ream bushing in one plate for lower end of
c. Remove lateral cyclic control damper. (Refer to hydraulic cylinder to, 0.813/0.814 inch. Ream bush-
paragraph 7-61.) ing in opposite plate to, 0.819/0.821 inch. The inside
diameter of the two bushings must be concentric
d. Remove lateral system power cylinder and sup- within 0.002 inch after reaming and coat I.D. of
port. (Refer to paragraph 7-83.) bushings with DRY film lube.
e. Remove cyclic control stick. (Refer to paragraph

7-25.) Vendors of DRY Film Lube
7-70. INSPECTION - LATERAL CYCLIC CONTROLS. LUBRI-BOND "A" Electrofilm Incorporated
P.O. Box 106
a. Inspect push-pull tubes and link-rods for cracks, 7116 Laurel Canyon Blvd
nicks or other surface damage, loose rivets, worn or North Hollywood, Calif.
rough rod-end bearings, security of attachment, align-
ment, and for possible interference with other parts. SURF-KATE Hohman Plating & Mfg. Co.
A-1625 814 Hillrose Avenue
Dayton 4, Ohio
b. Inspect bellcranks and supports for security of
attachment, cracks, nicks or other surface damage, DRY LUBE FILM Alpha-Molykote Corp.
elongated bolt holes, worn or rough bearings, and 65 Harvard Avenue
possible interference with other parts. Stamford, Conn.
7-37
Section VII (Part 2) BELL HELCOPTER COMPANY Models 47G & 47G-2
MAINTENANCE
e. If hydraulic power cylinder No. 1450 is installed on b. Install bellcrank, with arm having two bolt holes
Model 47G-2 helicoper, lockwire spring part No. 47- forward, in support on left side of cabin box beam
691-078-1, between clevis and control valve using under floor.
0.030 lockwire
0.030 lockwire to prevent spring
to prevent spring from
from interfering
interfering c. Install torque tube and supports. (Refer to para-
with proper function when bellcrank is in extreme
position. graph 7-81.)
position.
d. Install power cylinder, support, and bellcrank
7-72. INSTALLING- LATERAL CYCLIC CONTROLS- assembly. (Refer to paragraph 7-86.)
WITH FRANKLIN ENGINE.
e. Install cyclic control damper. (Refer to para-
graph 7-64.)
Note f. Rig lateral cyclic control system while installing
push-pull tubes. (Refer to paragraph 7-7.)
g. Check operation of system.
Parts of system may be installed in any
practical sequence. Rigging check must 7-74. TORQUE TUBE - LATERAL CYCLIC CON-
be performed after installation of any TROLS WITH LYCOMING ENGINE. (Figure 7-46.)
parts in system. (Refer to paragraph 7-On Lycoming-powered helicopters, a torque tube,
73 for procedure on Lycoming powered mounted between supports on left side of transmis-
sion case and on left forward upper structure of
center frame, is connected in lateral cyclic control
linkage between hydraulic power cylinder and swash-
a. Install cyclic control stick. (Refer to paragraph plate. On helicopters Serial No. 1342 through 1412,
7-31.) torque tube is of welded construction. On subsequent
b. Install bellcrank, with arm having two bolt holes installations, torque tube lever
lever arms
arms and
and supports
supports
forward, in support on left side of cabin box beam
under floor. 7-75. REMOVING - LATERAL CYCLIC TORQUE
c. Install bellcrank, with longest arm outboard (this TUBE AND SUPPORTS.
arm has part number in raised letters and should
be rubber-stamped "outboard"), between lateral sprag a. Disconnect bungee spring and control linkagefrom
mount bracket and vertical center frame tube below lever arms. Keep bushings and spring attachment
left Lord mount. spacer with bolts for reinstallation.
d. Install bellcrank, with longest arm forward and
pointing outboard, between brackets in left side of Note
engine mount frame.
Double bushings, consisting of an inner
e. Install power cylinder and support assembly. bushing slip-fitting in an outer bushing
(Refer to paragraph 7-85.) which is pressed into casting, are used
at three locations in lever arms and in
f. Rig lateral cyclic control system while installing one fork of forward support to eliminate
push-pull tubes. (Refer to paragraph 7-6.) clearance between bushings and bearing
inner race whenbolt is tightened.
g. Check operation of system.
b. Remove cotter pin and nut from aft end of tor-
7-73. INSTALLING - LATERAL CYCLIC CONTROLS- que tube. Remove bolt (and inner bushing), lift for-
WITHLYCOMINGENGINE. ward support from bracket, pull torque tube from
aft support, and remove washer from shaft. Remove
nut, support, and washer from forward end of tube
Note assembly.
c. Remove nuts and pull aft support from transmis-
Parts of system may be installed in any sion. Remove bolts and lift forward support bracket
practical sequence. Rigging check must from structure.
be performed after installation of any
part in system. (Refer to paragraph 7-72 7-76. DISASSEMBLING - LATERAL CYCLIC TOR-
for procedure on Franklin-powered heli- QUE TUBE AND SUPPORTS.
copter.)
a. Match-mark parts with quick-drying paint before
a. Install cyclic control stick. (Refer to paragraph disassembly. (No disassembly on torque tube of
7-31.) welded construction.)
7-38
b. Remove lever arms by removing bolts andtapered b. Buildup lateral cyclic torque tube as follows:
bushings.
c. When necessary for replacement, press bearings
and sleeves from supports or bracket. Note
This procedure is for the buildup of a lateral
torque tube using a new undrilled forward lever
7-77. CLEANING - LATERAL CYCLIC TORQUE (5), torque tube (6) and aft lever (7). If all new
TUBE AND SUPPORTS. Wash parts in cleaning solvent or parts are not being installed, proceed to the
kerosene. Dry with filtered compressed air. sub-step that is applicable.
1. Position torque tube (6) on aft lever (7) to the 1.75

7-78. INSPECTION - LATERAL CYCLIC TORQUE inch dimension. Drill a 0.257 (F drill) hole through torque
TUBE AND SUPPORTS. tube (6) and aft lever (7) at the 2.25 inch dimension and as
shown on Detail A. Use TC-27872-11 reamer and taper
a. Inspect for security of installation, surface dam- ream holes (from each side) so tapered bushings will extend
age, cracks, and excessive wear at bolt holes or 0.030 to 0.060 inch above torque tube when bolt (1) is
bushings. torqued. Temporarily install bushings (4), bolt (1), washer
b. Inspect bearings for excessive wear or roughness. (3) and nut (2).
c. Refer to Section I for Magnetic Particle and Fluorescent Note

Penetrant requirements.
A 20-0374-8 tapered bushing may be used if
any hole size needs to be increased to allow
7-79. REPAIR OR REPLACEMENT - LATERAL CY- proper clean-up.
CLIC TORQUE TUBE AND SUPPORTS.
a. Polish out shallow scratches or nicks. Replace 2. Drill a 0.257 (F drill) hole at the 0.62 inch dimen-
parts if cracked or excessively worn. sion from previous drilled hole in step 1., and located in
b. Replace worn or rough bearings, replacing sleeve accordance with detail A. Taper ream hole and temporarily
and ring-staking both sides. Replace bushings when install bushings (4), bolt (1), washer (3) and nut (2).
loose or excessively worn.
3. Position forward lever (5) on torque tube (6) to the
13.615 inch dimension and with levers positioned as shown
7-80. REASSEMBLY - LATERAL CYCLIC TORQUE in Detail B. Drill a 0.257 (F drill) hole through torque tube
TUBE AND SUPPORTS. (6) and forward lever (5) at the 10.48 inch dimension and
as shown in detail A. Use TC-27872-11 reamer and taper
Note ream holes (from each side) so tapered bushings will extend
0.030 to 0.060 inch above torque tube when bolt (1) is
If original parts are being reassembled refer to torqued. Temporarily install bushings (4), bolt (1), washer
step a. If new parts are being installed refer to (3) and nut (2).
step b.
4. Drill a 0.257 (F drill) hole at the 0.62 inch dimen-
a. Reassemble lateral cyclic torque tube as follows: sion from previous drilled hole in step 3., and located in
accordance with detail A. Taper ream hole.
1. Coat mating surface of forward lever (5, figure
746A) and torque tube (6) with unreduced zinc chromate 5. Remove nuts (2), washers (3), bolts (1) and
primer. Align match marks of forward lever (5), torque tube bushings (4). Remove forward lever (5) and aft lever (6)
(6) and taper pin holes. Coat tapered bushings (4) with from torque tube (6).
unreduced primer and install. Install bolt (1), washer (3)
and nut (2). Install bolts with heads as shown on figure 6. Install forward lever (5) in accordance with step
7-46A, and with washers (3) between nut (2) and tapered a.l.
bushing (4). Torque nuts 30 to 40 inch-pounds. Tapered
bushings to extend 0.030 to 0.060 above surface of tube 7. Install aft lever (7) in same sequence as in step
(6). Refer to Detail A. a.l.
2. Install aft lever (7) in torque tube (6) in same c. Lubricate bearings in forward support (3, figure 7-46),
sequence as in step 1. aft support (6) and bracket (1) with MIL-G-25537 grease.
(Rev. 1) 7-38A
5. Washer (Each end of Tube)

6. Aft Support
7. Control Tube (To Power Cylinder)
9. Cone Washer
47725-54
13.615"
10.48"
-06.62" 0.62
TYP.
60'TYP.
0.030"
to DETAILA -47-725-874 Lever
0.060"
1. Bolt
2. Nut
3. Washer 47-725-875-11 Lever
4. Tapered Bushing 47-725-875-11 Lever
5. Forward Lever DETAIL B
6. Torque Tube 0.15
7.6. Torque Tube 47-725-875-1 & -5 Lever
Aft Lever 0.25
47725-2
Figure 7-46A. Lateral Torque Tube
(Rev. 1) 7-39
7-81. INSTALLING - LATERAL CYCLIC TORQUE b. Disconnect hydraulic lines from valve body trun-
TUBE AND SUPPORTS. nions, allow hydraulic fluid to drain into container,
remove elbow fittings, and plug or cap all openings.
a. Install washer on each end of torque tube and in-
sert each end into support bearing. Install a coned c. Remove bolts attaching support to brackets or
washer on the outboard side of each bearing with the arm sets and remove support, cylinder, and bell-
coned end of washer facing outboard. Install nuts and crank as an assembly. Leave brackets or arm sets
cotter pins. There should be approximately 0.125" in place, if possible, to maintain alignment for re-
clearance between the outer edge of washer and torque installation. If brackets are removed, mark locations
tube support casting. and keep all shims with parts for reinstallation.
d. Separate support and bellcrank halves by re-

b. Place forward support bracket in channel on moving bolts and spacers. Remove power cylinder.
center frame structure, with raised part number
at inboard side, and install mountingbolts.
7-84. INSPECTION - POWER CYLINDER AND SUP-
c. Install washer on shaft, and insert through aft PORT - LATERAL CYCLIC CONTROLS. (Refer to
support bearing. Install nut and cotter pin on aft end paragraphs 7-36, 7-37, and 7-38 for cleaning, in-
of shaft. spection and repair or replacement.)
d. Connect push-pull tube from power cylinder to for-
ward lever arm. 7-85. INSTALLING - POWER CYLINDER AND SUP-
PORT - LATERAL CYCLIC CONTROLS WITH
e. Connect push-pull tube from swashplate, to aft lever FRANKLIN ENGINE. (Figure 7-47.)
arm.
f. Check rigging of lateral cyclic control system. Note

For corresponding installation with Ly-
g. Connect bungee spring (if installed). coming engine, refer to paragraph 7-86.
7-82. HYDRAULIC POWER CYLINDER AND SUP- a. Assemble halves of lever on valve body trunnions
PORT - LATERAL CYCLIC CONTROLS. With Frank- of power cylinder, with pressure port of valve facing
lin engine, the lateral cyclic control power cylinder left. (When assembling parts of 47-725-078 lever,
is mounted in a support attached under seat structure which are machined from bar stock, be sure clip is
at left side. The cylinder head trunnions are mounted located on aft side of right-hand lever-half and in-
in bushings in aft end of support. The valve body, on stall spacer between inner races of bearings. When
forward end of cylinder shaft, is attached through assembling 47-725-102lever, composedof cast halves,
trunnions and bushings to a lever pivoted in the trunnion lubricator fittings face aft.) Install bolts.
support and actuated by linkage from the lateral con-
trol arm on cyclic control stick. A clevis adapter b. Assemble halves of support on cylinder head trun-
on aft end of cylinder shaft provides attachment for nions and install spacers (not used with cast parts)
a push-pull tube connected to linkage controlling the and bolts. Align lever assembly in support and install
swashplate. Hydraulic pressure and return lines con- pivot bolt. Check operation of assembly and correct
nect to fittings in the valve body trunnions. With any binding due to misalignment.
Lycoming engine, installation is similar except that
cylinder and support are mounted vertically on seat- c. If removed, attach forward pair of arms sets,
back aft of firewall. With either installation, supports with bushings in place, about 12 inches left of heli-
are made of stamped sheet metal halves assembled copter center line on diagonal tube located between
with bolts and spacers or, in later design, of aluminum forward left corner of seat and aft seat support
alloy castings. cross tube. Shim to obtain maximum gap of 0.003
inch between halves of each arm set before tightening
bolts. (Arms to extend down and aft.)
7-83. REMOVING - POWER CYLINDER AND SUP-
PORT - LATERAL CYCLIC CONTROLS. d. Attach aft pair of arm sets, in same manner,
about 12 inches left of center on aft seat support
cross-tube. Position arms to extend aft and curve
a. Disconnect lateral system bungee spring. Dis- downward. (Firewall just above tube should be dished
connect push-pull tubes from cylinder shaft and lever. in to provide 1/4 inch clearance with arm set.)
7-40 (Rev. 1)
MAINTENANCE
e. Position cylinder and support assembly to align

forward pair of arm sets against right side of each
support-half, and aft pair of arms against outside
of support assembly. Install bolts.
f. Adjust clevis to obtain dimension of 1 7/32 inches
from aft end of cylinder shaft to center of clevis
7-40A
MAINTENANCE
1. Bell Crank (On Cabin Box Beam)

2. Push-Pull Tube
3. Forward Arm Sets and Bushings
4. Clip (Right Lever Half Only)
5. Bearing
6. Bushing - Valve Trunnion
7. Lever Halves
8. Valve Body (Pressure Port Left)
9. Aft Arm Sets and Bushings
10. Support Halves
11. Cylinder Head Trunnion
12. Cylinder Shaft
13. Push-Pull Tube
14. Bell Crank
15. Bell Crank
16. Grooved Spacer
17. Bungee Spring
18. Protective Plate
19. Clamps
20. Engine Mount CAST SUPPORT
21. Swashplate Horn AND LEVER
7/32"
NOTE: Shim to .003" max. gap between arm set

halves before tightening bolts.
Align cylinder shaft and tubes (2 and 13) on
straight line (viewed from below) between
bellcranks (1 and 14) in neutral.
TO C YCLIC
CONTROL STICK
47725-15
Figure 7-47. Power Cylinder Installation - Lateral Cyclic Control Franklin Engine
7-41
MAINTENANCE
bolt hole, with slot of clevis vertical. Connect push- c. Mount support assembly on lower and upper
pull tube between clevis and inboard (shorter) arm brackets and install bolts, with spacer between
of bellcrank near lateral sprag mount, and push-pull brackets. Upper end of cylinder should be inclined
tube between lever in support and longer arm of bell- approximately 4 degrees to left to align with attach-
crank mounted on left side of box beam under cabin ment bolt in forward lever arm on torque tube
floor. Both bellcranks should be in neutral, cylinder mounted above center frame. Check for binding at
shaft at half-travel (neutral) position, and valve trunnions, and correct any misalignment to eliminate
centering pin T101233 installed in place of valve body binding.
retaining bolt, when adjusting linkage. (Refer topara-
graph 7-6.) Align cylinder, by moving arm sets on d. Adjust clevis adapter on upper end of cylinder
structural tubes, so that push-pull tubes and shaft shaft to dimension of 1 7/32 inches from end of
form a perfectly straight line between bellcranks shaft to center of bolt hole, aligning slot of clevis
when viewed from below.fore and aft
Note e. Level helicopter. Determine neutral position of
cylinder shaft by measuring from upper end of shaft
Alignment may also be determined by to end of cylinder with shaft full up then full down.
stretching a cord between bolts inserted Set shaft in exact half-travel position. Remove bolt
in bellcrank arms. through valve body and cylinder shaft, and install
valve centering pin, T101233, to center body in neu-
g. Complete rigging of lateral cyclic control sys- tral position on shaft. Set torque tube to neutral posi-
tem. (Refer to paragraph 7-6.) Check operation of tion on shaft (attachment bolt in aft lever arm 5/32
system without hydraulic boost pressure, observing inch above level of torque tube center line) Adjust
carefully for misalignment and binding at trunnions and install push-pull tube between cylinder shaft
and linkage attachment points. clevis and forward lever arm of torque tube, main-
taining neutral positions of each.
h. Remove valve centering pin, T101233, and rein- .
stall bolt through valve body and power cylinder shaft.
Install elbow fittings in valve body trunnions and in both directions. Viewed from aft, center lines of
connect hydraulic pressure and return lines. Fill and tube and cylider should form a straight line. Ad-
purge hydraulic system. (Refer to paragraph 7-40.) just as necessary by moving upper bracket on hori-
zontal tube. Viewedfrom side, upper end of push-pull
Note tube should incline aft 1 degree from center line of
cylinder. Check with bubble protractor, and adjust
On helicopters with irreversible valves shims between upper cylinder support bracket and
installed hold check valve No. 1 (figure horizontal seat-back tube member as necessary to
7-41) while tightening hose to keep it from obtain this alignment. Check for freedom of operation
turning. through full range of travel. Lockwire upper cylinder
support bracket clamp bolts in pairs.
7-86. INSTALLING - POWER CYLINDER AND SUP-
PORT - LATERAL CYCLIC CONTROLS WITH g. Rig lateral cyclic system. (Refer to paragraph
LYCOMING ENGINE. (Figure 7-48.) 7-7.) Remove valve centering pin, T101233, and
reinstall bolt through valve body and power cylinder
Note shaft.
corresponding installation
For corresponding
For with Frank-
installation with Frank- h. Install elbow fittings in valve trunnions and con-
lin
lin engine,
engine, refer
refer to
to paragraph
paragraph 7-85.
7-85. nect hydraulic pressure and return hoses. Fill and
purge hydraulic system. (Refer to paragraph 7-40.)
a. Assemble halves of support on power cylinder
head trunnions, align spacers between halves, and 7-87. SYNCHRONIZED ELEVATOR. The synchro-
install bolts. Assemble halves of bellcrank on valve
body trunnions, with pressure port of valve to left,
and install bolts. Position bellcrank to lower end of by cables and mechanical linkage to the fore-aft
support and install pivot bolt. cyclic control system. Fore and aft movements of
cyclic control stick cause corresponding change in
b. If upper support brackets were removed, place elevator attitude, thus increasing controllability and
bracket and original shims against horizontal tube CG range, and providing for normal loadings within
member above lower support brackets (welded on CG range without reballasting.
lower horizontal seat-back tube near left side). In-
sert bolts through bracket plate and shims, and in- 7-88. REMOVING - ELEVATOR, CABLES, AND
stall a spacer on each bolt. Place two clamps, with BELLCRANK.
bushings, on firewall side of tube and start bolts into
clamps. Shim to maximum gap of 0.003 inch between a. Disconnect cables from elevator horns by re-
each spacer and clamp before tightening bolts. moving clevis pins.
7-42
MAINTENANCE
1. Push-Pull Tube (to bellcrank on cabin box beam)

2. Bellcrank
3. Spacer
4. Welded Bracket (2)
5. Seat - Back Structure
6. Clamp
7. Bushing
8. Shim
9. Spacer
10. Shims
11. Bracket
12. Support Bracket
13. Spacer
14. Cylinder Head Trunnion
15. Push-Pull Tube (to torque tube)
16. Adapter
17. Cylinder Shaft
18. Valve Body (pressure port to left)
19. Valve Body Trunnion
HYDRAULIC
CYLINDER
MAX= GAP CYLINDER SHAFT BEFORE

TIGHTENING (SEE DETAIL B)
47725-17
Figure 7-48. Power Cylinder Installation - Lateral Cyclic Controls Lycoming Engine
7-43
MAINTENANCE
b. Remove bolts from hinge support brackets and Nos. 2556 through 2570 only, install bolts through
lift elevator out of tail boom structure from either brackets and hinge bearings, attach with washers and
side. nuts. Check for gap, between bracket and hinge bear-
ing, in elevator at each bearing (0.006 maximum gap
c. Disconnect cable turnbuckles and remove aft cables allowed) shim as required.
by removing guard pins and fairlead. Disconnect for-
ward cables from bellcrank by removing clevis pins, b. Place bellcrank between supportbrackets, located
and remove cables. on lower center frame tubes in forward right area of
engine compartment, and install pivot bolt. (For in-
d. Disconnect linkage and remove pivot bolt and ele- stallation operated by linkage to fore-aft cyclic con-
vator control cable bellcrank. trol jackshaft, install bellcrank with arm havingthree
linkage adjustment holes up. On other installations,
7-89. CLEANING - ELEVATOR, CABLES, AND install bellcrank with short actuating arm aft and
BELLCRANK. Clean parts with dry cleaning solvent above pivot.)
or kerosene. Dry with filtered compressed air.
c. Connect fork terminal of forward lower cable
7-90. INSPECTION - ELEVATOR, CABLES, AND (108 1/8 inches from center of fork hole to end of
BELLCRANK. right-hand threaded terminal) to lower end of bell-
crank, using clevis pin and cotter pin. Route cable
a. Inspect elevator for security ofinstallation, cracks, under two outboard pulleys located below engine
dents, loose rivets, and structural damage. Inspect compartment, and over outboard pulley near lower
support brackets for cracks or elongated holes. In- tail boom attachment. Secure cable temporarily by
spect bearings for roughness or excessive wear. taping aft end to structure.
b. Inspect cables for security of installation and d. Connect fork terminal of aft upper cable (94 inches
proper routing through pulleys and fairleads. In- long and having left-hand threaded terminal) to upper
spect daily for broken or frayed wires, especially elevator horn. Route through upper end of fiber fair-
where running over pulleys or through fairleads. lead, and connect to forward lower cable by installing
turnbuckle.
c. Inspect pulleys for wear and for rough bearings.
and brackets for cracks. e. Connect fork terminal of forward upper cable
d. Inspect bellcrank for security, and roughness or (97 1/8 inches long and having right-hand threaded
excessive wear of bearing, terminal) to upper end of bellcrank. Route cable
over single pulley, under two inboard pulleys below
7-91. REPAIR OR REPLACEMENT - ELEVATOR, engine compartment, and over inboard pulley near
CABLES,ANDBELLCRANK. lower tail boom attachment. Install cable guard pins
at each pulley bracket. (See figure 7-32 for routing
a. Repair or replace elevator if structural damage of cables for differences in Models 47G and 47G-2.)
occurs. Replace worn or rough bearings.
Note f. Connect fork terminal of aft lower cable (105 5/8
inches long and having left-hand threaded terminal)
Operators in territorial United States to lower elevator horn. Route through lower end of
make repairs or replacements in accord- fiber fairlead and connect to forward upper cable by
ance with Civil Aeronautic Manual 18. installing turnbuckle.
Helicopters operated outside territorial
United States will be repaired in accord- g. Connect linkage to fore-aft cyclic control system.
ance with instructions issued by the licens- (Refer to paragraph 7-5.) Rig elevator system. (Re-
ing authority. fer to paragraph 7-8.)
b. Replace cables that show more than three broken 7-93. ELEVATOR CONTROLS- FORWARDLINK-
wires in any one inch of length. This is limited to AGE. (Figure 7-49.) Two linkage systems, to trans-
two such places on any one cable. Replace cables mit movement of fore and aft cyclic control system
if corroded or badly worn even though no broken to the elevator control cable bellcrank, have been
wires are found. installed as kits or original equipment on Models
c. Replace pulleys for excessive wear or rough bear- 47G and 47G-2 helicopters equipped with hydraulic
ings. Replace bellcrank bearing for wear or roughness. boost controls, and are listed below in order of
development. The last listed installation is available
7-92. INSTALLING - ELEVATOR, CABLES, AND on current production helicopters and kits, and is
BELLCRANK. designed for improved ease of operation and to pre-
vent feedback of forces from elevator to control stick.
a. Lubricate bearings with MIL-G-25537 grease. Lift
elevator into position and install clevis bolts through (1) Forward linkage of 47-267-074 installation, on
hinge bearings and brackets. On Model 47G-2, Serial Model 47G, consists of push-pull tube connecting the
7-44
MAINTENANCE
upper arm of the cable bellcrank with a lever arm on

the fore-aft cyclic control jackshaft.
(2) Forward linkage of 47-267-138 installation,
on Models 47G and 47G-2, consists of a torque tube
and support mounted on lower center frame tubes
7-44A
MAINTENANCE
1. Protective Plate
2. Clamp
3. Link
4. Spring
5. Adjustable Link
6. Bellcrank
7. Double Links
8. Cable (To Lower Elevator Horn)
9. Torque Rod
10. Fore-Aft Power Cylinder
11. Link-Rod
12. Cable (To Upper Elevator Horn)
13. Washer
14. Support
15. Arm Sets
16. Bushings
SHIM TO .001" - .005"

GAP BEFORE TIGHTENING
ARM SETS.
47267-28
Figure 7-49. Synchronized Elevator Forward Linkage
forward of engine, a link-rod connecting one torque Note

tube arm to lower end of fore and aft hydraulic power
cylinder, and a double link connecting the other tor-
que tube arm to the cable bellcrank. b., Steps
stallation only.c., apply to 47-267-138 in-
and
stallation only.
7-94. REMOVING - ELEVATOR FORWARD LINKAGE.
b. Disconnect bungee spring. Disconnect link-rods
Note from torque tube arms. Remove bolts attaching legs
of support to arm sets on center frame tubes, and
Step a., applies to 47-267-074 installa- lift torque tube and support assembly from engine
tion only. compartment.
a. Disconnect and remove push-pull tube from fore
and aft cyclic control jackshaft and elevator cable c. Mark locations of arm sets for reinstallation.
bellcrank. Remove bolts, arm sets, bushings, and shims.
7-45
MAINTENANCE
7-95. DISASSEMBLING - ELEVATOR CONTROL Note

TORQUE TUBE.
Step b., applies to 47-267-074 installation
a. Match-mark arms and torque tube with quick only.
drying paint before disassembly. Push roll pins from
inboard arm, remove nut and washer from endof tor- b. Set elevator in neutral and connect push-pulltube,
que tube. with adjustable end aft to arm on cyclic control jack-
shaft and to middle hole in upper arm of cable bell-
b. Pull torque tube from support, removing inboard crank. Check rigging. (Refer to paragraph 7-8.)
arm and washer. Push out roll pins and remove out-
board arm from tube. Note
7-96.
7-96. CLEANING
CLEANING -- ELEVATOR
ELEVATOR FORWARD
FORWARD LINK-LINK- Steps c., through e., apply to 47-267-138
AGE. Wash parts in dry cleaning solvent or kerosene.
installation only.
Dry with filtered compressed air.
7-97. INSPECTION - ELEVATOR FORWARD LINK- c. Assemble upper halves of arm sets on legs of
AGE. torque tube support, with attachment lug ends for-
ward (on outside of forward legs, on inside of aft
a. Inspection installation for security of mounting, legs) Place assembly on tube-cross below fore
alignment, and freedom of operation. and aft hydraulic cylinder, with a spherical bushing
between each arm set and tube.
b. Inspect all parts for cracks, corrosion, surface
damage, and excessive wear. Inspect bearings for
wear or roughness. d. Assemble lower parts of arm set, with bushings,
under tubing and install bolts. Install laminated shims
c. Inspect parts by Magnaflux or Zyglo as required. to obtain gap of 0.001 to 0.005 inch with nuts finger-
tight, then tighten to standard torque.
7-98. REPAIR OR REPLACEMENT - ELEVATOR
FORWARD LINKAGE.
e. Install link-rod between inboard lever arm and
a. Replace unserviceable parts. clevis at lower end of fore and aft hydraulic power
cylinder, and double link between outboard lever arm
b. If necessary to replace any bearing inlever arms, an elevator cable bellcrank, moving torque tube as-
torque tube support, or cable bellcrank, replacebear- sembly as necessary for alignment. Check rigging of
ing sleeve also, and ring-stake sleeve at both sides elevator system (Refer to paragraph 7-8.)
with bearing in place.
7-101. VENTRAL FIN. (Figure 7-50.) The ventral
7-99. REASSEMBLING- ELEVATOR CONTROL fin is a fixed, non-adjustable vertical stabilizer. The
TORQUE TUBE. fin is made of aluminum honeycomb core covered
by bonded aluminum alloy sheet and is attached by
Note brackets and braces below the aft endof the tail boom.
Lubricate bearings with MIL-G-25537 7-102. REMOVING - VENTRAL FIN.

grease.
a. Remove brace from each side of fin by removing
a. Place shorter lever arm on outboard end of tor- bolts through braces and fin and bolts through braces
que tube, align holes and install two roll pins, with and welded bracket.
slots either forward or aft. Install lockwire through
each pin. b. Remove bolts at three brackets on lower tube of
tail boom and remove fin.
b. Insert torque tube through outboard bearing. Place
longer lever arm on inboard end of tube, install and 7-103. CLEANING - VENTRAL FIN. Cleanparts with
lockwire two roll pins. Install washers, and insert a cloth moistened with cleaning solvent.
tube through inboard bearing. Install washer (fail-safe
washer, larger than bearing), nut and cotter pin. 7-104. INSPECTION - VENTRAL FIN.
7-100. INSTALLING - ELEVATOR FORWARD LINK- a. Inspect fin for security of attachment, scratches,
AGE. dents, punctures, and structural damage.
a. Install valve centering pin, T101233, to center b. Inspect braces and brackets for cracks.
valve body on fore-aft power cylinder shaft. Center
cyclic control stick to place fore and aft cyclic sys- c. Check condition of chafing pad between braces
tern in neutral. (Refer to paragraph 7-5.) and lower tube of tail boom.
7-46
MAINTENANCE
1/16 2
1. Fin
2. Chafing Pad
3. Tail Boom CLEAN AND
4. Angle Brace BONDNG TAPE
METAL PATCH
47267-30
47267-31
Figure 7-50. Ventral Fin
Figure 7-51. Repair of Ventral by Patching
7-105. REPAIR ORREPLACEMENT -VENTRAL FIN.
b. Cut patch plate, large enoughfor 1/2 inchoverlap,
a. Replace chafing pad when necessary to prevent from 24S-T3 aluminum alclad sheet, 0.012 inch thick.
chafing of lower tail boom tube by braces of ven-
tral fin. Make pad from 5/8 ID x 1/16 x 2.0 inch
rubber tubing, (Specification No. MIL-R-6855, Class c. Use aumnum wool to clean skin area where
II, or equivalent), split and bonded to tail boom tube patch is to be applied. Wipe clea wth dry cloth.
with rubber cement, EC776 (Minnesota Mining, and
Mfg. Co., Detroit, Mich.) or equivalent. Pad may also d. Apply one coat of primer, Narmco No. 2105 (Narm-
be made by wrapping tail boom tube with "Scotch" co Resins and Coatings Co., Costa Mesa, Calif.) to
Electric Tape, or equivalent, to a thickness of 1/16 patch plate and to fin patch area. Allow to dry 24
inch over an area 2.0 inches long. hours.
b. Repair cracks or punctures in skin up to 1/2 inch e. Cut piece of bonding tape, Narm Tape No. 102-
diameter by patching. (Refer to paragraph 7-106.) 45, to size of metal patch plate. Use special care in
keeping tape clean to obtain satisfactory bond.
c. Repair damage to fin greater than 1/2 inch di-
ameter by insertion. (Refer to paragraph 7-107.) f. Lay bonding tape over damage area. Positionpatch
on bonding tape and bond at 15 to 25 PSI with heating
d. Repair damage to edge of fin. (Refer to paragraph iron or vacuum blanket for 25 minutes at 350°F.
7-108.)
7-106. REPAIR OF VENTRAL FIN BY PATCHING. g. Clean off squeezed-out bonding tape and refinish
(Figure 7-51.) Repair cracks or punctures in skin, area.
up to 1/2 inch diameter, as follows:
7-107. REPAIR OF VENTRAL FIN BY INSERTION.
a. Stop-drill crack or cut out punctured damage and (Figure 7-52.) Repair damage to ventral fin which
smooth edge of hole in skin. is greater than 1/2 inch in diameter as follows:
7-47
MAINTENANCE
more strips of bondingtape same size as large patch

plates. Prepare a strip of bonding tape to fit around
edge of core insert. Use special care in keeping
tape clean to obtain satisfactory bond.
f. Wrap bonding tape around core insert and posi-

tion in hole. Place smaller pieces of bonding tape
and smaller patch plates in hole on each side of honey-
comb insert. Cover hole, at each side of fin, with
larger pieces of bondingtape and overlap patch plates.
Apply 15 to 25 PSI with heating irons for 25 minutes
at 350°F.
CUT OUT
DAMAGED g. Clean off squeezed-out bonding tape and refinish
AREA area.
7-108. REPAIRING EDGE OF VENTRAL FIN. Dam-

age to edges of neutral fin maybe repaired as follows:
a. Repair honeycombcore or fin skins as necessary.

b. Prepare a mixture of Narmco No. 3119 resinputty

and Narmco No. 3119-C catalyst (Narmco Resins and
Coatings Co., 600 Victoria St., Costa Mesa, Calif.)
according to directions on container. (Alternate ma-
terial: EC1184 Glazing Cement, Minnesota Mining and-
Mfg. Co., 417 Piquette Ave., Detroit, Mich.)
c. Apply putty mixture to edge of fin with putty
1. Heating Iron 5. Honeycomb Core knife, forming a contour slightly larger than that
2. Patch Plate Insert of undamaged edge to allow for shrinkage. Let dry
3. Bonding Tape 6. Bonding Tape 24 hours.
4. Filler Plate 7. Ventral Fin
47267-243 d. Dress repaired edge with fine mill file to same
contour as undamaged edge.
Figure 7-52. Repair of Ventral Fin by Insertion 7-109. TAIL ROTOR CONTROLS. Pedals, push-pull
tubes, jackshaft, control cables, pitch change mecha-
nism operating through the tail rotor gear box and
a. Cut out damaged skin and core, and smooth edge shaft, and linkage to the tail rotor blades compose
of hole. Clean skin around hole with aluminum wool a system for control of the tail rotor to counter-
and wipe off with clean dry cloth. act main rotor torque and to change the helicopter
b. Cut piece of aluminum core to replace damaged attitude around the vertical axis (mast).
section. (Core specification is 0.250 thick x 0.250
hex. 1.5 mil x 3.4 density aluminum honeycomb, Hexcel 7-110. TAIL ROTOR CONTROL PEDALS. (Figure
Products Co., 955 Sixty-first St., Oakland 8, Calif. or 7-31.) The pedal assembly, located in the cabin for-
equal.) ward of the cyclic control stick, consists of two
pedals made of welded steel tubing, two shaft as-
c. Cut two patch plates of same material as skin semblies incorporating adjustment ratchets and lever
(Aluminum Alclad 24S-T3, 0.012 inch thick) and same arms, and two bearing housings mounted on forward
size as hole. Cut two more patch plates of same corners of box beam instrument column. Each pedal
material and large enough to allow one inch overlap has an adjustment pawl which engages shaft ratchet
around hole. to allow adjustment for the pilot's convenience. Push-
d. Apply one coat of primer, Narmco No. 2105 pull tubes connect to shaft lever arms to transmit
(Narmco Resins and Coatings Co., 600 Victoria St., pedal movement to the jackshaft in box beam.
Costa Mesa, Calif.), to honeycomb core, to both sides
of smaller patch plates, and to one side of each over- 7-111. REMOVING- TAIL ROTOR CONTROL PEDAL
lap plate. Allow primer to dry 24 hours. ASSEMBLY.
e. Cut two pieces of bonding tape, Narm Tape No. a. Disconnect push-pull tubes from lever arms on
102-45, same size as smaller patch plates. Cut two shafts.
7-48
MAINTENANCE
3. Pawl USE FLAT SPACERS AS REQUIRED

TO ADJUST END PLAY.
Tubes
Push-Pull
10.(Tapered)
12. Spacer
1. Pedal Assembly
2. Adjusting Lever
4. Ratchet Shaft 20. Stop

Screws
7. Coupling Tube
Tube Assembly
Assembly 21.g
8. Adapter Plug
9. Bearing Housing 8
10. Push-Pull Tubes
12. Spacer (Tapered) 18. Pulley

13. Bearing Housing 19. Pulley Retaining Bolt
14. Jackshaft 20. Stop Screws
15. Cover 21. Cable Guards
16. Spacer (Tapered) 22. Cable Retaining Bolt
17. Bearing Housing 23. Stop
47722-30
Figure 7-53. Tail Rotor Controls and Jackshaft Installation

7-49
MAINTENANCE
b. Remove bolts attaching shaft bearing housings to and adjust, by removing lever and rod attachment
box beam and lift assembly from cabin. pins and screwing rod into or out of pawl, so that
pawl clears highest ratchet tooth by 1/32 inch maxi-
7-112. DISASSEMBLING - TAIL ROTOR CONTROL mum when lever is raised against upper stop. Set
PEDALS. both pedals in aft notch of ratchets.
a. Remove pin attaching adjusting lever to bracket d. Insert longest ratchet shaft (left pedal) through
on forward side of each pedal, lift pawl clear of aft bearing of left-hand housing. Place coupling shaft
ratchet and slide pedal from end of shaft, with lever arm farthest right (open side of arm for-
ward and arm pointing up) over end of ratchet shaft
b. Remove pin through adjusting lever and end of against bearing. Align holes and install tapered bush-
adjusting rod, and remove lever. Unscrew rod and ings and screws through coupling shaft and ratchet
remove rod, pawl and spring. shaft. Bushings should protrude 1/32 inch minimum
from surface of shaft.
c. Remove screws and tapered bushings and separate
ratchet shafts, coupling shafts, bearing housings, e. Insert shortest ratchet shaft (right pedal) through
and adapter plugs (used in right ends of coupling forward bearing of left-hand housing. Place coupling
shafts except when dual controls kit is installed). shaft with lever arm farthest left (open side of arm
Push bearings from housings. forward and arm pointing up). Lay a straight bar
along forward sides of pedals and clamp to each pedal
7-113. CLEANING - TAIL ROTOR CONTROL to hold alignment. Align holes and install tapered
PEDALS. Wash parts in dry cleaning solvent or bushings and screws through coupling shaft and ratchet
kerosene and dry with filtered compressed air. shaft. (Lever arm bolt holes should now be aligned.)
7-114. INSPECTION - TAIL ROTOR CONTROL f. Place right-hand bearing housing on ends of cou-
PEDALS. pling shafts. Insert adapter plug through bearing into
each shaft, align holes, and install tapered bushings
a. Inspect bearings for wear or roughness and screws.
b. Inspect parts for cracks, surface damage, cor- 7-117. INSTALLING- TAIL ROTORPEDALS.
rosion, wear, and elongated holes.
a. Lift pedal assembly into position, align bearing
c. Inspect installation for security of attachment housings on each side of box beam instrument column,
and proper operation. and install bolts.
7-115. REPAIR OR REPLACEMENT - TAIL ROTOR b. Connect push-pull tubes, with adjustment ends for-
CONTROL PEDALS. ward and longest tube at left, between arms on cou-
pling shaft and jackshaft in box beam.
a. Replace bearings for wear or roughness.
b. Replace any excessively worn or unserviceable 7-118. TAIL ROTOR CONTROL JACKSHAFT. (Fig-
parts. ure 7-53.) The tail rotor control jackshaft is located
in the cabin box beam, mounted vertically in upper
7-116. REASSEMBLING - TAIL ROTOR CONTROL and lower bearings, and has a large pulley installed
PEDALS. on shaft end below box beam. Push-pull tubes con-
nect arms near upper end of shaft to lever arms on
a. Lubricate bearings with MIL-G-25537grease and the pedal assembly. The tail rotor control cable is
install bearings in housings. installed on the pulley, locked by a bolt and kept in
pulley groove by cable guards secured to each side
b. Insert spring and pawl in lower end of guide on of box beam. Adjustable stop-screws in each side of
right side of pedal tube. Insert adjusting rod through pulley act against a fixed stop, located forward of
top of guide and screw into pawl (to approximate pulley, to limit travel.
adjustment length). Check that spacer (or stop) and
pin are installed in aft end of adjusting lever. Posi- 7-119. REMOVING - TAIL ROTOR CONTROL JACK-
tion lever, with rod attachment clip to right, on SHAFT.
pedal from aft side, and install pin, with head to-
ward pedal tube, attaching rod to lever. (Omit cotter a. Secure pedals in approximately neutral position.
pin until rod length is adjusted in later assembly.) Remove box beam access plates and access door
under cabin.
c. Assemble each pedal on a ratchet shaft, raising
pawl to engage in ratchet, with straight side of pawl b. Cut lockwire and loosen turnbuckles on tail rotor
tooth forward. Insert pin attaching lever to brackets control cables. Remove push-pull tubes between arms
on forward side of pedal. Check adjusting rod length on pedal shafts and jackshaft.
7-50
MAINTENANCE
c. Loosen bolts securing cable guards to box beam, Mining and Mfg. Co.) or equivalent, using care to keep
remove cable locking bolt and slip cable from pulley cement from entering bearing or space between cover
under box beam. Stow cable to prevent damage. Re- and shaft collar.
move bolt and pulley from shaft.
e. Install pulley, with attachment bolt hole down and
d. Match-mark, with quick-drying paint, upper and cable locking bolt hole forward when jackshaft arms
lower bearing housings and spacers before removal. (opensides forward) are at right angles (approximately)
(Spacers are tapered and match-drilled with bearing to helicopter center line. Install pulley retaining bolt.
housings.) Remove bolts and lower bearing housing
and spacer. Break cement seal between box beam f. Connect push-pull tubes, with adjustable ends for-
floor and bearing cover, and pull shaft downward out ward and longest tube at left, between jackshaft
of upper bearing. Remove shaft through access open- arms and lever arms on pedal shafts.
ing in box beam. Remove bearing cover. Remove bolts
and upper bearing housing and spacer. 7-123. TAIL ROTOR CONTROL CABLES. Two sec-
tions of standard (NAS)preformed, corrosion resis-
7-120. INSPECTION -TAIL ROTOR CONTROLJACK- tant, flexible steel aircraft cable are jointed by
SHAFT. turnbuckles located in tail boom structure near the
lower boom attachment to center frame. The tail
a. Examine parts for corrosion, excessive wear, rotor control cable so formed is a continuous loop,
cracks, and other damage. locked to and actuated by the control jackshaft pulley
at forward end, and locked to and actuating a spirally-
b. Inspect bearings for wear or roughness. grooved pitch change drum (on left side of tail rotor
gear box) at aft end. A series of pulleys and fairleads
c. Inspect installation for security and proper opera- support and guide the cable under and through center
tion. frame and tail boom. At original installation, pulleys
or brackets are color coded (red and white) and
7-121. REPAIR OR REPLACEMENT - TAIL ROTOR corresponding color code isappliedoncableterminals
CONTROLJACKSHAFT. to aid in proper routing in reinstallation. Forward
section of cable has right-hand threaded turnbuckle
a. Replace bearings for wear or roughness. terminals, aft section has left-handthreaded terminals.
b. Replace any excessively worn or unserviceable 7-124. REMOVING - TAIL ROTOR CONTROL
parts. CABLES.
7-122. INSTALLING -TAILROTORCONTROLJACK- a. Secure control pedals in neutral by placing a bar
SHAFT. across front sides, clamped or taped to both pedals.
a. Lubricate bearing with MIL-G-25537 grease and b. Disconnect cable turnbuckles.
install upper bearing housing and spacer (or spacers)
with match-marks aligned (thick end of spacer aft c. Remove access door under cabin. Loosen bolts
and larger bore up) against doubler at inside top of securing cable guards to each side of box beam, re-
box beam. Install bolts through top of box beam, move cable locking bolt and cable from jackshaft
spacers and bearing housing. pulley.
b. Place bearing dust cover on lower end of shaft, d. Remove guard pins or pulleys as necessary and
remove forward section of cable.
above collar, place shaft in box beam through access
opening, and insert end through hole in bottom of box e. Loosen cable locking screw in pitch change drum
beam. on tail rotor gear box, anddisengage cable from drum.
c. Lubricate bearing with MIL-G-25537 grease and
assemble spacer (thin end aft) and bearing housing, f. Remove guard pins or pulleys as necessary, re-
on lower end of shaft. Insert upper end of shaft into lease cable from fairlead in tail boom, and remove
upper bearing, align lower bearing housingand spacer, aft section of cable.
and install bolts through box beam floor, spacer and 7-125. CLEANING-TAILROTORCONTROLCABLES.
bearing housing. Check for free rotation of shaft and Wash cables with dry cleaning solvent or kerosene.
for excessive end play. If necessary, install or remove Dry with filtered compressed air. Wipe pulleys and
spacers (triangular, match-drilled to tapered spacer, fairleads with cloth dampened with cleaning solvent.
and 0.125 inch thick) between box beam doubler and
upper bearing spacer. 7-126. INSPECTION - TAIL ROTOR CONTROL
d. Slip bearing dust cover down on collar of shaft, CABLES.
turning bolt heads to align flats for clearance and
positioning cover with a long edge aft. Seal cover to a. Inspect control cables for corrosion or excessive
box beam floor with cement, EC524 (Minnesota wear.
7-51
MAINTENANCE
b. Inspect cables for broken or frayed wires, espec- 7-133. RIGGING- COLLECTIVECONTROL
ially where running over pitch change drum of pulleys, SYSTEM. (Figure 7-54.)
or through fairleads, by wiping cable with a clean
soft cloth, examine cable carefully in areas where Note
cloth pulls.
Tolerance for all angular settings is plus
c. Inspect pulleys for excessive wear, cracks or orminus one-half degree. If only the pitch
damage. Inspect pulley bearings for excessive wear change link-rods are being rigged, it is
and binding. Inspect brackets for cracks. not necessary to level helicopter.
d. Inspect system for security and proper operation. main rotor mast for vertical alignment,usingabubble
protractor or square head. Adjust sprag-rods and
7-127. REPAIR OR REPLACEMENT - TAIL ROTOR safety cables as necessary for alignment. (Refer to
CONTROL CABLES. Section V.)
b. Disconnect both push-pull tubes from bell-
a. Replace cables that show more than three broken crank located on lower horizontal seat-back struc-
wires in any one inch of length. This is limited to tural tube near left side.
two such places on any one cable. Replace cables if
corroded or badly worn even though no broken wires c. Set collective pitch control stick at 37 1/2
are found. degrees above horizontal and secure with friction
adjuster. Position bellcrank so that center line through
b. Replace pulleys for excessive wear, damage, or pivot point and bolt hole in long arm makes an angle
for rough or excessively worn bearings. of 17 1/2 degrees above horizontal. Adjust andinstall
tube between collective torque tube and bellcrank.
7-128. INSTALLING - TAIL ROTOR CONTROL d. Cut safety wire and move collective sleeve
CABLES. boot up on mast. Install rigging fixture T101234 in
position on mast with four legs contacting the control
a. Observing color coding at pulleys and on cable plate. Secure in this position. (See figure 7-55.) Cut
terminals, route aft section of cable through pulleys safety wire, loosen jam-nut and screw low pitch col-
and fairlead, installing guard pins. Loop cable loose- lective stops on transmission case cap in enough to
ly over pitch change drum. prevent interference when rigging. Install rigging fix-
ture T101235 between outboard end of collective bell-
b. Loop forward section of cable on jackshaft pulley, crank and fore-aft arm of control plate. Adjust link-
adjust guards to retain cable on pulley, and thread rod to accommodate a bolt through collective pitch
ends aft through fairlead in bulkhead. Route cable levers, link-rod and rigging fixture, T101235. Adjust
under pulleys below center frame and over pulleys at vertical tube assembly to the necessary length for
lower tail boom attachment point, installing guard installation on bellcrank. Remove riggingfixture T101
pins in pulley brackets. 235. Install tube assembly. Install bolts, washers and
cotter pins.
c. Join ends of cable loosely at turnbuckles. Rig
tail rotor control system. (Refer to paragraph 7-9.) Note
Cotter pin, washer and nut may be left off
7-129. TAIL ROTOR PITCH CONTROL ROD AND the bolt through fore and aft control plate
HEAD. A pitch control rod, operating through the horn if the cyclic control is to be rigged.
tail rotor gear box rear cap and rotor shaft, trans-
mits movements of pitch change cable drum to link- e. Adjust low pitch collective stop screws on
age which controls tail rotor blade angles. (Refer transmission case cap so they just touch collective
to paragraphs 7-9 and 7-10 for rigging and adjust- levers. Tighten jam-nuts and safety.
ment. Refer to Section VI for overhaul procedures.)
f. Remove rigging fixture T101234 from mast and
7-130. FLIGHT CONTROLS. with a soft pencil, place a mark on the mast exactly
(Model 47G-2, Serial Nos. 2556 at the end of the collective pitch sleeve. Place a
through 2570.) similar mark on the mast 23/32 inch above the first
mark. (See figure 7-25.)
7-131. DESCRIPTION.
(Refer to paragraph 7-2.) g. Release friction adjustment and move col-
lective pitch stick up until the end of the collective
7-132. RIGGING FLIGHT CONTROLS. pitch sleeve is exactly opposite the higher mark on
(Refer to paragraph 7-3.) the mast and secure with friction lock.
7-52
MAINTENANCE
HIGH PITCH STOP
NOTE:
TOLERANCEFORALL SETTINGS
°
±1/2 CHECKLOWPITCHBLADE
ANGLESBEFOREFLIGHT
HIGHPOSITION
LOWPOSITION
HIGHPITCH POSITION
IS APPROXIMATE
47749-1-
Figure 7-54. Rigging Diagram Collective Pitch Control System

7-53
h. Adjust high pitch stop screw on the collective links by lengthening on one side and shortening on
pitch lever assembly to contact the stop in this posi- opposite side, as necessary.
tion. Tighten jam-nut and safety wire stop screw.
m. Check low pitch blade angles, to establish
i. Release friction adjustment and position col- safe autorotational rotor rpm on test flight, by fol-
lective pitch stick in low pitch position and secure lowing procedure. Place collective pitch control stick
with friction lock. in full down position. Place a spirit level chordwise
on flat area of one blade root, or on outboard end
j. Position collective pitch sleeve boot over of grip. Raise or lower one end of stabilizer bar to
sleeve and safety wire in place around mast. obtain level reading. Keeping this blade level, place
protractor on other blade in same manner and check
k. Disconnect both link-rods from stabilizer bar for angular measurement of one-half degree to one
mixing levers and pitch horns on rotor hub. Adjust and one-half degrees, leading edge up. Adjust to cor-
rods 7 13/16 inches between center of bolt holes and rect reading by lengthening or shortening both link-
reinstall. Pins on rigging fixture T101234 may be rods, between stabilizer bar mixing lever and blade
used. Use 7 13/16 dimension. (See figure 7-55.) pitch horns.
Note Note
Step k., above applies to initial rigging. If When adjusting link-rods for collective
performing rigging check after flight tests, pitch, adjust each rod an equal amount,
and it is knownthat link-rods were adjusted see note following step k.
to unequal length in a "Grip-rolling" op-
eration to compensate for a high trim tab n. Check complete system for security and for
condition in tracking blades, omit step k. freedom of operation. Start and warm-up engine.
Install link-rods observing color code and Track main rotor blades.
proceed to step 1.
Note
1. Level swashplate and stabilizer bar. Check
main rotor hub yoke to determine if it is level. If During first flight after rigging collective
hub yoke is not level chordwise, adjust pitch change pitch system, check main rotor rpm in
autorotation. Gross weight will affect auto-
rotation rpm so that it should be adjusted
in the configuration and gross weight at
which the helicopter will be operated. Make
an autorotation descent with the collective
pitch control full down at an indicated air
speed of 50 mph and check for a rotor
speed of approximately 340 rpm. Then in
a autorotation descent at an indicated air-
speed of 50 mph, execute a moderate flare.
Rotor speed should not exceed 370 rpm in
the flare.
o. If rotor speed was below 340 rpm in auto-
rotation at 50 mph airspeed, decrease blade angle in
low pitch by shortening both link-rods which connect
pitch horns to stabilizer bar mixing levers. If rotor
speed in flare exceeds 370 rpm, increase blade angle
rods evenly in 1/2 turn increments. Repeat test flight
after adjustment.
p. Cruise at 23 inches Hg manifold pressure,
and check for forces in collective pitch control lever.
Install heavier counterweight if control lever tends
to creep downward. Continue this procedure until a
selection of weight is found which provides a stabi-
lizer main rotor pitch setting at 23 inches Hg mani-
47749-6 fold pressure. A maximum weight allowed is one
counterweight (approximate weight 2.18 pounds each)
plus nine small washers (approximate weight 0.125
Figure 7-55. Swashplate Rigging Fixture pound each) on each side.
7-54
MAINTENANCE
23/64" SLEEVETRAVEL EACH

WAYFROMNEUTRAL CLAMPSCISSOR
LEVERS IN
NEUTRAL
HIGH PITCH STOP
NOTE:
FigureDiagram
7-56. Rigging TOLERANCE FOR ALL SETTINGS
°
± 1/2 CHECK LOWPITCH BLADE
ANGLESBEFORE FLIGHT
EXTREMETRAVEL POSITIONS
ARE APPROXIMATE
47723-10
Figure 7-56. Rigging Diagram Collective Pitch Control System (Alternate Method)
7-55
MAINTENANCE
7-134. RIGGING COLLECTIVE PITCH CONTROL h. Refer to paragraph 7-133 steps k. through p.,
SYSTEM (ALTERNATE METHOD). for completion of collective rigging.
(Figure 7-56.)
7-135. RIGGING - FORE AND AFT CYCLIC CON-
Note TROL SYSTEM. (Figure 7-26.) (Refer to paragraph
7-5, use centering fixture, T101232, in lieu of 47-
Tolerance for all angular settings is plus 300-001-T222.)
or minus 1/2 degree. If only the pitch
change link-rods on the hub are being 7-136. RIGGING - LATERAL CYCLIC
rigged it is not necessary to level heli- CONTROL SYSTEM.
copter. (Figure 7-57.)
Note
a. Level helicopter. Check main rotor mast for
vertical alignment, using a bubbleprotractor or square Tolerance for all angular settings is plus
head. Adjust sprag-rods and safety cables as neces- or minus 1/2 degree.
sary for alignment.
b. Disconnect both push-pull tubes from bell- vertical alignment of mast, adjusting sprag mount
crank located on lower horizontal seat-back structural rods and safety cables as necessary. (Refer to Sec-
tube near left side. tion V.)
c. Clamp swashplate scissor levers in neutral. b. Clamp centering fixture T101232, around base
(See figure 7-24.) of cyclic control stick, below outer bell. If fixture
is not available, use bubble protractor or square
d. Set position of bellcrank, mounted to support head to place stick in vertical position. Tighten
on transmission, by adjusting length of link to allow friction, by turning knurled nut, to hold stick firmly
rigging fixture, T101235, to be installed over ends in position.
of bellcrank pivot bolt, push-pull tube attachment
bolt, and bolt attaching link to swashplate lever. c. Remove access door under cabin. Disconnect
link-rod between control stick horn and bellcrank
Note mounted on left side of box beam under cabin floor.
Set bellcrank so that center line through pivot and
If rigging fixture, T101235, is not avail- bolt hole in aft arm is 90degreesto side of box beam.
able use a bubble protractor across pivot Adjust and reinstall link-rod.
and push-pull tube attachment bolts to set
forward end of bellcrank six degrees, 55 d. Disconnect push-pull tube between bellcrank
minutes above horizontal. on cabin box beam and bellcrank below lateral power
cylinder. Disconnect push-pull tube between clevis
e. Set bellcrank aft of pilot's seat so that center
line through pivot point and bolt hole in long arm
makes an angle of six degrees, 35 minutes below
horizontal. Adjust and install push-pull tube between
this bellcrank and bellcrank to transmission. clevis bolt hole.
f. Set collective pitch control stick 56 1/2 de- e. Remove bolt and install valve centering pin,
grees above horizontal and tighten friction knob to T101233, with flats of pin parallel to cylinder center
hole position securely. Adjust and install push-pull line and tapered shoulders seated fully in elongated
tube between arm on collective pitch torque tube and hole to center valve body in neutral position on shaft.
bellcrank aft of pilot's seat. (See figure 7-27.)
g. Place a pencil mark on mast in line with top

of collective pitch sleeve. (See figure 7-25.)Measure CAUTION
23/64 inch above top of sleeve and place second mark
on mast. Remove clamps from swashplate scissors
levers, release friction lock and move collective pitch Do not move cylinder shaft or valve with-
control stick to high pitch position. Adjust stop-screw out either bolt or T101233 pin in place,
on collective pitch lever arm to align top of sleeve because of possible damage to parts by
with upper mark on mast. With control stick full accidentally pulling valve body off end of
down, adjust stop-screws on transmission cap to shaft. Keep bolt and pin clean and protect
allow 23/64 inch travel of sleeve below neutral machined surfaces. T101233 pin is neces-
position mark. Tighten lock-nuts and lockwire stop- sary, for accurate rigging, to eliminate
screws. movement between shaft and valve body.
7-56
MAINTENANCE
VIEWA-A
VIEW ,B-B
4 7 725-53
Figure 7-57. Rigging Diagrams - Lateral Cyclic Controls

7-57
MAINTENANCE
SECTION A-A
AS REQUIRED FOR 29
A SHIM AS REQUIRED
FOR .002" TO .004"
BACKLASH IN GEARS

7-58
MAINTENANCE
1. Lever - Throttle Control 24. Housing

2. Lock-Nut 25. Shims (2)
3. Spacer 26. Gear - Throttle Control
4. Bushing 27. Pinion Gear
5. Screw 28. Pins
6. Shaft - Throttle Control 29. Pin
7. Plug 30. Control Stick
8. Shim 31. Rod - Throttle Friction
9. Tube - Pitch Control 32. Grip
10. Bearing - Friction Lock 33. Nut - Throttle Friction
11. Shim 34. Sleeve
12. Washer (Complete) 35. Lock-Ring
13. Rod - Friction Control 36. Roll Pin
14. Spacer 37. Washer
15. Knob - Friction Control 38. Screw - Pinion Retaining
16. Nut 39. Plug Button
17. Crank Arm - Pitch Control 40. Washer (Leather)
18. Pins 41. Rod-End
19. Clamp Bolt 42. Pin
20. Bearing 43. Plug Button
21. Washer 44. Screw - Gear Retaining
22. Spacer 45. Switch Assembly
23. Pins
47631-41
Figure 7-58. Collective Pitch and Throttle Control Assembly (sheet 2 of 2)
f. Set bellcrank below power cylinder so that 7-138. RIGGING - TAIL ROTOR CONTROLS.
center line through pivot bolt and lower cylinder (Figure 7-33.)
trunnion is 10.75 degrees down aft (or measure
travel of cylinder shaft and set in half-travel posi- a. Cut lockwire and loosen two turnbuckles to
tion). Adjust and install push-pull tube between bell- provide slack in tail rotor cables. Remove lockwire,
crank below cylinder and aft arm of bellcrank on loosen set screw and unwind cable from pitch change
cabin box beam. drum on tail rotor gear box.
g. Disconnect push-pull tube located between b. Remove cabin box beam access plates and ac-
swashplate horn and aft arm of torque tube. Install cess door under cabin. Check that pedal adjustment
swashplate fixture, T101234 or set swashplate with pawls are in aft notch at each pedal. Clamp pedals
a bubble protractor to zero degree. Position lateral in neutral, using a suitable straight bar laid across
torque tube so that center line of bolt hole in forward forward side and secure withC-clampsonbothpedals.
arm is 4.34 inches above support spacer base. (See
figure 7-57.) Adjust and install push-pull tube to fit c. Remove cable locking bolt from jackshaft
between swashplate and aft arm of torque tube. pulley. Adjust push-pull tubes between jackshaft arms
and pedal coupling shaft lever arms to align jack-
h. Release piston rod and shorten push-pull tube shaft pulley in neutral (cable locking bolt hole on
by 1/2 turn (1/2 degree) of rod-end. Reinstall push- helicopter center line).
pull tube.
Note
i. Check security of installation and proper
safetying throughout lateral control system. Remove When pulley is in neutral, right arm lever
centering fixture or release friction from control on upper endof jackshaft is slightly forward
stick. Move control stick to extreme lateral posi- of left arm. Push-pull tubes are unequal
tions, checking for freedom of movement and checking in length. If adjustment causes one tube to
with bubble protractor on leveling plate for swash- be excessively lengthened and other tube
plate angles of 7 1/2 degrees with stick full left and excessively shortened, as shownby number
6 1/2 degrees with stick full right. (Seefigure 7-29.) of exposed threads, remove and reinstall
tubes in correct locations.
7-137. RIGGING - SYNCHRONIZED ELEVATOR.
(Figure 7-32.) (Refer to paragraph 7-8, use center- d. Clamp right-hand cable to structure so as to
ing fixture, T101232, in lieu of 47-300-001-1-T222.) locate forward end of cable terminal sleeve nine to
7-59
MAINTENANCE
eleven inches aft of center line of pulley near lower 7-139. COLLECTIVE PITCH AND THROTTLE CON-
tail boom attachment point. Draw cable snugfromthis TROL ASSEMBLY. (Refer to paragraph 7-14, and
point forward around right side of jackshaft pulley, add the following: A switch box, containing the starter
properly seated in all pulley grooves, and install and landing light switches, is mounted on top of the
cable locking bolt. (Cable passes behind bolt, with control stick.)
washer and nut on bolt below cable.) Remove clamp
used to position cable end. 7-140. REMOVING - COLLECTIVE PITCH AND
THROTTLE CONTROL ASSEMBLY. (Figure 7-58.)
e. Turn pitch change drum to right to limit of (Refer to paragraph 7-15.) Add step d. Disconnect
inward travel. Turn drum to left, 3/4 turn, and check switch box wiring at disconnect under pilot's seat.
alignment of drum. Slot to be forward with base of
slot at 90 degrees to center line of tail boom extension.
Realign drum, if necessary. (Refer toparagraph7-32.) 7-141. DISASSEMBLING- COLLECTIVE PITCH
AND THROTTLE CONTROL ASSEMBLY. (Refer to
paragraph 7-16.) Add the following to step a. Re-
f. Tighten turnbuckle on right cable sufficiently move screws and washers from switch box; remove
to allow later tension adjustment without exposing lock-ring. Cut lockwire, remove screws and washers
terminal threads. Holding pitch change drum in at lower end of switch assembly at housing assembly.
neutral, pull right cable tight and place in second
groove from inboard of underside of drum. (See
figure 7-34.) Keeping cable tight, wrap cable up and 7-142. REASSEMBLING - COLLECTIVE PITCH
around drum until 3 1/2 turns have been made and AND THROTTLE CONTROL ASSEMBLY. (Refer to
cable fills equal number of grooves on each side paragraph 7-17, steps a.,b., c. and d.) Add the follow-
of slot. Install and lockwire cable lock-screw. Do not ing steps:
pierce cable with lock-screw.
e. Install throttle lever through torque tube slot
g. Tighten turnbuckles evenly to obtain 12 to 15 into throttle shaft. Adjust to length of 1.82 inches
pounds cable tension. Lockwire turnbuckles. between center of bolt hole and surface of collective
tube, tighten lock-nut. Check operation by rotating
h. Install rigging jig, T101425, on tail boom ex- collective grip. (Refer to Throttle Rigging, Section V.)
tension housing tube, using hole nearest end of jig.
(Figure 7-35.) With graduated sector of tool extend- f. Insert throttle friction control rod through
ing toward tail rotor, slide jig downtube against top upper end of stick. Place friction washer on flanged
of yoke casting. Sight across top of jig, aligning upper sleeve, place sleeve on lower end of rod and install
edge parallel with tail rotor shaft. Tightenclampbolt. pin. Push sleeve up into end of stick. Screw knurled
nut on upper end of rod and secure with washer and
cotter pin. Snap plug button into top of stick.
i. Turn rotor to place one blade in jig. Hold
leading edge against step in jig, and check angular g. Install switchbox,lock-ring,coverandscrews.
position of blade on graduated sector at trailing edge Lockwire screws.
approximately 1 1/2 inches from tip. Adjust pitch
control link-rod to obtain neutral setting of plus two h. Apply corrosion preventive compound, to ex-
degrees. Adjust opposite blade in same manner, posed bare steel surfaces of cross tube.
j. Remove clamps, and bar used to hold pedals 7-143. SERVICING AND TESTING - HYDRAULIC
in neutral. Adjust stop-screws on jackshaft pulley BOOSTSYSTEM. (Refer to paragraph 7-40.) In step
to obtain blade settings of plus 12 1/2 to plus 13 1/2 d., change system pressure to 265 to 285 psi.
degrees when left pedal is full forward, and minus
10 1/2 to minus 11 1/2 degrees with right pedal full 7-144. LATERAL CYCLIC CONTROL SYSTEM. A
forward. Tighten lock-nuts and lockwire stop-screws. system of linkage transmits lateral movement of the
Check freedom of operation through full range. If cyclic control stick to horn on left side of swash-
cable piles up on pitch change drum, recheck align- plate, tilting the swashplate and controlling main rotor
ment of drum. Remove rigging fixture. attitude through rotating linkage on the mast. Lateral
system linkage consists of a link-rod from control
Note stick to bellcrank on cabin box beam, push-pull tubes,
a hydraulic power cylinder assembly, a torque tube
Check that quadrant hits stops instead of on upper left of center frame.
pitch change sleeve bottoming out at delta
hinge bolt. 7-145. INSTALLING - LATERAL CYCLIC
CONTROLS.
k. Check security and safetying of entire system. (Refer to paragraph 7-73.)
Install access door under cabin and access plates
on cabin box beam. Check track of tail rotor blades 7-146. TORQUE TUBE - LATERAL CYCLIC CON-
during ground run. (Refer to Section VI.) TROLS. (Figure 7-46.) A torque tube, mounted be-
7-60
MAINTENANCE
1. Reservoir 8. Pump
2. Filler Cap 9. Ground Test - Pressure
3. Vent Line 10. Line Filter
4. Vent Filter 11. Solenoid
5. Power Cylinder (Ref.) 12. Ground Test-Return
6. Check Valve 13. Relief Valve
7. Irreversible Valve
47690-34
Figure 7-59. Hydraulic Boost System

7-61
Section VII (Part 2) BELL HELCOPTER COMPANY Models 47G & 47G-2
MAINTENANCE
RETURN
VALVE
FIXED BOOSTCYLINDER
FORCE RETURNPRESSURE
WORKINGPRESSURE
PRESSURE
NOTES: A. PRESSURE LINE CHECKVALVE

B. PRESSURE RELIEF VALVE
C. NORMALOPERATIONRETURN
RELIEF VALVE
D. LOWPRESSURE CHECKVALVE
DETAIL 1. NORMALBOOSTONOPERATIONSHOWING CONTROLHEADVALVE

OPEN DUETO ROTORLOADOR PILOT LOADOPPOITE IN DIRECTION
BOOSTCYLINDERPISTON CONTROLHEAD
FORCE
FIXED BOOSTCYLINDER A
RECIRCULATING
PRESS.2
WORKING
PRESS.
NOTES: A. PRESSURE LINE CHECK VALVE

B. PRESSURERELIEF VALVE
C. BOOSTFAILEDOPERATION
CHECKVALVE
D. LOW PRESSURE CHECK VALVE
DETAIL 2. FAILED BOOST PRESSURE OPERATION SHOWINGCONTROL

HEAD VALVE OPEN DUE TO ROTOR LOAD OR PILOT 47690-26C
LOADOPPOSITEIN DIRECTION
Figure 7-60. Hydraulic Irreversible Valves

7-62
MAINTENANCE
ROTORCONTROL
S.
D« FILTER
VENT
RESERVOIR
POWERCYLINDER
CAP FOR
GROUND TEST RESTRICTOR
1014
RELIEF
VALVE CHECK VALVE
1-U-1025
VALVE IRREVERSIBLE
VALVE
PILOP FITTING
CAP FOR
GROUND TEST -- PRESS - 67B025PUMP
DRAIN
HOSE
DE-ENERGIZED ENERGIZED
FILTER
SCHEMATICOF 1-U-1025 VALVE
47690-48
Figure 7-61. Schematic of Hydraulic Boost System
tween supports on left side of transmission case and 7-148. ELEVATOR CONTROLS - FORWARD LINK-
on left forward upper structure of center frame, is AGE. (Figure 7-49.) A linkage system to transmit
connected in lateral cyclic control linkage between movement of fore and aft cylic control system to the
hydraulic power cylinder and swashplate. Torque elevator control.
tube lever arms and supports are of cast construction.
7-147. INSTALLING -LATERAL CYCLIC TORQUE 7-149. REPAIR OR REPLACEMENT - FORE -
TUBE AND SUPPORTS. (Refer to paragraph 7-81, AFT CYCLIC CONTROLS.
steps a., b., c. and d.) Add the following steps:
e. Connect push-pull tube from swashplate to aft a. Replace any damaged or unserviceable parts.
lever arm, with grooved spacer and large washer Replace bearings for excessive wear or roughness.
on bolt forward of arm.
f. Check rigging of lateral cyclic control system. b. Replace leaking or malfunctioning power cyl-
(Refer to paragraph 7-136.) inder. (Refer to paragraph 7-143.)
7-63/7-64
Models 47D-1, 47G & 47G-2 BELL HELICOPTER COMPANY Section VIII
Section VIII
Instruments
8-1. INSTRUMENTS.(Figure 8-1.) Note
8-2. DESCRIPTION. All engine andflightinstruments Instruments must be tested and repaired
(except the compass) are mounted in a panel, se- by an authorized repairstation; therefore,
cured to the pedestal, in the forward center of the disassembly of any unit is not recom-
cabin. The panel is hinged at the lower end and se- mended.
cured to the pedestal by Dzus fasteners. This ar-
rangement provides ready access to instruments and
connections for inspection or replacement. The com- Indication Probable
pass is mounted in a bracket attached to the left-hand of Trouble Cause Remedy
door frame. of Trouble
______Cause ________Remedy
Gage registers Poor connec- Clean and tighten
8-3. TROUBLE SHOOTING.For instruments which "Full" or con- tions or trans- connection
have electrical connections, refer to Section XI for sistently high mitter ground
circuit diagrams. reading
0 0 0 0 0 0
MODEL 47D1 MODEL 47G MODEL 47G-2

1. Compass Correction Card 10. Engine Gage Unit
2. Compass Support Bracket 11. Fuel Level Gage
3. Compass 12. Ammeter
4. Carburetor Air Temperature Gage 13. Cylinder Head Temperature Gage
5. Battery Switch 14. Altimeter
6. Generator Switch 15. Airspeed Indicator
7. Dual Tachometer 16. Ignition Switch
8. Manifold Pressure Purge Valve 17. Starter Switch
9. Manifold Pressure Gage
Figure 8-1. Instrument Panels - Models 47D-1, 47G & 47G-2

8-1
Section VIII BELL HELICOPTER COMPANY Models 47D-1, 47G & 47G-2

Gage registers Grounded lead Replace or repair No reading on Break in leads Repair or replace
"Empty" at all wires. Defec- wire. Replace in- temperature leads
times tive indicator. dicator. Replace gage with bat-
Defective transmitter tery switch Defective Replace switch
transmitter "On" either switch
constant or
Erratic and Corrosion on Clean contacting intermittant Defective Replace indica-
inconsistent movable con- surfaces or re- indicator tor
readings tact arm or place transmitter
resistance Low reading Kinked tubing Clean or replace
coil on oil or fuel or obstruction tubing
pressure in- in line
Defective in- Replace indicator. dicator
dicator. Loose Tighten connec-
connection, tions or replace Inaccurate or Defective in- Replace instru-
partially lead sticking fuel strument ment
broken lead or oil pressure
reading
Gage reading Resistance Adjust trans-
not at "Empty" out of adjust- mitter Sluggish oil Sludge or heavy Bleed line. (Refer
with empty ment pressure oil in pressure to paragraph
tank reading line 8-14)
Gage reading Resistance Adjust trans- Fluctuating Air in pres- Bleed line. (Refer
not at "Full" out of adjust- mitter oil pressure sure line to paragraph
with full tank ment 8-14)
ENGINE GAGE UNIT MANIFOLD PRESSURE GAGE
Indication Probable
Indication Probable of Trouble Cause Remedy
Excessive error Instrument not Adjust instru-
Oil tempera- Open or short Replace indicator at existing properly ad- ment. Refer to
ture reading circuit in in- barometric justed paragraph 8-15
off scale at dicator pressure
low tempera- Defective in- Replace instru-
ure end or Short circuit Repair or replace strument ment
low reading in leads of leads
either con- resistance Excessive Leak in line Tighten or repair
stant or inter- bulb error when line
mittent engine is
Ground in lead Make continuity running
from resis- check and re- DUAL TACHOMETER
tance bulb to place lead
indicator Indication Probable
Short circuit Replace bulb
in bulb Excessive scale Weak magnets Replace tachom-
error in tachometer eter generator
Oil temper- Break in leads Replace or repair generator
ature reading to resistance leads
off scale at bulb Pointer moves Leads reversed Change leads at
high temper- backward in- at generator generator plug
ature end or Open circuit Replace bulb dicates only plug
high reading, in resistance one-half
either con- bulb actual speed Leads connec- Refer to wiring
stant or inter- ted to wrong diagram andin-
mittant Open or short Replace indicator terminal of stall wires in in-
circuit in in- indicator dicator plug cor-
dicator rectly
8-2
MAINTENANCE

No reading on Break of short Repair or replace Open circuit Replace bulb

indicator either circuit in leads leads in resistance
constant or bulb
intermittent Poor connec- Clean or tighten
tion at indi- connections Open or short Replace indicator
cator or gen- circuit in in-
erator plugs dicator
Break in unit Replace unit af- COMPASS
circuit fected
Indication Probable
Low reading Poor connec- Clean and tighten of Trouble Cause Remedy
on indicator, tions at indi- terminals at plugs
either con- cator or gen- Erratic indi- Insufficient Replace instru-
stant or inter- erator ter- cation liquid in bowl ment
mittent minals
Leakage of Leaky gasket Replace instru-
High reading Indicator re- Replace indicator liquid ment
on indicator sistance out
either constant of adjustment Compensation Weak magnet Replace instru-
or intermittent does not have in compensa- ment
sufficient tor
CARBURETOR AIR TEMPERATURE GAGE effect
Indication Probable Sluggish op- Dirty jewels Replace instru-
of Trouble Cause Remedy eration or pivots ment
No reading Break in leads Repair or replace AIRSPEEDINDICATOR

with battery leads
switch "ON", Indication Probable
either con- Open or short Replace indicator of Trouble Cause Remedy
stant or inter- circuit in in-
mittent dicator Pointer fails Pressure lines Make proper
to respond not connected connection
Reading off Short circuit Repair or replace properly
scale at low in leads to leads
temperature resistance Line clogged Disconnect from
end, or low bulb with foreign instrument and
reading, either matter or blow line clean
constant or Ground in lead Make continuity moisture
intermittent from resis- check and re-
tance bulb to place lead Pointer indi- Leak in line Repair or replace
indicator cates incor- line
rectly
Short circuit Replace bulb Defective or Replace instru-
in bulb leaky instrument
ment
Open or short Replace indicator
circuit in in- Vent obstructed Drain moisture or
dicator or baffle bent clean obstruction
from static line.
Reading off Break in leads Replace or repair Straighten baffle
scale at high or resistance leads
temperature bulb Pointer Instrument Tighten instru-
end, or high vibrates loose on ment mounting
reading, Open circuit Replace bulb panel screws
either con- in resistance
stant or inter- bulb Pointer Leak in line Repair or replace
mittent oscillates line
8-3
MAINTENANCE
ALTIMETER opening into instrument. Remove mounting screws

from panel and instrument and remove instrument.
Indication Probable
of Trouble Cause Remedy 8-5. DISASSEMBLY - GENERAL. Disassembly of
instruments is not recommended. Instruments must
Pointer Vent plugged Clean vent be repaired and tested by an authorized repair
indicates station.
incorrectly Instrument Replace instru-
defective ment 8-6. CLEANING - GENERAL. Wipe dust and clean
instrument cover glass with a soft, clean, lint-free
CYLINDER HEAD TEMPERATURE INDICATOR cloth.
Indication Probable 8-7. INSPECTION - GENERAL. Inspect instruments
of Trouble Cause Remedy for loose or cracked cover glasses and for legibility
of range markings. Inspect instrument for security
Temperature Poor connec- Repair or replace of mounting.
reading low tions or faulty leads
throughout partial break 8-8. TESTING- GENERAL.Instruments must be
scale in leads tested by an authorized instrument repair station.
Defective in- Replace instru- 8-9. REPAIR OR REPLACEMENT - GENERAL. Re-
strument ment place instrument if cover glass is loose or broken.
Replace range markings, if needed.
No reading, Poor connec- Repair or replace
either con- tion, partial defective parts 8-10. REASSEMBLY - GENERAL. Instruments must
stant or in- or complete be reassembled and tested by an authorized repair
termittent break in leads station.
or thermocouple
element 8-11. INSTALLATION - GENERAL. Make certain
battery switch is "OFF". Position instrument to panel
and install mounting screws. Remove tape or cover
Indication Probable and connect wires or tubes to instrument. Close panel
Indication
of
of Trouble Probable Remedy and tighten Dzus fasteners.
Cause Remedy
8-12. REPLACING INSTRUMENT RANGE MARK-
No reading Malfunctioning Repair or replace INGS.
or erratic generator generator
reading a. When replacing instruments range markings (see
Voltage regu- Adjust or replace Flight Manual for ranges) use a suitable lacquer,
lator out of voltage regulator scotch tape, or prepared decals. Protect markings
adjustment by applying a light coat of clear adhesive varnish
or lacquer.
Pointer sticks Dirty or worn Replace ammeter b. All maximum and minimum (red) markings shall
mechanism be 1/4 inch long, excepttransmissionoiltemperature,
which shall be 3/8 inch long.
8-4. REMOVAL - INSTRUMENTS - GENERAL.
Note c. Mark maximum engine and transmission oil tem-
perature with white letters "E" and "T", 1/8 inch
The removal procedure for all instru- high. Paint a white index mark across the joint be-
ments is relatively the same, except it tween glass and case, at bottom center, of all in-
is necessary to disconnect wiring from struments having range markings.
one type of instrument and tubing from
another; therefore, a single removal and 8-13. RANGE MARKINGS - DUAL TACHOMETER.
installation procedure will suffice for all (Figure 8-2.)
instruments.
a. If tachometer is General Electric 8DJ19GAEor
a. Make certain battery switch is "OFF". Disengage 8DJ19GAF, observe that "ROTOR" dial graduations
fasteners around edge of panel and tilt panel aft. Pro- are not numbered and do not represent even units
tect instruments from frontal damage and wires and of rotor RPM, being extensions of marks on outer
tubes behind panel from becoming twistedor strained. (engine) dial.
b. Disconnect wires or tubes from back of instru- b. Apply range markings accurately on cover glass
ment ard tape or place cover over ends. Cover as shownin figure 8-2.
8-4
MAINTENANCE
8-14. BLEEDING OIL PRESSURE GAGE LINE.
a. Disconnect oil pressure gage line at engine inlet

and place end of line in a receptacle so that end will 222.2 RPM
be covered by accumulated fluid in receptacle. Station (REF.)
a man at the receptacle to observe when a bubble- YELLOWARC -YELLOW ARC
free flow has been established. 200 TO 230 294 TO 322
b. Operate Dzus fasteners and carefully tilt panel RED LE AT

aft. Protect instruments from frontal damage, and 2900 AND3100
wiring and tubes behind panel from being twisted or
strained. Disconnect oil pressure gage line at the GREEN ARC
instrument and connect a low pressure filter gun, 2900 TO 3100
filled with light lubricating oil, to gage line. Apply RPM
pressure slowly so line will be filled with light oil,
displacing fluid in line. Continue to force light oil - 333.3 RPM
into line until a steady flow is established at the (REF)
aft end. 35
GREEN ARC
c. When bleeding has been satisfactorily completed, 322 TO 360
remove filler gun and connect gage line to instru- ROTOR 40
ment, take precaution to hold fluid loss to a minimum ENGINE RED LINE AT
while connecting line. Carefully close instrument 294 AND 360
panel, taking care that wiring and tubes behind panel
stow without twisting or interference, secure panel. WHITE INDEXMARKBETWEEN
Connect aft end of gage line at engine inlet. GLASSANDCASE
8-15. ADJUSTING MANIFOLD PRESSUREGAGE. The LEACH GRADUATION
manifold pressure gage should indicate existing bar- DENOTES22.2 RPM
ometric pressure when the engine is not running
(or when the drain valve button, beside the instru- 47110-14
ment, is pushed in while the engine is running).
Check reading against calibrated instrument or altim-
eter. To adjust, remove instrument from panel and Figure 8-2. Range Markings Dual Tachometer
remove screw located on underside of cylindrical
case. Insert a small screw driver through the screw
hole and turn compensating screw to obtain correct cator through a line whichventsto the underside of the
reading. If the gage cannot be adjusted satisfactorily, nose section of the cabin. Pitot static systems of
replace gage. different models differ only in location of lines,
routing and methods of attachment of lines, and
8-16. ADJUSTING CYLINDER TEMPERATURE IN- details of construction of the pitot static tube.
DICATOR.
8-19. REMOVING - PITOT TUBE. Disconnecttubing
a. With one thermocouple lead disconnected, check from pitot tube at elbow forward of box beam. Re-
the instrument pointer setting by comparing with an move clamp at hole where pitot tube enters box
accurate thermometer placed near the indicator, beam. Remove screws attaching flange of pitot tube
Allow time for instrument and thermometer to ac- to cabin forward fairing. Pull pitot tube forward to
quire the temperature of the surrounding air. Adjust remove from helicopter.
pointer to correct temperature reading by means
of the zero adjusting screw on front of the cover 8-20. INSTALLATION - PITOT TUBE. Checkcondi-
glass. tion of neoprene gasket on flange of tube. Insert
closed end of tube through holes in forward cabin
b. Connect thermocouple lead to indicator. Check fairing and forward side of box beam, with 90 degree
that all connections are clean and tight. Handle leads elbow fitting up and pointed aft. Connect and tighten
carefully, as repeated bending or flexing will cause tubing line to elbowfitting. Push pitot tube assembly
leads to break. aft until flange is in contact with cabin fairing, align
holes in flange and fairing and install mounting
8-17. PITOT STATIC SYSTEM. (Figures 8-3 and screws. Check that tube does not foul against sides
8-4.) of hole in box beam, install mounting clamp around
tube and secure to box beam. Pressure test system
8-18. DESCRIPTION.The pitot static system con- for leaks.
sists of a pitot tube, static pressure tube, and air-
speed indicator. Pitot pressure is conductedthrough 8-21. DRAININGPITOT TUBE. A drain plug is in-
tubing from the pitot tube to the airspeed indicator. corporated in the pitot tube to facilitate draining of
Static air pressure is supplied to the airspeed indi- water from line. Cut lockwire and remove drain
8-5
MAINTENANCE
plug, disconnect line at instrument and blow filtered

compressed air through line and tube to eliminate
moisture. Do not apply pressure to instrument.
Connect line to instrument. Install and lockwire drain
plug.
8-22. PRESSURE TEST PITOT SYSTEM.
CATION
Do not apply suction to pitot lines.
a. With the system completely installed, apply care-
k fully regulated air pressure to the pitot intake. When

airspeed indicator shows a reading of between 50 and
100 MPH, close off pressure line to hold pressure
A good method is constant.
as follows: Use a piece
of vinylite tubing (or similar flexible tubing) which
will fit tightly over end of pitot tube. With a man
observing the airspeed indicator, fold free end of
tubing over and roll tubing slowly to create pressure.
When observer signals that the desired reading has
been reached, stop rolling and hold rolled end tightly
1. Flexible Pitot Line 5. Pitot Line and steadily for one minute, thus holding pressure
2. Flexible Static Line 6. Static Line constant.
3. Airspeed Indicator 7. Drain Line
4. Altimeter 8. Pitot Tube b. Observer should tap lightly on panel near the
indicator to overcome any friction which might
47714-3 affect the pointer, watchingfor a drop in the reading
which would indicate leakage. If reading drops more
than 5 MPH in one minute, check line connections,
Figure 8-3. Pitot System - Model 47D-1 correct leakage, and repeat test.
1.Pitot
Flexible
Line
1. Flexible Pitot Line
2. Flexible Static Line
3. Airspeed Indicator
4. Altimeter
5. Pitot Line
6. Static Line
7. Drain Plug
8. Pitot Tube
47714-2
Figure 8-4. Pitot System - Models 47G & 47G-2

8-6
Models 47D-1, 47G & 47G-2 BELL HELICOPTER COMPANY Section IX
MAINTENANCE
Section IX
Electrical System
9-1. ELECTRICAL SYSTEM. 9-3. TROUBLE SHOOTING.
9-2. DESCRIPTION. The electrical system is a Note

single-conductor type, using the helicopter structure
as a ground return line. A storage battery and enginejustments or repairs not covered
driven generator supplies the system with electrical manual consult the handbook
energy at a constant regulated voltage, published by the manufacturer involved.
A 24-volt, 25 ampere system is standard equipment
on Model 47D1 with a 50 ampere generator kit avail- Indication Probable
able for installation as a kit. of Trouble
A 24-volt, 50 ampere system is standard equipment Battery
Battery will Battery
Battery dead
dead Replace
Replace battery
battery
on Model 47G. A 24-volt, 50 ampere system is hold
not
optional on Model 47G and standard equipment on charge Voltage regu- Adjust voltage
Model 47G-2. All wiring is adequately shielded and lator incor- regulator
regulator
wires are marked with identification letters and rectly set
numbers. Demand too Reduce use of
great starter. Use ex-
WIRING IDENTIFICATION CODE ternal power
wheneverpossible
CIRCUIT
FUNCTION Impurities in Replace battery
LETTER DESCRIPTION electrolyte
D Instrument Circuits (Other than Short or Repair wiring

Flight Instruments) grounded
wire
E Engine Instrument Circuit
Broken cell Replace battery
J Ignition Circuit partitions
K Engine Control Circuit Short battery Level of Refill and re-
life electrolyte charge battery
L Lighting Circuit below top of
plates
P Power - Gen. and Battery Circuit
Sulphation due Replace battery
R Radio Circuit to disuse
Identification of each cable is accomplished by a Impurities in Replace battery

combination of letters and numbers. electrolyte
E 17 B 20 N Battery leaks Cracked case Replace battery
Ground Letter Frozen battery Replace battery

Wire Size Compound Charging or Reduce charging
melts on top discharging rate or heavy load
Cable Segment of battery too fast
Cable Number Excessive Level of Adjust level of

spillage of electrolyte electrolyte
Circuit Function electrolyte too high
9-1
MAINTENANCE

Battery freezes Specific gravity Replace battery. Ammeter does Voltage regu- Remove regulator,
of electrolyte Maintain specific not register lator improp- clean grounding
too low gravity of elec- charge (cont) erly grounded surfaces and re-
trolyte at 1280 install regulator
when operating in Malfunctioning Replace unit
freezing tempera- voltage
ture regulator
Battery con- Charging rate Reduce charging Ammeter Adjustment set Adjust voltage
sumes ex- too high rate registers full too high regulator
cessive charge
amount. constantly Ground in field Repair or replace
of water circuit of gen- generator or volt-
erator or voltage regulator as
age regulator applicable
Actuation of Battery re- Replace relay
battery toggle lay points Ammeter Adjustment of Adjust voltage
switch fails to corroded or registers voltage regu- regulator and
turn on power burned constant lator or current current control
low charge control set too
Battery relay Replace switch low
switch contacts
corroded or Battery ter- Clean battery ter-
burned minals corroded minals
Erratic charg- Brushes worn Replace brushes Erratic Malfunctioning Replace unit
ing rate of charge on voltage
generator Brushes not Remove and clean ammeter regulator
free in brush brushes with
holder alcohol Starter will Weak or dis- Replace battery
not crank charged
Brushes spring Replace springs engine battery
tension too low External Increase external
power supply power output
No charge or Commutator Repair or replace too low
erratic charge dirty, pitted generator Defective Replace switch
of generator or uneven starter switch
Voltage regu- Adjust regulator Broken wire or Replace wire or
lator out of connection connection
adjustment
Defective relay Replace relay
Incorrect Make correct Brushes worn Replace brushes
connections connections
Brushes not Remove and clean
No indication Open or short Replace ammeter free in or replace
on ammeter circuit in holders brushes
ammeter
Brush spring Adjust or replace
Ammeter does Defective Replace switch tension too springs
not register master switch low
charge
Defective gen- Replace relay Insufficient Weak or dis- Recharge or re-
erator relay cranking speed charged place battery
battery
Poor connec- Repair connec-
tion or broken tion, repair or External Increase external
wire replace broken power supply power out
wire too low
9-2
MAINTENANCE
9-4. EQUIPMENT LIST. The major component of the

electrical system are listed in the equipment chart.
EQUIPMENT ITEM MANUFACTURER PART NO. BELL P/N 47D1 47G 47G2 REMARKS
Battery
12V 12 amp-hr Reading S12 X
24V 12 amp-hr AN3154-1A X X
Battery Relay
24V Leach 7220-24 47-759-036-1 X
24V Leach 7220-24 47-759-036-3 X X
Generator
28V 25 amp Pierson E2425 X
28V 50 amp Leach Neville M3 X
or
Eclipse
28V 50 amp Leece Neville 15600
Type 2591G12 X
Voltage Regulator
28V 25 amp Eclipse 1202-16-A 47-706-034-3 X
28V 50 amp Westinghouse A-24-A9170 X X
Type AVR-89
Reverse
Current Relay
50 amp Hartman A718 X X
Pedal Control Delco 1109662 X X

Push Button
Control Eclipse-Pioneer 756-22 X
External Power
Receptacle AN2552-3A X X X
External Power
Relay AN3370-2 X X X
Ignition Switch Decker 3267AX 47-711-018-4 X

AN3212-1 X
AN2212-1 X
Temperature Bulb
(Engine Transmis- AN5525-1 X X
sion Oil and Car-
buretor Air) MS28034-1 X
Fuel Level Stewart-Warner 439159 X 24V Systems

Transmitter Stewart-Warner 380-AV X
Stewart-Warner 439159 X
Tachometer
Generator
Rotor Kollsman 985G-02-0 X X
985F-02-0 X
Tachometer
Generator
Engine 985G-02 X X
AN5547-2 X
9-3
Section IX BELL HELICOPTER COMPANY Models 47D-1, 47G & 47G-2
MAINTENANCE
9-5. BATTERY. terminal box cover and tighten and lockwire thumb-
screws. Install vent tubes to vents on each side of
9-6. DESCRIPTION. The battery installation on Model battery and tighten hose clamps.
47D1 consists of two type S-12 batteries, enclosed
in a two-compartment box assembly, connected in
series to provide a capacity of 24 volts. On Model CAUTION
47G and 47G-2 one 24-volt shielded aircraft battery
is mounted on a support in the tail boom which
provides for moving the battery forward or aft for As shipped from manufacturer, vents are
weight and balance purposes. sealed airtight. Be sure that tip is cut off
the vent before installing tube.
9-7. REMOVING BATTERY - MODEL 47D1.
9-11. CHECKING SPECIFIC GRAVITY AND REFILL-
a. Disconnect battery leads at quick-disconnect plug. ING BATTERY. Remove battery cover and filler
Pull up to release clamp on each hold-down rod. Lift caps. With a hydrometer, check each cell for a
battery assembly from helicopter. specific gravity reading of 1.260 to 1.280, com-
pensating readings for temperature. Recharge or
b. Pull out latch pins and remove battery box covers. replace battery if reading is below 1.260. If level
Disconnect negative cable from battery and tape cable of acid solution is below tops of separators, fill
end. Disconnect positive cable and tape end. Dis- with distilled water to not more than 1/4 inch above
connect and remove bus bar which connects the two separators (1/2 inch above protector on top of sepa-
batteries. Lift batteries from box. rators on AN3154-1A battery, used on Models 47G
and 47G-2). Replace filler caps and install battery
9-8. REMOVING BATTERY - MODELS 47G AND cover when check is completed.
47G-2. Remove two thumb screws from terminal box
and remove terminal box cover. Remove wing-nut Note
and disconnect negative cable from battery terminal.
Cover cable end with tape. Disconnect and tape posi- accurate
tive cable. Loosen clamps and pull upper ends of specific gravity reading cannotbe obtained
vent tubes from vents on each side of battery. Loosen solution has beenthoroughly mixed
wing-nuts on hold-down rods. Disengage hold-down by charging or operation.
rods from slots in bar on battery cover. Lift battery
out of support.
9-12. TESTING BATTERY.
9-9. INSTALLING BATTERY - MODEL 47D1.
a. Check specific gravity with a hydrometer (see
a. Position batteries in box assembly with terminals paragraph 9-11) noting any variations among cells.
of both batteries inboard. Note that positive post of If readings are below 1.260, or if cell readings vary
one battery and negative post of the other battery is much more than 0.015, recharge the battery (see
in line with cut-outs in the inboard side of boxes. paragraph 9-13).
Install bus bar connector between these terminals,
with the two grommets on the connector in position b. If specific gravity readings continue to vary ex-
in the cut-outs. Secure with wing-nuts on terminals. cessively among the cells when charging is completed,
Connect positive cable to positive post and negative perform a high rate discharge test of cell voltages.
cable to negative post, secure with wing-nut. Be sure Follow carefully the manufacturer's instructions for
grommet shields the cable where it passes through the test equipment used. Observe that voltage° of each
box. Install box cover assembly, securing latches cell should be 1.7 volts or higher (at 70 - 80°F
with lock-pins. electrolyte temperature) and that cell voltages should
be fairly uniform value (see paragraph 9-11), and
b. Determine location accordingto loadingconfigura- recharge battery for continued service.
tion. (Refer to Flight Manual.)Lift battery onto support,
inserting drain adapters on bottom of box into mating 9-13. CHARGINGBATTERY.
parts on support. Install battery hold-down rods.
Push disconnect plug into receptacle and tighten a. Wash all dirt from battery and clean terminals.
securely. Do not allow dirt to get into cells. Bring liquid level
of cells to correct level. If battery is extremely cold,
9-10. INSTALLING BATTERY - MODELS 47G AND allow it to warm up before adding water, as the level
47G-2. Place battery on support with terminals for- will rise as it warms.
ward. Seat battery cover carefully, engage hold-down
rods in slots of bar on cover, and tighten wing nuts b. Use only direct current from a controlled charg-
snug. Lockwire wing nuts. Connect cables to battery ing source so that the rate to the battery will not be
terminal, connecting positive cable first. Install excessive.
9-4
MAINTENANCE
Note 9-16. REMOVING - BATTERY RELAY. Disconnect

cable from negative battery terminal and tape end
These cover
These procedures procedures
cover points of
general points
general of cable. Disconnect wires to relay. Remove mount-
battery charging practice. Follow manu- bolts and remove relay
facturer's instructions for charging equip- 9-17. INSTALLATION BATTERY RELAY. Place
ment used.
relay in position and install mounting bolts. Connect
c. Charge batteries at a rate of 1 ampere per posi- wires
wires to
to relay.
relay Remove tape and
Remove tape and connect
connect battery
battery
tive plate per cell. (Example: If a battery has 15 cable.
plates per cell, 7 plates will be positive so the charg-
ing rate for the battery would be 7 amperes.) Watch 9-18. TESTING - BATTERY RELAY. Test operation
temperatures carefully and reduce charging rate if by closing master or battery switch and observe for
temperature of electrolyte reaches 110°F (43°C). As indication on fuel level gage (or on ammeter if other
soon as battery approaches fully charged state, take switches are on). If test is unsatisfactory, remove
hydrometer readings hourly. Abattery is fully charged relay and check continuity of actuating coil circuit.
when all cells are gassing freely and gravity reading
fails to rise at three successive hourly readings. 9-19. GENERATOR.
9-20. DESCRIPTION.A direct current generator is
mounted on the transmission and driven by an ac-
cessory drive gear in the transmission. The gen-
When cells are gassing, the gravity read- erator circuit is controlled by a reverse current
ing may be falsely low, due to gas bubbles relay and voltage regulator. The generator output
in liquid. Allow bubbles to rise to top of is connected to the electrical system by placing the
liquid in hydrometer before reading scale.
Maketemperature
Make temperature correction,
correction, as
as warm
warm generator switch in the "ON"position.
electrolyte will read low.
9-21. REMOVAL - GENERATOR.
For 24-volt installations, the manufacturer recom-
mends a charging rate of 4 amperes at start and 2 a. Disconnect leads from generator terminals and
amperes at finish, and that the electrolyte tempera- tape end of leads or, if so equipped, disconnect cannon
ture does not exceed 120°F (49°C). plug from quick-disconnect.
d. If the specific gravities of all cells are not within

5 points of desired value after full charge, remove
some of the electrolyte with the hydrometer and add On Models 47G and 47G-2 the right fuel
On
tank Models
may be 47G
water to reduce gravity if too high, or add 1.400 sp. and 47G-2 the right fuel
removed to facilitate removal
gr. acid to raise the gravity if too low. Continue
charge, to mix electrolyte, and read gravity after of generator. (Refer to Section V.)
another hour. b. Remove nuts and washers from studs through
mounting flange, pull generator outboard until shaft
Note is free of drive assembly. Remove generator through
engine mount frame.
Do not adjust gravity of any cell which
does not gas freely on charge. Do not add 9-22. INSTALLATION - GENERATOR.
acid unless certain that cell will not attain
normal gravity by continued charging. a. Place gasket on mounting studs. Position genera-
Unless acid has been lost by leakage or tor on studs, engaging splines of shaft with drive as-
spilling, it should not be necessary to add sembly. Install washers and nuts.
acid during the life of the battery. Do not
attempt adjustment of specific gravity on b. Connect leads or cannonplug on generator. Install
charging equipment which does not pro- fuel tank, if removed.
vide a controlled charging rate.
9-23. JUNCTION BOX ASSEMBLY.
9-14. BATTERY RELAY.
9-24. DESCRIPTION. The junction box assembly is
9-15. DESCRIPTION. The battery relay, is an elec- mounted in the lower right side of the engine com-
trically operated switch between the battery and main partment. The unit consists of a voltage regulator
bus bar. It is controlled by a master or battery reverse current relay, ammeter shunt, and external
switch, mounted on the instrument panel, which opens power relay. A cover on top of the box is easily re-
and closes the circuit to the actuating coil of the moved for access to various electrical units mounted
relay. inside.
9-5
9-25. VOLTAGE REGULATOR be approximately in the center of the windings. switch
some d-c load (battery, lights) on and off while check-
9-26. DESCRIPTION. The voltage regular is a car- ing voltage adjustment. Observe ammeter on instru-
bon pile type and islocated inthe junction box. The ment panel for indication that generator is delivering
regulator adjusts the charging rate of the generator current.
by increasing or decreasing resistance in the shunt
of the field coil winding.
S-21. REMOVAL - VOLTAGE REGULATOR. If ammeter reads zero, refer to trouble

shooting chart. Do not increase regulator
a. cut lockwire and remove cover from junction box. output voltage before locating and correct-
Disconnect electrical leads from regulator and tape ing trouble.
ends.
c. Return throttle to idle. With battery and generator
b. Remove mounting hardware and lift regulator
switches "ON", and a load of approximately 19 am-
from box.
peres switched on, slowly advance throttle. observe
S-28. INSTALLATION - VOLTAGE REGULATOR. voltmeter for a reverse current cut-out closing volt-
age of 27 volts (plus or minus 0.2 volts). Continue to
advance throttle, noting that voltmeter needle rises
to maximum voltage setting. Return throttle to idle.
As throttle is advanced, the voltmeter

needle will rise gradually, then drop mo-
9-29. ADJUSTING VOLTAGE REGULATOR - mentarily 1/4 volt or more at the moment
ECLIPSE 1202-2 OR 1202-16-A. the cut-out points close, then continue to
rise as RPM is increased. The drop should
a. Remove cover from control unit and check that occur between 26.8 and 27.2, or at least
reverse current cut-out points are open. Connect
l
0.5 volt below the no-load (or minimum
a d-c test voltmeter (0 to 30 volt) terminals load) bus voltage. Accomplish following
marked "A" POS and "B". step d. if satisfactory readings are not
obtained.
b. Start and warm up engine. Turn battery switch
"OFF", generator switch “ON”. With collective pitch d. Break seal on ratchet wheel of cut-out (figure
control full down, open throttle until tachometer 9-1) and turn ratchet wheel clockwise to increase
indicates 3109 RPM. Allow time for regulator to closing voltage, or counterclockwise to decrease
‘warm up. Observe voltmeter for a reading of 28.5 closing voltage. When adjustment is satisfactory,
volts (plus or minus 0.7 volt). Adjust by turning turn off load snitches, leaving battery and generator
rheostat adjusting screw clockwise to increase volt- switches "ON”. Reduce engine speed slowly, ob-
age, or counterclockwise to decrease voltage. (see serving ammeter for maximum discharge reading
figure 9-l.) The sliding arm on the rheostat should before cutout points open and ammeter returns to
zero. Replace unit if reverse current flow (discharge
from battery to generator) exceeds 5 amperes.
e. Remove and replace control panel ifsatisfactory

settings cannot be obtained by these adjustments.
Disconnect voltmeter and install and lockwire control
box cover when tests are completed.
9-30. ADJUSTING VOLTAGE REGULATOR - WEST-

INGHOUSE A-24-A-9179 . (Figure 9-2.)
a. Remove cover from junction box. Connected a d-c

test voltmeter to voltage regulator terminal marked
"B" and to a ground.
b. Start and warm up engine. With battery switch

and load switches "OFF" and generator switch "ON",
accelerate the engine to 3109 RPM. Check voltmeter
for a reading of 28 volts. Adjust rheostat (figure 9-2)
Figures 9-1. Adjusting Voltage Regulator - as required, by loosening lock-nut and turning adjust-
1202-2A or 1202-16-A ing screw clockwise to increase voltage or counter-
9.6
9-31. EXTERNAL POWER RECEPTACLE.
Q-32. DESCRIPTION. The external power receptacle

is mounted to the structure tubing on the right side
of the engine compartment. The receptacle is the
contact point for external power plug-in.
Q-33. REMOVAL - EXTERNAL POWER RECEP-

TACLE.
a. Remove nuts and washers from terminal poet

and remove wires. Tape ends of wires.
b. Remove nuts, bolts, clamps, and spacers that

secure receptacle to structure. Remove receptacle.
Q-34. INSTALLATION - EXTERNAL POWER

RECEPTACLE.
a. Position receptacle to structural tubing and se-

cure with clamps, spacers,. bolts and nuts.
b. Remove tape and connect wires to receptacle.

Make certain ground wire is grounded to diagonal
frame.
Q-35. TEMPERATURE BULBS.

Figure Q-2. Adjusting Voltage Regulator -
Westinghouse A-24-A-9170 Q-36. DESCRIPTION - GENERAL. Electrical resis-
tance type bulbs are installed at various points to
clockwise to decrease voltage. After adjustment indicate carburetor air, engine oil, and transmission
tighten lock-nut and recheckvoltmeter reading. Switch oil temperatures. Each bulb is connected to an elec-
on battery and some d-c load and recheck voltmeter trical resistance thermometer on the instrument
reading. Turn d-c load off, leaving generator switch panel, which indicates an increase of temperature
ON, and return throttle to idle. as the resistance in the bulb circuit is increased
by rise of temperatures in the bulb core. The re-
Note sistance elements of the bulbs are hermetrically
Observe ammeter, if no indication stop sealed in metal wells.
engine and check for trouble before pro-
ceeding. 9-37. CARBURETOR AIR TEMPERATURE BULB.
c. With battery and generator switches ON, and a 9-38. DESCRIPTION. The car-r air tempera-
load of approximately 10 amperes switched on, check ture bulb is located on the air control valve and con-
reverse current cut-out operation by advancing throttle nected to the indicator on the instrument panel.
slowly, observing for a closing voltage of approxi-
mately 21 volts, or at least 0.5 volts below the maxi- 9-39. REMOVAL - CARBURETOR AIR TEMPERA-
mum no-load voltage of the generator. TURE BULB. Disconnect electrical plug from bulb
and tape end of plug. Cut lockwire and unscrew bulb
Note from air control valve.
As speed is increased, the voltage needle 9-40. INSTALLATION - CARBURETOR AIR TEM-
will rise gradually, then drop momen- PERATURE BULB. Apply a light coat of anti-seize
tarily 1/4 volt or more at the moment compound, to threads of bulb and screw into air con-
when the cut-out contacts close, then control valve. Tighten bulb and lockwire. Remove tape
tinue to rise until maximum voltage setting and connect electrical plug.
is reached.
9-41. ENGINE OIL TEMPERATURE BULB.
d. Stop engine when test is complete. Replace re-
verse current cot-out if operation is not satisfactory. 9-42. DESCRIPTION. The engine oil temperature bulb
Do not attempt adjustment of this sealed cut-out is located in a well in the engine oil inlet line. The
(Hartman A718). Disconnect voltmeter and install bulb is connected to the engine gage unit on the in-
junction box cover. strument panel.
9-7
MAINTENANCE
9-43. REMOVAL - ENGINE OIL TEMPERATURE 9-57. REMOVAL - ENGINE TACHOMETER GEN-
BULB. Disconnect electrical plug and tape end. Cut ERATOR. Disconnect electrical plug and tape end.
lockwire and unscrew bulb from well. Remove nuts and pull generator from mounting studs.
Remove gasket.
9-44. INSTALLATION - ENGINE OIL TEMPERATURE
BULB. Apply a light coat of anti-seize compound to 9-58. INSTALLATION - ENGINE TACHOMETER
threads and screw bulb into well. Tighten bulb and GENERATOR. Place gasket on studs. Position gen-
lockwire. Remove tape and connect electrical plug. erator on mounting studs and secure with nuts. Re-
move tape from electrical connection and connect
9-45. TRANSMISSION OIL TEMPERATURE BULB. plug.
9-46. DESCRIPTION. The transmission oil tempera- 9-59. ROTOR TACHOMETER GENERATOR.
ture bulb is located on the right-hand side of the
transmission and connected to a gage on the instru- 9-60. DESCRIPTION. The rotor tachometer genera-
ment panel. tor is mounted on the left aft side of the transmission.
9-47. REMOVAL - TRANSMISSIONOIL TEMPERA-
TURE BULB. Disconnect electrical plug and tape end. 9-61. REMOVAL - ROTOR TACHOMETER GEN-
Cut lockwire and unscrew bulb from transmission. ERATOR. Disconnect electrical plug and tape end.
Remove nuts from mounting studs and remove gen-
9-48. INSTALLATION - TRANSMISSIONOIL TEM- erator and gasket from adapter.
PERATURE BULB. Coat threads of bulb with anti-
seize compound and screw bulb into transmission 9-62. INSTALLATION. Position gasket and genera-
and lockwire. Remove tape and connect electrical tor on adapter studs and secure with nuts. Remove
plug. tape from plug and connect plug to generator.
9-49. ENGINE CYLINDER THERMOCOUPLE.
9-63. IGNITION SYSTEM.
9-50. DESCRIPTION. A bayonet type thermocouple is
threaded into a cylinder of the helicopter engine 9-64. DESCRIPTION.The ignition system consists
(number 3 cylinder of Franklin engine and number 2 of two high tension aircraft magnetos, (mounted on
cylinder of Lycoming engine). The thermocouple is and driven by the engine) ignition harness, ignition
connected to a lead which in turn is connected to a switch, and necessary connections.
temperature indicator in the instrument panel.
9-65. IGNITION SWITCH.
9-51. REMOVAL - ENGINE CYLINDER THERMO-
COUPLE. Unzip cooling fan shroud. Press knurled 9-66. DESCRIPTION. The ignition switch is mounted
ring of thermocouple inward and turn counterclock- on the instrument panel, and controls the operation
wise. Remove thermocouple and disconnect lead. of the two magnetos. Four positions are provided on
the switch: "OFF", "L", "R", and "BOTH." The
9-52. INSTALLATION - ENGINE CYLINDER THER- switch provides a means of testing magnetos indi-
MOCOUPLE. Connect lead to thermocouple. Insert vidually and to ground magnetos to stop engine when
thermocouple into cylinder, press inward on knurled the switch is in "OFF" position.
ring and turn clockwise. Close cooling fan shroud.
9-67. REMOVAL - IGNITION SWITCH.
9-53. TACHOMETER GENERATORS.
a. Disconnect battery and tape terminal ends. Dis-
9-54. DESCRIPTION. Two tachometer generators are engage fasteners and open instrument panel. Protect
provided to indicate engine and rotor speeds on the instruments from being twisted or strained.
dual tachometer unit of instrument panel. Each tach-
ometer circuit is a self-contained electrical system b. Disconnect ignition harness and ground wire at
consisting of a three-phase alternating current gen- rear of switch. Remove attaching screws from switch
erator, electrical connections, and a three-phase and panel. Remove switch.
synchronous motor. The dual tachometer unit is
driven by the out-put of the generator. 9-68. INSTALLATION - IGNITIONSWITCH.
9-55. ENGINE TACHOMETER GENERATOR. a. Position switch to instrument panel and install
mounting screws. Connect ignition harness and ground
9-56. DESCRIPTION. The engine tachometer gen- wire to switch.
erator is mounted on the engine accessory case and
connected to the dual tachometer unit on the instru- b. Close instrument panel, noting that wires and
ment panel to indicate engine RPM. tubes stow without binding. Secure fasteners.
9-8
MAINTENANCE
9-69. FUEL LEVEL TRANSMITTER. 9-74. ELECTRICAL SYSTEM.

9-70. DESCRIPTION. A fuel level transmitter is (Model 47G-2 Serial No's. 2556
mounted in top of the fuel tank. (Both tanks on Model
47G and 47G-2.) This float operated, variable resis-
tance unit operates a fuel quantity gage on the instru-
ment panel. The circuit is energized when the battery
as a ground return line. A storage battery and engine
switch is in the "ON" position. On ModelModel 47G and
47G and driven generator supplies the system with electrical
47G-2 fuel level of either tank may be obtained by
operating the selector switch on the instrument panel.
ampere system is standard equipment on all Model
9-71. REMOVAL - FUEL LEVEL TRANSMITTER. 47G-2. All wiring is adequately shielded and wires
are marked with identification letters and numbers.
a. Place battery switch in "OFF" position. Discon- (Reference Wiring Identification Code of paragraph
nect battery terminals and tape ends. 9-2.)
b. Disconnect wire from terminal on transmitter. TROUBLESHOOTING.
Cut lockwire, remove attaching screws and lift
transmitter from tank. (Both tanks on 47G and 47G-2.)
Use care not to bend arm or damage float during 9-77. EQUIPMENT LIST. Themajorcomponentsof
the electrical system are listed in the equipment
9-72. INSTALLATION - FUEL LEVEL TRANSMIT- chart. (See figure 9-3.)
TER.
9-78. BATTERY.
a. Make certain battery is disconnected and battery
switch is in "OFF" position. Examine gasket and 9-79. DESCRIPTION. The battery installation on
replace if needed. Place gasket on tank and care- Model 47G-2 consists of one 24-volt shielded aircraft
fully insert transmitter into tank using care not to battery mounted on a support in the tail boom, which
bend arm or damage float. Align holes intransmitter, provides for moving the battery forward or aft for
gasket, and tank and install screws. Install trans- weight and balance purposes.
mitter in both tanks 47G and 47G-2. Adjust trans-
mitter, if necessary, refer to paragraph 9-73. 9-80. REMOVING BATTERY - MODEL 47G-2. Re-
move two thumb screws from terminal box and re-
b. Connect wiring to transmitter(s). Remove tape move terminal box cover. Remove wing-nut and dis-
from battery connectors and connect to battery. connect negative cable from battery terminal. Cover
Place battery switch in "ON" position and check cable end with tape. Disconnect and tape positive
operation of transmitter. cable. Loosen clamps and pull upper ends of vent
tubes from vents on each side of battery. Loosen
wing-nuts on hold-down rods. Disengage hold-down
9-73. ADJUSTMENT FUEL LEVEL TRANSMITTER. rods from slots in bar on battery cover. Lift battery
out of support.
Note
9-81. INSTALLING BATTERY - MODEL 47G-2.
Place battery on support with terminals forward.
Adjust transmitter for "EMPTY" reading Seat battery cover carefully, engage hold-down rods
in slots of bar on cover, and tighten wing-nuts snug.
mitters to set stops so gage will indicate Lockwire wing-nuts. Connect cables to battery ter-
"EMPTY" with a small amount of fuel in minal, connecting positive cable first. Install termi-
tanks. nal box cover and tighten and lockwire thumb-screws.
Install vent tubes to vents on each side of battery
a. Make certain battery switch is in "OFF" position. and tighten hose clamps.
Disconnect battery and tape ends of connections.
Drain fuel from tank(s).
CAUTION
b. Remove transmitter(s) from tank(s). (Refer to
paragraph 9-71.) Adjust stop on transmitter so that
pointer on gage will read slightly below "EMPTY". As shipped from manufacturer, vents are
sealed air tight. Be sure that tip is cut off
c. Install transmitter(s) in tank(s). (Refer to para- the vent before installing tube.
graph 7-72.) Connect battery cables, place battery
switch in "ON" position and check "EMPTY" reading
on gage. If position of pointer is satisfactory turn 9-82. CHECKING SPECIFIC GRAVITY AND
battery switch to "OFF" position, lockwire trans- REFILLINGBATTERY.
mitter attachment screws and refill fuel tank(s). (Refer to paragraph 9-11.)
9-9
Section IX BELL HELICOPTER COMPANY Models 47D-1, 47G & 47G-2
MAINTENANCE
EQUIPMENT BELL 1960 47G-2

ITEM MANUFACTURE PART NO. PART NO. 2556-2570 REMARKS
Battery 12V
12 Amp. hr AN3154-1A X
Battery Relay
24V MS24183-1 X
Generator 28V
50 Amp. Leece Neville G0012591-GA X
Voltage Regulator
28V - 50 Amp. General Electric CR2795-B105A1 X
Reverse Current
Relay 50 Amp. AN3025-100 X
Push Button
Control (Starter) Eclipse Pioneer 756-22 X
External Power
Receptacle AN2552-3A X
External Power MS24171D1(Alt) X

Relay AN3370-2 X
Ignition Switch AN3212-1 X
Temperature Bulb
Engine Trans. MS28034-1 X
Oil Carburator Air
Fuel Level
Transmitter Stewart-Warner P380-AV X
Tachometer
Generator (Rotor) Kollsman 985G-02 X
Tachometer
Generator (Engine) AN5547-2 X
Starting
Vibrator Bendix 10-87999-1 X
Figure 9-3. Equipment List
9-10
9-83. REMOVAL - GENERATOR. 9-85. FUEL LEVEL TRANSMITTER.
a. Disconnect leads from generatorterminalsand 9-86. DESCRIPTION. A fuel level transmitter is

tape end of leads or, if so equipped, disconnect cannon mounted in top of the fuel tank. This float operated,
plug from quick-disconnect. variable resistance unit operates a fuel quantity gage
on the instrument panel. The circuit is energized
Note when the battery switch is in the "ON" position. On
Model 47G-2 fuel level of either tank may be obtained
On Model 47G-2 the right fuel tank may be by operating the selector switch on the instrument
remove to facilitate removal of generator. panel.
(Refer to Section V.)
b. Remove nuts and washers from studs through 9-87. REMOVAL - FUEL LEVEL TRANSMITTER.
mounting flange, pull generator outboard until shaft
is free of drive assembly. Remove generator through a. Place battery switch in "OFF" position. Dis-
engine mount frame. connect battery terminals and tape ends.
9-84. ADJUSTING VOLTAGE REGULATOR. b. Disconnect wire from terminalontransmitter.

Cut lockwire, remove attaching screws and lifttrans-
a. Remove cover from junction box. Connect a mitter from tank. Use care nottobendarm or damage
DC test voltmeter to voltage regulator terminal float during removal.
marked "B" and to a ground.
9-88. INSTALLATION - FUEL LEVEL
b. Start and warm up engine. With battery switch TRANSMITTER.
and load switches "OFF" and generator switch "ON"
accelerate the engine to 3100 rpm. Check voltmeter a. Make certain battery is disconnected and
for reading of 28 volts. Adjust rheostat as required, battery switch is in "OFF" position. Examine gasket
turning adjusting knob clockwise to increase voltage and replace if needed. Place gasket on tank and care-
or counterclockwise to decrease voltage. After ad- fully insert transmitter into tank using care not to
justment recheck voltmeter reading. Switchonbattery bend arm or damage float. Align holes in trans-
and some DC load and recheck voltmeter reading. mitter, gasket, and tank and install screws. Install
Turn DC load off, leaving generator switch ON, and transmitter in both tanks. Adjust transmitter, if
return throttle to idle. necessary, refer to paragraph 9-89.
Note b. Connect wiring to transmitters. Remove tape
from battery connectors and connect to battery. Place
Observe ammeter, if no indication stop battery switch in "ON" position and check operation
engine and check for trouble before proof transmitter.
ceeding. 9-89. ADJUSTMENT FUEL LEVEL
TRANSMITTER.
c. With battery and generator switches ON, and
a load of approximately ten amperes switched on, Note
check reverse current cut-out operation by advancing
throttle slowly, observing for a closing voltage of Adjust transmitter for "EMPTY" reading
approximately 27 volts, or at least 0.5 volts below only. It is desired when adjusting trans-
the maximum no-load voltage of the generator. mitters to set stops so gage will indicate
"EMPTY" with a small amount of fuel in
tanks.
Note
a. Make certain battery switch is in "OFF"posi-
As speed is increased, the voltage needle tion. Disconnect battery and tape ends of connections.
will rise gradually, then drop momentarily Drain fuel from tanks.
1/4 volt or more at the moment when the
cut-out contacts close, then continue to b. Remove transmitters from tanks. (Refer to
rise until maximum voltage setting is paragraph 9-87.) Adjust stop on transmitter so that
reached, pointer on gage will read slightly below "EMPTY".
c. Install transmitters in tanks. (Refer to para-
d. Stop engine when test is complete. Replace graph 9-88.) Connect battery cables, place battery
reverse current cut-out if operation is not satis- switch in "ON" position and check "EMPTY" read-
factory. Do not attempt adjustment of this sealed ing on gage. If position of pointer is satisfactory
cut-out. Disconnect voltmeter and install junction turn battery switch to "OFF" position, lockwire
box cover. transmitter attachment screws and refill fuel tanks.
9-11/9-12
Section X
Body and Landing Gear
10-1. BODY AND LANDING GEAR. (Figures 10-l metal door frames and fairing. This large flexiglas
and 10-2.) area affords the pilot with unobstructed visibility.
Ventilators are installed in each door assembly.
10-2. DESCRIPTION. The body and landing gear in-
stallation consists of a cabin contruction of trans-
parent plastic, firewalls, center frame, tail boom, 10-5. REMOVAL - CABIN, MODEL 47D1.
and landing gear. This section of the handbook con-
tains information necessary for removal, installation,
alignment, and repairs necessary to maintain the 2. Support door to prevent dropping. Turn emergency
helicopter in flying condition. release handle forward to break lockwire and to re-
lease hinge pins. Remove doors. Remove cap swears
10-S. CABIN ASSEMBLY. from forward corner brackets and bolts which secure
10-4. DESCRIPTION. The cabin assembly is con- upper aft ends of door frame to fittings on cabin
structed of a transparent plastic bubble, except for fairing and firewall.
Figure 10-1. Body and Landing Gear - 47D1

lo-l
Section X BELL HELICOPTER COMPANY Models 47D-1, 47G & 47G-2
b. Place a man at each door opening to support b. Lift doors into position and turn release handle
cabin while bolts are being removed. Remove bolt8 to install hinge pins. Lockwire emergency release
which attach cabin to lower forward fairing. Remove handles with 0.020 brass lockwire.
bolts which secure upper ends of side fairings to fire-
wall, operate Dzus fasteners and spring upper ends of 10-7. REMOVAL - CABIN. MODELS 47G AND G-2.
fairings upward slightly. Operate Dzus fasteners which
secure upper aft fairing to top of firewall. Lift cabin
upward slightly to clear firewall, then forward, and a. Open door and support to prevent dropping. Grasp
emergency release handle, push forward to break
remove from helicopter.
lockwire and disengage hinge rod ends. Lift doors
from helicopter.
10-6. INSTALLATION - CABIN, MODEL 47D1.
b. Unfasten Dzus fasteners holding aft cabin fillet
a. Carefully lift cabin into position and engage Dzus to firewall. Remove all screws from Clamp nuts which
fasteners which secure upper aft fairing to top of secure cabin to structure. Remove screws holding
firewall. Install (do not tighten) bolts which secure antenna lead-in to bubble (if installed).
cabin to lower faking. Start cap screws into lower
forward corner brackets and install bolts which
secure upper aft ends of door frames to fittings on C. With a man on each Side, lift bubble from heli-
fairings and firewall. Tighten all bolts and screws copter. Place open end of bubble down on padded sur-
securely. Press upper ends of cabin fairings down- face. Place weights against edges of bubble to prevent
ward, install bolts and engage Dzus fasteners. spreading and possible breakage.
lo-2
Models 47D-1, 47G & 47G-2 BELL HELICOPTER COMPANY Section X
MAINTENANCE
10-8. INSTALLATION - CABIN, MODELS 47G AND g. Exterior plexiglas surfaces may be cleaned with
G-2. an approved plexiglas cleaner.
a. Lift bubble into position and install sheet metal 10-10. PLEXIGLAS REPAIRS. Plexiglas may be re-
screws and clamp-nuts. Fasten Dzus fasteners hold- paired by drilling a small hole at each end of the
ing aft fillet to firewall. Install antenna lead-in wires crack or repaired by patching. Overlay or plug type
(if removed). patches may be employed to repair holes or tears
in plexiglas. As patching results in serious impair-
b. Lift doors into position and turn emergency re- ment of vision it should not be used in an area where
lease handle to install hinge pins. Lockwire emer- vision is important except in an emergency. The
gency release handle with 0.020 brass lockwire. damaged sections should be replaced as soon as
possible.
10-9. CLEANING- CABIN. possible.
10-11. DRILLING TO LOCALIZE CRACKS. This
Note should be done at the first sign of a crack developing.
A hole 1/8 to 3/16 inch in diameter should be drilled
For removal of Spray Lac, from new plexi- at the extreme end of the crack, serving to localize
glass bubbles, we recommend using soap the crack and to prevent further splitting by dis-
and water, Naphtha TT-N-95 Type T (will tributing the strain over a large area. (Figure 10-3.)
not craze), Spray Lac remover SC-1055C Support area to be drilled by backing up with a wood
which can be purchased from Spray Lac block (shaped to contour for formed areas) to prevent
Corp., 1 Park Avenue, New York 16, N.Y. breakage while drilling.
Note
Note
Observe steps a. through d. when cleaning
the exterior and steps e. through g. for If a regular machine twist drill is to be
cleaning interior. used, it should be modified to prevent
pulling and grabbing. (Figure 10-4.)
a. Flush the exterior of cabin with plenty of water,
using the bare hand to feel and dislodge dirt, salt, 10-12. OVERLAY PITCH. (Figure 10-5.)
or mud.
b. Wash with mild soap and water. A soft clean
cloth, sponge or chamois may be used in washing, CAUTION
but only to carry soapy water to the surface. Go over
the surface with the bare hand so that any dirt can
be detected and removed before it scratches the Do not attempt to apply a flat patch to a
surface. formed surface nor attempt to form a heat-
ed patch over the area to be repaired.
c. Flush with plenty of water to remove soap, and Form patches for contoured surfaces by
dry with a clean, damp chamois. making a plaster of paris mold of the
d. Remove oil and grease by rubbing lightly with a area to be repaired.
clean cloth, wet with naptha or hexane.
a. Cut a piece of plexiglas large enough to cover
CAUTION the damaged area and bevel the edges. If surface is
.. : contoured, make a plaster of paris mold of area.
When mold has hardened, cover with a piece of clean
Do not use the following materials on grit free cotton outing fannel or billiard felt. Heat
plastic surface: Acetone,alcohol, benzene, patch over a hot plate or in an oven until it is soft
carbon tetrachloride, deicing fluid, fire and pliable (220°F to 300°F). Avoid extremely high
extinguisher fluid, gasoline, lacquer thin- temperatures or the surface will become too soft.
ner, or window cleaning sprays because Place patch in mold and press contour with a pad of
they will soften the plastic and cause cotton outing flannel and permit to cool.
crazing. Use only approved plexiglas
cleaners. b. Drill a small hole at end of each crack and trim
edges of damaged areas. Position formed patch over
e. Dust the interior lightly with a soft clean cloth. damaged area and mask surrounding area to within
Do not wipe surfaces with a dry cloth. 1/4 inch of joint with tough paper or cellophane tape,
which is impervious to cement action. This is to
f. Wipe interior surfaces with a soft damp cloth confine the softening action of cement to patched
or chamois. Keep the cloth or chamois free of grit area. Apply tape carefully, making sure no air is
by rinsing frequently in clean water. present under tape.
10-3
47360-4A
Figure 10-3. Stop Drilling Cracks
Drills, like all machine tools, should

135 have a scraping rather than a cutting
action on the plexiglas
60
(For Drill Press Use)

Ordinary metal down Grind to
Drill has a long to widen /this shape
Lip ground to zero (For HandDrilling) "lead" angle or/
Rake Angle 47360-3
Figure 10-4. Modified Twist Drill
BEVEL ALL PATCHES
TEAR HOLE OR CRACK
47360-1
Figure 10-5. Typical Overlay Patch

10-4
MAINTENANCE
Note
Suitable tape may be obtained from In-
dustrial Tape Corp., New Brunswick, N.J.
(Tape No. XB-97) or from Minnesota
Mining and Mfg. Co., St. Paul, Minn.
c. Mask entire area (except area to be cemented) to

protect it against cement action. Use PS 18 cement
manufactured by Rohm and Haas (which may be pur-
chased locally or from Bell Helicopter Company).
Handle PS 18 cement in accordance with instructions
furnished by the cement manufacturer. Apply patch
carefully and using just enough pressure to force out
all air bubbles. Hole patch in place, with a jig or
weights, until cement adheres, handling time of patched
area approximately four hours.
10-13. PLUG PATCH. (Figure 10-6.)
a. Trim hole to a perfect circle or oval, tapering

the edges slightly. Cut a patch out of plexiglas slightly
thicker than the section being repaired. The plug
should be slightly larger than the hole and given a
more oblique taper than the hole.
b. Heat edges of patch in an oven or over an alcohol

lamp until soft and pliable (220°F to 300°F), then
press patch into hole and allow to cool. Remove patch
after it has cooled and mask both surfaces to protect
it from cement action.
10-4A
MAINTENANCE
Note b. Mask areas around the surface to be cemented,

with cellophane fibre tape No. 670 or scotch tape.
The method described in preceding step c. Apply the mixed PS18 cement to either one or
b., is not recommended for formed sur- both surfaces to be joined. Clamp track or socket to
faces. Whenplug-patching formed surfaces, force out excess cement, but not too tight to craze
file patch to fit exactly and omit the heat- the glass. Remove tape from glass. Allow to dry for
ing operation. approximately 4 hours.
c. Apply PS18 cement plug patch and areatobe plug- 10-14. RE P LACING WEATHER STRIPPING ON
ged, press patch into hole and apply slight pressure. DOORS. Drill out rivets and pull stripping from
Handling time of patched area approximately four door. Before applying cement, wipe matching sur-
hours. faces (metal and rubber) with a clean cloth soaked
in carbon tetrachloride to remove any grease. Brush
d. File, sand, and buff patch to level of surrounding a generous coat of rubber cement on matching sur-
area. faces; allow to dry approximately 10 minutes. Apply
weather strip to door after cement is dry but still
10-13A. Replacement of sliding window track, andor tacky and after setting, drill matching holes, install
sockets, in cabin door windows. rivets and washers with rivet heads outboard.
a. Remove track or socket, by using any suitable tool, 10-15. FIREWALLS. (Figure 10-7.)
grind off area to remove rough spots and use 240-400
sandpaper to roughen area for application of PS 18 10-16. DESCRIPTION. The firewall is in three sec-
cement. Use caution not to damage window. tions. The lower section forms the seat section,
center section forms the seat back and the upper
Note section complete the installation. The assembly is
constructed of stainless steel and fastened to the
A PS18 cement 5 ounce kit, may be ordered structure with bolts and Dzus fasteners.
from Bell Helicopter Company, or obtained
from a local distributor, or ordered from 10-17. REMOVAL - SEAT SECTION.
Cadillac Plastics and Chemical Co., 15111
Second Ave., Detroit, Michigan, 48203. a. Remove handle from collective control friction
lock. Remove metal plate-bushing around friction
lock control shaft. Remove knob and nuts from fuel
shut-off control and slide control from firewall. Un-
fasten dust boots from around control sticks.
b. Remove screws and nuts from angles on each
Instructions for use of PS18 cement (con- side of the seat firewall. Remove screws holding
tained in each kit) for plexiglass, MUST seat firewall to floor assembly. Remove screws
be adhered to strickly, for installation of securing seat firewall to center section of firewall
track or socket. and lift seat firewall forward and up from helicopter.
PATCH SHOULD BE OF THICKER MATERIAL
SHARPER /
ANGLE FILE, SAND AND BUFF
THAN MATERIAL AFTER CEMENT HAS HARDENED
47360-2
Figure 10-6. Typical Plug Patch

10-5
1. Upper Firewall
2. Forward Firewall
3. Firewall and Seat Assembly
47323-2
Figure 10-7. Firewall Installation
10-18. INSTALLATION- SEAT SECTION. secure the center section firewall to the top section
firewall and lift the center section firewall from the
a. Lift firewall into helicopter and place into posi- helicopter.
tion. Install screws holding firewall to structure.
Install screws securing seat firewall to center section 10-20. INSTALLATION- CENTERSECTION.
firewall.
a. Lift center section firewall into position in hell-
b. Slide fuel shut-off control through firewall and copter and secure Dzus fasteners holding center
install retaining nut and control knob. Install metal section firewall to top section firewall.
plate-bushing over collective control friction lock-
shaft. Install collective control friction lock control b. Install bolts through firewall and throttle cam
knob. box bracket. Install screws and bolts through firewall
securing firewall to structure.
10-19. REMOVAL - CENTER SECTION.
c. Position left and right plate assemblies and in-
a. Remove seat section firewall. (Refer to paragraph stall screws through firewall and screws through
10-17.)Removescrewsthat secure left and right plate structure. Install safety belt attaching bolts. Install
assemblies to cabin structure. seat section of firewall. (Refer to paragraph 10-18.)
b. Remove screws that secure left and right plate 10-21. REMOVAL - TOP SECTION.
assemblies to firewall center section and remove
plate assemblies from helicopter. Remove safety a. Release Dzus fasteners holding top of firewall to
belt attaching bolts. cabin structure and bottom of firewall to center sec-
tion firewall. Remove screws holding radio jack box
c. Remove bolts that secure throttle cam box to to firewall (if installed). Disconnect wiring from jack
firewall. Remove screws and bolts that secure fire- box and remove jack box from helicopter. Remove
wall to tubing structure. Release Dzus fasteners that wiring clips from firewall.
10-6
MAINTENANCE
b. Remove screws from top right and left cabin

fairing and remove screws that secure fairing to
firewall and lift firewall from helicopter.
10-22. INSTALLATION - TOP SECTION.
a. Lift firewall into position and secure Dzusfasten-

ers holding firewall to the cabin structure and center
section firewall.
10-6A
MAINTENANCE
b. Position left and right fairings and install screws connect push-pull tubes from control sticks at jack-
through firewall and screws through cabin structure. shaft by removing cotter pins, bolts and nuts. Before
Connect radio jack box wiring and install jack box disconnecting and removing, be sure that rod end
on firewall (if removed). lock-nuts are tight. Disconnect starter cable (47D1
and 47G) from pivot arm.
10-23. CABIN DOORS.
c. Remove forward tail rotor control cable. (Refer
10-24. DESCRIPTION. The doors are constructed of to Section VI.) Do not make short bends in flexible
formed transparent plastic and have a welded tubular cable. Remove seat section of firewall. (Refer to
frame which insures rigidity. A metal fairing around paragraph 10-17.)
the outside edge has a sponge rubber seal which
provides complete dust-proof and moisture-proof d. Support floor assembly and remove bolts which
protection. Two plastic ventilators inserted in the secures the assembly to body structure. Carefully
top and bottom of each door can be rotated to control free floor assembly from structure, move forward
ventilation or pulled in flush to prevent entrance of slowly, guiding carburetor heat and mixture control
air. The doors are hinged at their forward side and cables and starter control cable out of structure and
are equipped with cam-type door latches. Conventional- guide battery cable through grommet in aft firewall.
type latches are installed on Model 47D1. (Model 47D1.)
10-25. REMOVAL - CABIN DOORS. Support door to 10-30. INSTALLATION - FLOOR ASSEMBLY.
prevent it falling. Turn emergency release handle
forward to break lockwire and to release hinge pins. a. Lift floor assembly and while placing into posi-
Lift doors from helicopter. tion, guide carburetor heat and mixture controls and
starter cable into place. Support floor assembly and
10-26. INSTALLATION- CABIN DOORS.Lift doors start bolts in outboard side to keep it in place. Insert
into position. Align hinges and turn emergency re- remaining bolts and start nuts onto threads. Tighten
lease handle to install hinge pins. Lockwire emer- after all bolts are in place. Install screws attaching
gency release handle with 0.020 brass lockwire. seat section of firewall to aft bulkhead of floor assem-
bly, and also those which attach cabin formers to aft
10-27. FLOOR ASSEMBLY. (Figure 10-8.) side of bulkhead.
10-28. DESCRIPTION. The floor assembly, consisting Note

of the cabin floor and beam assembly, is composed
of bulkheads, formers, stringers, and gussets. To A maximum of 0.050" gap is permissible at
this structure, the floor, beam assembly, and outer box beam and center frame attach points.
skin on the underside are riveted to form a strong Install 0.032" maximum shim of like ma-
single unit. The beam assembly forms a raised terial and pull up remainder of gap with AN
portion or tunnel longitudinally through the floor and standard bolts. Do not exceed 20-25 inch-
extending upward at the forward end to provide for pounds standard torque on AN bolts. Shim
mounting the instrument panel. Wiring and tubing dimension to be 0.75" x 1.0" minimum.
from the instrument panel pass through the tunnel
to the aft bulkhead, where wiring and tubing are pro- b. Install forward tail rotor control cable. (Refer
vided with quick disconnect plugs and couplings, to Section VI.) Connect cyclic control push-pulltubes
Doors in either side of the tunnel provide access to jackshaft with bolts, nuts, washers and cotter pins.
to wiring, tubing, and pedal connections to the tail Connect electrical cordage at disconnect plugs, re-
rotor controls. Access to control stick linkage is move tape from fittings and tubing. Connect instru-
gained through an excess cowling on the underside. ment and hydraulic lines at aft side of bulkhead. Se-
cure carburetor heat and mixture control cables in
10-29. REMOVING - FLOOR ASSEMBLY. guide clips; be sure handles are pushed down. Con-
nect cables to carburetor. Connect starter cable to
a. Remove cabin. (Refer to paragraphs 10-5 or 10-7.) pivot arm with clevis bolt and cotter pin.
On Model 47D1, disconnect batteries and remove
from helicopter. On Models 47G and G-2, disconnect c. Install cabin. (Refer to paragraphs 10-6 or 10-8.)
battery but do not remove since it is located in the Install and connect battery. Checktail rotor pedals and
tail boom. control sticks for freedom of operation. Checkrigging
of control systems. (Refer to Section VII.) Check all
b. Disconnect carburetor heat and mixture controls controls for proper response on run-up. Install
at the carburetor, loosen screws andremove support- access doors.
ing clamp from structure. Disconnect electrical
cordage at disconnect plugs and instruments and 10-31. LANDING GEAR. (Figure 10-9.)
hydraulic tubing at couplings at aft side of aft bulk-
head of floor assembly. Cover ends of tubing and 10-32. DESCRIPTION. A skid-type landing gear is
couplings with tape to prevent entry of dirt. Dis- installed to allow the helicopter to land on uneven
10-7
Section X BELL HELICOPTER COMPANY Models 47-1, 47G & 47G-2
MAINTENANCE
47313-1A
Figure 10-8. Floor Assembly
terrain. The landing gear assembly consists of for- landing gear assembly until clear of center frame
ward and aft cross tubes, skids and shoes. Brackets saddles and remove from helicopter.
to accept ground handling wheels (furnished as loose
equipment) are provided on each skid. 10-34. INSPECTION - LANDING GEAR ASSEMBLY.
10-33. REMOVAL- LANDINGGEARASSEMBLY. a. Inspect landing gear assembly for security of at-
tachment and for bent or damaged cross tubes.
a. Hoist or jack helicopter until skids are clear of
ground. On Model47D1 block tail rotor controlpedals b. Inspect skid shoes (if installed) for excessive wear.
in neutral position. Clamp a small wood or fiber
block at each side of tail rotor cable at pitch change 10-35. REPAIR OR REPLACEMENT - LANDING
drum to prevent cable unwinding when turnbuckles GEAR ASSEMBLY. Landing gear cross tubes may be
are loosened. Clamp forward section of cable at aft straightened in accordance with paragraphs 10-38
side of floor assembly in a similar manner. Cut and 10-39
lockwire and loosen turnbuckles on control cables.
Note 10-36. INSTALLATION - LANDING GEAR AS-
SEMBLY.
On Model 47G and G-2 it is not necessary
to remove control cables as they are a. Position cross tubes of landing gear assembly
routed over cross tubes. in structure saddles (collars of forward tube inboard
of saddles and collars of aft tube outboard of saddles)
b. Hold landing gear assembly to prevent falling. and hold in place. Place bearing straps in position,
Remove nuts, washers, and bolts, which secure slide shims into place, insert attachment bolts (wash-
cross tubes to center frame saddles. Carefully lower er under head) and install washers and nuts.
108
MAINTENANCE
Skid
1.
2. Leg
3. Cross Tube - Forward
4. Ground Handling Wheels
5. Cross Tube - Aft
6. Saddle Straps
47500-6
Figure 10-9. Landing Gear Assembly
b. Connect control cables at turnbuckles and tighten c. Subtract measurement "B" from measurement
sufficiently to remove slack. Do not lockwire. Re- "A" to obtain the amount of deflection "C" on each
move clamps and block from tail rotor cables. Lower side. Straighten cross tube if deflection of either
helicopter from jacks. Check rigging of tail rotor tube on either side exceeds 3 1/2 inches.
controls. (Refer to Section VII.)
Note
Note
If helicopter is hoisted or jacked to deter-
Perform this inspection daily, and after mine deflection, straighten cross tube if
every hard landing; helicopter to be rest- deflection exceeds followinglimits.
ing on reasonably smooth ground, and
ground handling wheels retracted. Front Tube - Limit 1 15/16 inches.
10-37. CHECKINGCROSS TUBE DEFLECTION. (Fig- Aft Tube - Limit 1 1/4 inches.
ure 10-10.)
10-38. STRAIGHTENINGCROSS TUBES WITH
a. Sight through each skid cross tube; if light is WEIGHT OF HELICOPTER. (Figure 10-11.)
visible at opposite end of tube, deflection is normal.
Accomplish steps b. and c., if light is not visible. a. Hoist or jack helicopter until it is clear of ground.
(Refer to Section I.) Remove bent cross tube from
b. Place a suitable straight edge along the skids helicopter and save all hardware for use on reas-
adjacent to the fore and aft skid legs to obtain meas- sembly. Zyglo or dye check inspect bent cross tube
urements "A" and "B". for cracks. (Refer to Section I.)
10-9
MAINTENANCE
C SIGHT LINE C
STRAIGHT EDGE
NORMAL STATIC DEFLECTION OF CROSS TUBES
WITH EMPTY HELICOPTER RESTING ON SMOOTH
GROUND:
FRONT CROSS TUBE - 7/16 INCH APPROX.
AFT CROSS TUBE - 1 1/8 INCH APPROX.
47500-1
Figure 10-10. Checking Cross Tube Deflection
b. Rotate both cross tubes 180 degrees from original Rigid guides near the center of tube prevents tube
installed position and secure to helicopter using pre- from turning. Load tube at two points to duplicate
viously removed hardware. Tighten saddle straps only loading encountered on helicopter. Straighten cross
enough to keep cross tubes from rotating. tubes.
Note Note
Both cross tubes must be rotated 180 de-

grees whether only one or both cross tubes be straightened as often
are bent. Cross tubes may be rotated as as necessary, providing tubes are inspec-
necessary providing cross
necessary providing are in-
tubes are
cross tubes in- ted by dye check or Zyglo "after" straight-
spected by dye check or Zyglo after straigh-
tening. Replace tubes if cracks kinks or distortion is evident.
distortion is evident.
c. If desired, both cross tubes may be rotated 180
c. Place skid legs in position against cross tubes degrees from their original position (as often as de-
3/8 inch outboard of their original installed position. sired), and installed on helicopter using the previ-
Lower helicopter until skid legs are seated on cross ously remove hardware. Tighten saddle straps only
tube. enough to prevent cross tubes from rotating.
Note d. If cross tubes were rotated 180 degrees, place
skid legs in position against cross tubes 3/8 inch out-
All legs must be positioned 3/8 inch outboard of their original position. Lower helicopter un-
board whether only one or both tubes are til skid leg saddles are seated on cross tubes. Drill
bent. cross tubes to match mounting holes in legs and se-
cure with the previously removed hardware. (See
d. Drill cross tubes to match mountingholes inlegs. figure 10-11.)
Secure legs to cross tubes using previously removed
hardware. With weight of helicopter on cross tubes, e. If cross tubes were straightened, inspected by
adjust and tighten saddle straps. dye check or Zyglo and found satisfactory reinstall
on helicopter, using the previously removed hardware.
10-39. STRAIGHTENING CROSS TUBE WITH
FIXTURE. (Figure 10-12.)
Note
a. Hoist or jack helicopter until it is clear of the
ground. (Refer to Section L) Remove cross tubes and If a new cross tube is installed the match-
save all attaching hardware for use on reassembly. ing tube may be rotated to its original
position.
b. Erect a straightening fixture similar tofigure 10-
12 which will support the end of tube and allow tube f. With weight of helicopter on cross tube adjust and
to slide freely in the direction of its spanwise axis. tighten saddle straps.
10-10
Models 47D-1, 47G & 47G-2 BELL HeLICOPTER COMPANY Section X
MAINTENANCE
10-40. SKIDS - LANDING GEAR ASSEMBLY.
10-41. DESCRIPTION.The skids are constructed from

aluminum alloy tubing. Abrasion resistant steel shoes
are attached to the underside of the skids at the for-
ward end and at the contact points under the landing
gear legs. Maple plugs close the ends of the tubes
to exclude moisture. Brackets bolted to the skids,
midway between the leg attachment points, provide
mounting points for ground handling wheels.
10-10A
MAINTENANCE
°
BENT TUBE ROTATED 180
WEIGHT FREE
BENT TUBE WITH WEIGHT

OF HELICOPTER APPLIED
STRAIGHTEN TUBE WHEN

MEASURED DEFLECTION OF
NORMAL OR STRAIGHT TUBE ANY TUBE EXCEEDS 3.50
WEIGHT FREE INCHES
NORMAL OR STRAIGHT TUBE

WITH WEIGHT OF
HELICOPTER APPLIED
3"
MEASURED DEFLECTION OF NORMAL TUBE 8
FRONT CROSS TUBE: 7/16 INCH
AFT CROSS TUBE: 1 1/8 INCH
ALL LEGS MUST BE REPOSITIONED 3/8 INCH

OUTBOARD WHETHER ONLY ONE OR BOTH
TUBES HAVE BEEN STRAIGHTENED
ROTATE TUBE 180° FROM
ORIGINAL INSTALLED POSITION
47500-25
Figure 10-11. Straightening Cross Tubes with Weight of Helicopter

Rev. 3 10-11
Section X BELL HELIOPTER COMPANY Models 47D-1, 47G & 47G-2
MAINTENANCE
RIGID GUIDES NEAR CENTER

TO PREVENT TUBE FROM TURNING
SUPPORT HERE SUPPORT HERE
84
PRESSURE APPLIED
HERE PRESSURE APPLIED
HERE
HYDRAULIC JACK
47500-24
Figure 10-12. Straightening Cross Tubes with Fixture
10-42. REMOVAL - SKIDS. Hoist or jack helicopter 10-46A. INSTALLATION - NEW SKID LANDING GEAR.
until skids clear the ground by approximately six
inches. Remove nuts, washers, and bolts which attach
steel shoes and skids to landing gear legs and lower a. Remove skid landing gear, as instructed in para-
skids from legs. graph 10-42. Removal skids.
10-43. INSTALLATION- SKIDS. Raise skids into b. Position cross tubes, leg assemblies, and skid
position, place a washer onto each attachment bolt tubes, as shown on figure 10-12A. Lower helicopter
(under head) and pass bolts through legs and skids. until skid leg saddles are seated on cross tubes and
Position steel shoes (one under each leg) with open skid tubes.
end of slotted holes aft and slide shoes aft into place
on bolts. Install washers and nuts and tighten at- c. Using holes in skid leg saddles as a guide, drill
tachment bolts securely. Lower helicopter from hoist holes in tubes. (See figure 10-12A.)
or jacks.
d. Install bolts, nuts, and washers previously re-
moved and assemble skid gear assembly.
10-44. LEGS - LANDING GEAR ASSEMBLY. The
legs are constructed of steel tubing with a piece of e. Attack skid gear assembly to centerframe, as in-
tubing welded to each end which fits over the cross structed in paragraph 10-43. Install skids.
tubes and skids and are secured with bolts and nuts.
10-47. GROUND HANDLING WHEELS. Ground ban-
10-45. REMOVING - LEGS. Removeskids. (Refer to dling wheels with an eccentric axle are provided
10-46. INSTALLING - LEGS. Position legs to cross 10-48. REMOVAL - GROUNDHANDLING WHEELS.
tubes so that lower end of leg (forwardor aft) extends with wheels retracted, remove lock-pin from out-
slightly forward when attachment bolt holes are board end of axle. Slide wheel and axle from bracket
aligned. Align bolt holes and install bolts, washers, on skid. Make certain thrust washer is in place on
and nuts. Install skids. (Refer to paragraph 10-37.) axle and reinstall lock-pin.
10-12 Rev. 3
MAINTENANCE
10-49. INSTALLATION - GROUND HANDLING

WHEELS. Remove lock-pin from axle and make
certain thrust washer is in place on axle. Coat axle
lightly with grease, Specification MIL-G-3287, and
pass axle through bracket on skid from inboard side.
Make certain handle portion of eccentric axle ex-
tends aft and install lock-pin.
10-50. CHECKING CENTER FRAME AND TAIL
BOOM ALIGNMENT.
Note
The following procedure will disclose dis-
tortions and bends in structural members
which cannot be detected by visual exam-
ination. Accomplish this procedure follow-
ing abnormal landings to avoid eventual,
unnecessary mechanical failure.
a. Procure or fabricate a trammel rod which can
be adjusted for length and has two trammel points
10-12A
STA STA
47-500-003-17 TUBE ASSYOF: AFT
47-500-045-16 SKIDR.H. OPP

47-500-045-15 SKIDL.H. SHN
0.249
0.2552 HOLESIN LINE 3 PLCS
30
18 0 R
47-500-004-1 LEG ASSYOF L.H. FWD 47-500-004-9 ASSYL.H. AFT
47-500-004-2 LEG ASSYOF: R.H. FWD 47-500-004-10 LEG ASSYR.H. AFT
DETAILB
9.0
47-500-007-3 SHOE 2 REQD 47-500-006-3 SHOE 4 REQD STA 47-500-045-7 SKID ASSY OF
STA +4.00 47-500-045-19 SKID TUBE
0.255 2 HOLES IN LINE THRU SKID "
TO MATCH LEG ASSY
J
47-500-027-5 PLUGASSYOF:
4 REQD INSTALL WITH EC 847
47-500-045-17 TUBE FWD CEMENTOR EQUIV
HELICOPTER 47-322-012-1 47-500-045-5 TUBE ASSYOF: FWD
STRAP4 REQD
0.2498 HOLESTO MATCH47-500-004 LEG ASSYOF : 4 PLCS
2.38 0.255
4 HOLES THRU AT RT ANGLES TO 2 (0.406) HOLES
IN BOTTOM OF TUBE FOR FLOAT INSTL
B.L. (0,406)HOLES
(0.406) 0.280 HOLESIN LINE (2 PLACES)TO
FLOAT INSTL
MATCH47-500-030 BRACKET
0.2492 HOLES IN LINE TO MATCH
47-500-030 BRACKET
45.00 2.50
0.312
. 2 HOLESIN LINE STA
0.319
DN L.H. SIDEONLY +4.00 DETAIL B
SECTION A A DETAIL B
MAINTENANCE
which are long enough to clear objects and permit center line of tail boom attachment bolt (upper).
accurate measurements of points indicated in figures (Item 6.) Not applicable on Models 47G or 47G-2.
10-13 and 10-14.
b. Measure and record distance between the follow-

c. Measure and record distance between the same
assembly.
ing fixed points on one side of center frame assem- Compare measurements. All measurements except
Compare measurements. All measurements except
Figure ~10-13.) that of number one bearing hanger, must be the same
within plus or minus 1/8 inch. Measurement of
1. Center line upper surface of forward landing
gear cross tube saddle to center line of engine mount
bolt hole at forward side of fitting. (Item 1.)
Note
2. Center line upper surface of aft landing gear
cross tube saddle to center line of engine mount If measurements of all items (1 through 5)
through bolt at aft side of fitting. (Item 2.) do not come within tolerance, examine
frame carefully for bent or distorted tub-
3. Center line of forward saddle to center line of ing. Operators in Territorial UnitedStates
aft saddle. (Item 3.) make repairs or replacement in accord-
ance with Civil Aeronautics Manual 18.
4. Center line of engine mount through bolt hole, Helicopters operated outside the United
at aft side of fitting to center line of lower tail boom States of America, will be repaired in ac-
attachment bolts. (Item 4.) cordance with instructions authorized by
licensing authority. (Do not relocate num-
5. Center line of engine mount through bolt hole, ber one bearing hanger at this time.)
at aft side of fitting, to center line of upper tail boom
attachment bolt at opposite side of frame. (Item 5.) d. Measure and record distance between following
points on one side of tail boom assembly. (Figure
6. Center line of number one bearing hanger to 10-14.)
NOTE
STRIPPED FRAME USED AND CENTER
LINES PROJECTED FOR CLARITY
47322-1
Figure 10-13. Alignment Check Points - Center Frame

10-13
MAINTENANCE
47267-1A
Figure 10-14. Alignment Check Points - Tail Boom
1. Center line of upper attachment bolt hole (to Note

forward frame) to center line of extension yoke at-
tachment bolt hole on opposite side of frame. (Item 1.) If measurements of items 1 and 3 do not
come within this tolerance, examine tail
boom carefully for bent or distorted tub-
2. Center line of lower attachment bolt hole (to ing. Operators in Territorial United States
forward frame) to center line of extension yoke make repair or replacement inaccordance
attachment bolt hole on the same side of frame. with Civil Aeronautics Manual 18. Heli-
(Item 2.) copters operated outside the United States
of America will be repaired in accordance
with instructions authorized by the licens-
3. Center line of upper attachment bolt hole at ing authority. Differences in measurement
underside of upper longeron to center line of lower of item 2, indicates twist and the necessity
attachment bolt hole. (Item 3.) for correction cannot be determined by
measurement. Accomplish step f., to de-
termine if correction is required.
e. Measure and record distance between the same f. Level helicopter longitudinal and laterally. (Re-
points on opposite side of tail boom assembly. Com- fer to Section I.) Place a bubble protractor on tail
pare measurements. Measurements of items 1 and 3 rotor shaft (outboard of tail rotor gear box) and
must be the same, within plus or minus 1/8 inch. check for its being horizontal within plus or minus
10-14
MAINTENANCE
one degree (up or down from horizontal). Straighten h. Pull cord taut (approximately level), center loop
tail boom if tolerance is exceeded. on head of engine mount through-bolt and tape in
place. (Figure 10-15.) Attach a "line level" to cord
and level cord exactly by moving aft end of cord
g. Pass end of length of heavy cord (chalk line) up or down as required. Check for measurement
around upper engine mount and tie loop. (Figure of 8.406 inches, plus or minus 1/2 inch from center
10-15.) (If T100909 tool is available, position tool line of yoke attachment bolt hole to cord. (See fig-
on engine mount bolt, see figure 10-15.) Do not tie ure 10-15.) A measurement of less than 7.906 inches
cord tight around fitting, it must be free to find its indicates excessive droop and must be corrected.
own horizontal center. Pull cord aft and tie to an Check for elongated attachment bolt holes and/or
object at aft end of tail boom (a stake driven into the bent or distorted structure tubing. Repair elongated
ground is satisfactory) which will allow cord to clear bolt holes, straighten or replace damaged structural
all objects and pass close enough to extension yoke tubing in accordance with instructions in Civil Aero-
attachment bolt holes to permit measurement from nautics Manual 18 or instructions issued by the
this point. (See figure 10-15.) licensing authority.
Detail A
47267-3A
Figure 10-15. Checking Alignment of Tail Boom

10-15
MAINTENANCE
Note holes. (Figure 10-16.) Tape ends of rod to structure

If all measurements (steps a. through h.) to keep rod from sliding.
are within tolerance, alignment of center j. Measure from machined surface of inboard lug
frame and tail boom is satisfactory. How- of clevis at aft end of tail boom and locate exact
ever, as natural distortions, due to use, center of rod. (See figure 10-16.) Mark center of rod
have not been taken into accord in the with a pencil. Place a dummy bearing, T100288, in
measurements given, it is possible that number one bearing hanger (with boss extending
tail rotor drive shaft bearing hangers are forward) and one in number seven hanger (with boss
not in alignment. Accomplish steps i. extending aft). Install and tighten bearing retainers.
through s. to check hanger alignment. Note
i. Check condition of Lord mounts. (Refer to Sec- If special tools required for this procedure
tion V.) Check engine alignment. Remove tail rotor are not suitable, fabricate them in ac-
drive shafts. (Refer to SectionVI.)Removebolts which cordance with details provided in figure
secure tail boom extension to tail boom and insert 10-17. Use the following material to make
a piece of 0.372 inch diameter rod through mounting tools.
ALIGNMENT CHECK
ON TYPICAL HANGER
(HIGH CONDITION)
TAPE VERTICAL
IN POSITION
HORIZONTAL CENTERING
47267-4B
Figure 10-16. Details of Tail Rotor Drive Shaft Bearing Alignment

10-16
MAINTENANCE
ALL DIA MUST BE CONCENTRIC

WITHIN .005 TOTAL INDICATOR
READING OF TAPERED HOLE.
SCRIBE INDICATOR LINES AT 90 ° .812
INTERVALS ON BOSS FACE, AS 4375
SHOWN.
.375 DIA
1.625 + .000 DIA
1.000 DIA 15 DEGREES
SHARP CORNER
.062R .031R (TYPICAL)
Dummy Bearing T100288-2 required, make from aluminum alloy.

IMPRINT, WITH FINE LINES, PERMANENTLY, RECTANGLE
AND ARROW AS SHOWN. RELATION OF RECTANGLE AND
ARROW MUST BE MAINTAINED. .125
I .250
+010
Plug T100286-1 required, make from hardwood.
.125 .0302R .375 DIA

3/16 DRILL 1.000 DIA
.605 DIA -
.813
NO. 72 DRILL ALL DIA MUST BE CONCENTRIC
WITHING .005 TOTAL INDICATOR
READING OF NO. 72 HOLE.
Centering Plug T100289-1 required, make from aluminum alloy.
CUT NOTCH APPROX. 3/32 INCH
DEEP.
DEEP. .094 (3/32)
SCRIBE ARROWS, ONE INCH

APART.
APART. Alignment Gage - make from standard 6" scale.
47644-20
Figure 10-17. Detail of Dummy Bearings

10-17
MAINTENANCE
No. inch. Replace hanger if more than 1/8 inch shim is

Part No. Title Material Req. required. Taper ends of shims to obtain maximum
seating and avoid pinching bearing excessively. Install
T100288 Dummy Bearing Aluminum Alloy 2 shim in bearing seat of hanger and repeat step 1.
T100286 Plug 1 n. Cut hanger from structure with a hacksaw using
T100287 Disc Transparent care not to damage structural tubing. Clean fillets of
Plastic weld from structure. Adjust, relocate or replace
hanger to proper position and weld to structure.
T100289 Centering Plug Aluminum Alloy 1
o. Remove plastic disc from forward end of cord
and pull cord from number one bearing. Thread
k. Insert centering plug, T100286, into spline of tail centering plug, T100289, onto cord with tapered end
drive coupling with arrow on plug pointing
rotor centering plug, T100289, onto cord with tapered end
rotor drive coupling with arrow on plug pointing forward, thread cord through bearing and press
vertically downward. (Figure 10-16.)Threada plastic centering plug into tapered bore of dummybearing.
disc, T100287, onto a nylon cord (fish line, approxi- Pull cord taut and tie to structure
mately 1/32 inch diameter) with scribe marks on disc
facing aft and thread cord through dummy bearings p Slide plastic disc against boss on aft side of
in number one and seven hangers. Thread a second number seven bearing and observe if disc centers
disc onto cord with scribe lines facing forward on boss or is within 1/32 inch (any direction) of
(toward boss of dummy bearing in number seven centering. Record direction and amount if misalignment
hanger, see figure 10-16). Pass cord around rod exceeds 1/32 inch.
through aft end of tail boom and tie a loop. Do not
tie cord tightly around rod; it must be free to seek q. Remove screws and retainer from number seven
its own horizontal center whencord is heldtaut. hanger, slide dummy bearing forward and position
in number six hanger. Slide disc forward and observe
1. Pull cord taut, (from forward side of number one if disc centers onboss within 1/16 inch (any direction).
hanger) hole tension on cord and make certain loop Record direction and remove if misalignment exceeds
in cord is on center mark on rod through aft end 1/16 inch.
of tail boom. Extend cord forward to centering plug
in spline of tail rotor drive, pull cord taut and hold r. Repeat step q. at each of the remaining four
in exact center of rectangle scribed on upper left hangers. Permissible misalignment (any direction)
side of plug. Slide plastic disc against boss of dummy with respect to center of each of these hangers is
plug in number one hanger and note if disc (disc is 1/8 inch. Record the hanger number, direction and
the same diameter as plug) is flush around entire amount if misalignment exceeds 1/8 inch.
circumference of boss. If disc is centered on boss,
or can be centered by moving end of cord to any
point within the rectangle on plug, number one bear- s. Shim, remove, adjust and/or relocate any hanger
ing hanger is properly located. If hanger is properly (two through seven) if misalignment exceeds specified
located disregard following note and steps m. and n. tolerance.
and proceed with step o.
Note
Note
If disc is not centered on boss, recheck Additional measurements of center frame

condition of engine mounts and engine and tail boom are shown in figures 10-19
alignment before proceeding. (Refer to and 10-20. These dimensions may be used
Section III.) When it has definitely been for complete check of structure.
established that the hanger is out of
alignment note direction and amount of
misalignment by observing scribe marks 10-51. REPAIRING TAIL BOOM AND CENTER
on face of plastic disc (side toward bear- FRAME ELONGATED ATTACHMENT
ing boss). These scribe marks are 1/32 HOLES. (Figure 10-21.)
inch apart and provide a ready means of
measurement. If disc extends below the a. Disconnect forward tail rotor drive shaft, from
boss (figure 10-18), indicating hanger is center tail rotor drive shaft. (Refer to Section VI.)
low, accomplish step m. If disc extends Disconnect pitch change cables. (Refer to SectionVII.)
below boss indicating hanger is high, or Disconnect battery cables and tape end. Disconnect
sidewise misalignment, accomplish stepn. synchronized elevator cables, if applicable. (Refer to
Section VI.) Remove forward tail rotor drive shaft
m. Fabricate a shim of correct thickness (determined bearing housing retainer. Support tail boom, remove
by amount disc extends above bearing boss)tofit con- bolts, attaching tail boom to center frame, move tail
tour of bearing seat in hanger. Do not exceed 1/8 boom aft to clear center frame.
10-18
MAINTENANCE
BEARING HANGER OUT OF ALIGNMENT - LOW BEARING HANGER OUT OF ALIGNMENT - HIGH
BEARING HANGER OUT OF ALIGNMENT - SIDEWIS BEARING HANGER IN ALIGNMENT
TYPICAL SHIM FOR LOW HANGER 47267-2A
Figure 10-18. 'Tail Boom Hanger Alignment

10-19
MAINTENANCE
W.L41.802 CENTER
OF UPPER ATT. HOLE
33.001
HORIZONTAL
DIST.
41.750
CENTER OF 27.00"
LINE REAM AFTER 17.500 128.OO DETAIL"D" 47267-1003

19.750 70.00
WL.
3.00"
STA. STA.
-70.00
7.500 DETAIL
"B"
STA.
-36,999 55.00"
12.375" VERTICAL 0.375" 0.001 DIA.

LIDNEGREA
TORQUE SHAFT 27 00 WL DETAIL"C"
DISTANCE
HORIZONTAL 0.3125
SEE DETAIL
W
L STA
-70.00 DETAIL "D" 47267-1003
Figure 10-20. Tail Boom Measurements

MAINTENANCE
PLAIN(FLUSH)STEEL BUSHING
(REF.) b. Reamtail boom and/or center frame attaching
BUSHINGMAX.O.D. 0.625
MAX.OD.0.625
BUSHING holes to clean up elongation, maximum hole size to
be 0.6248 inch, minimum edge distance (thickness of
metal around hole) after reaming 0.125 inch.
c. Fabricate flush type bushing of 4130 or 4140

steel, ID to be 5/16 (0.312 inch), OD to a maximum of
(0.625 inch), minimum wall thickness of bushing to be
0.060 inch.
0.125
d. Position and attach tail boom to center frame.
Connect pitch change cables and rig. (Refer to Sec-
tion VII.) Connect battery cables. (Refer to Section
& INSTALL
DRILL STEELBUSHING IX.) Connect tail rotor drive shaft. (Refer to Section
MAX. INTERFERENCEFIT 0.0004 VI.)
NOTE: (INTERFERENCE0.002- 0.0004)
HOLE IN BUSHING MAY BE OFF CENTER
MAINTAINING MIN. OF 0.060 WALL. 47322-10
Figure 10-21. Repair of Tail Boom and Center

Frame Bolt Hole
10-21/10-22
Models 47D-1, 47G & 47G-2 BELL HELICOPTER COMPANY Section XI
MAINTENANCE
Section XI
Wiring Data
11-1. WIRING DATA. 11-3. WIRING IDENTIFICATION CODE. Each elec-
trical wire in the helicopter is coded to identify its
circuit function, size, etc., as illustrated in table
11-2. INTRODUCTION. This section containsawiring below. Listed are the main electrical circuits in the
schematic diagram of the electrical circuits and an helicopter and to the left of each listing is the circuit
installation diagram showing the location of the elec- code letter which will appear on each wire of that cir-
trical equipment installed in the helicopter. cuit.
WIRING IDENTIFICATION CODE
Circuit Function
Letter Description
D Instrument Circuits (Other Than
Flight Instruments)
E Engine Instrument Circuit
J Ignition Circuit
K Engine Control Circuit
L Lighting Circuit
P Power - Gen. & BATT. Circuit

R Radio Circuit
Identification of each cable is accomplished by a com-

bination of letters and numbers as illustrated below.
E 1 7 B 2 0 N
GROUND LETTER
WIRE SIZE
CABLE SEGMENT
CABLE NUMBER
CIRCUIT FUNCTION
11-1
Section XI BELL HELICOPTER COMPANY Models 47D-1, 47G & 47G-2
MAINTENANCE
B g
E33 14
N23 J3
D
A2
A E26
-
B E11 L15
E28 E23
E30 E25
N24
20E1 19 P26 E27

L22 E28 - E29
E32 E30 E31
L21 P30 P29
A3 A7
A5
2
A2 A1
11-2
Figure 11-1. Wiring Diagram - 47D1 - 47G (Sheet 1 of 3)
11-2
BELL HELICOPTER COMPANY Section XI
Models 47D-1, 47G & 47G-2
MAINTENANCE
GENERATOR GENERATOR
A7
BAT CKT BAT.CKT.

BAT.CKT.
BKR. BKR.
G ARM. ARM.
BAR BAT. BAR BAT.

VOLTAGE VOLTAGE
REGULATOR GEN. REGULATOR
GEN.CKT.
C
K CKT RELAY
RELAY BKR RELAY
26
-- - ^E
MAINTENANCE
1. Instrument Panel (Viewed from rear) 22. Cyclic Control Trigger Switch
2. Circuit Breaker - Position Lights 23. Landing Light
3. Circuit Breaker - Landing Lights 24. Left Magneto
4. Circuit Breaker - Instrument Lights 25. Right-hand Navigation Light
5. Rehostat - Instrument Lights 26. Generator
6. Fuel Level Gage 27. Voltage Regulator
7. Clarastat 28. Starter
8. Engine Gage 29. Left-hand Navigation Light
9. Instrument Lights 30. Right Magneto
10. Dual Tachometer 31. Engine Tachometer Generator
11. Circuit Breaker - Battery 32. Engine Oil Temperature Bulb
12. Circuit Breaker - Generator 33. Rotor Tachometer Generator
13. Carburetor Air Temperature Gage 34. Transmission Oil Temperature Bulb
14. Ignition Switch 35. Fuel Level Transmitter
15. Hopper Selector Switches 36. Carburetor Oil Temperature Bulb
16. Ammeter 37. Battery
17. Engine Oil Temperature Switch 38. Battery Relay
18. Circuit Breaker - Instrument 39. Tail Light
19. Circuit Breaker - Left-hand Hopper Motor 40. External Power Relay
20. Circuit Breaker - Right-hand Hopper Motor 41. External Power Receptacle
21. Cockpit Light
Figure 11-1. Wiring Diagram - 47D1 - 47G (Sheet 3 of 3)
BATT. GEN. GENERATOR

SWITCH SWITCH
N3 P6
P12
P30 P31 P34
P22 P21 POWER

47752-10
Figure 11-2. Battery and Generator Circuit 47D-1 - 620 and Subs
11-4
MAINTENANCE
P3 P3A A P3B P34A A P34B

P17 P56 B -P56A P50A-B -P50-
P35 X P34 C-P34A C
D N50A-D N50-
P58 P57 E P57A
P37-X- P36 F P36A -P24
N51
B GENERATOR
AMMETER
P58 R.C.RELAY
P51
P35 P11 P6 P12

N38 P30 P20 P23 P6 47752-11
TO and
Figure 11-3. Battery EXT.Generator
POWER Circuit 4 7G
BATTERY BATTERY CIR. BKR.
N3 P6 BUS
BAFT A B C BATTERY
DISC. PLUG &
RECEPTACLE
0
P6 P12 P3 P20 P23
P19 P22- P21

P10 N6 P24
FORWARD EXTERNAL
A B C D BATTERY POWER
DISC. PLUG& RECEPTACLE
P85 RECEPTACLE NP2A
P84 P20 STARTER PK1A PP4A
P12 X2
NP3
47752-15
N5
PP5A
Figure 11-4. Starter Circuit 47D1

11-5
MAINTENANCE
BATT. SW. NP3
A1 A2
BATTERY
P23 I EXT.POWER RELAY P21
STARTER
P22
PP5A
+
TO EXT. POWER
Figure 11-5. Starter Circuit - 47G
LH.
IGNITION MAG
J4
R
STA. 53 STA.+ 35.75 STA.
Figure 11-6. Ignition Circuit - 47D1

11-6
MAINTENANCE
STA. + 2
L.H.
J2 B J44
IGNITION
J 3
N9 STA. +35.75
J- STA.+ 2
STA. + 53
Figure 11-7. Ignition Circuit - 47G
CARB. A -E32 -
0 -- ----- ~ ~--E33 -- E34
TO BATTERY
Figure 11-8. Temperature Bulb Circuit 47D-1

11-7
Section XI BELL HELICOPER COMPANY Models 47D-1, 47G & 47G-2
MAINTENANCE
A -E32
E33 N24
TEMP C N23 N23
GAGE
A -EIO
ENGINE
GAGE
E33 E34
E 14 X E 15
E12 X E13
ENGINE GAGE
SWITCH
E32
TO FUEL LEVEL GAGE
E 10
TO BATTERY
Figure 11-9. Temperature Bulb Circuit 47G
E21
E23
E23 ROTOR
TACH.
E25 B
E20 E21 I
E21
E2 2 X E 23
DUAL C E24 X E25
TACHOMETER
-E26 E27
E28X E29
C-E30 E31
STA.+ 53 E27 A
ENGINE
STA+ 35.75 E31
STA.O
Figure 11-10. Dual Tachometer Circuit - 47D-1 and 47G

11-8
Models 47D-1, 47G & 47G-2 BELL HELICOTER COMPANY Section XI
MAINTENANCE
P3
TO FORWARD BATTERY BUS(REF) STA.--24
RECEPTACLE (REF) BUS(RE FUEL LEVEL
FUEL LEVEL GAGE 100 OHM TRANSMITTER
INSTRUMENT CIR.BKR.
EI - TO ENGINE GAGE(REF)
E7
E32- TO CARB.AIR TEMP. GAGE.(REF) E4
Figure 11-11. Fuel Level Transmitter Circuit 47D1
RIGHT TANK
E4
FUEL LEVEL GAGE
TANK RIGHT
FUEL LEVEL
EIA TRANSMITTERS
I G N.
LEFT
E35 E36
LEFT TANK
TO R.C. RELAY (REF.)
E1O TO ENGINE GAGE (REF)

E32--- TO CARB. AIR TEMP GAGE
Figure 11-12. Fuel Level Transmitter Circuit - 47G

11-9
MAINTENANCE
INSTRUMENT LIGHTS (
TAIL LT.
L13 COCKPIT (W
LIGHT
L17
NAV. LTS.
L13 L24 L25
LANDING LIGHT
L9 LB
L21
WIRES TAPED AND STOWED
Figure 11-13. Light Circuit - 47D-1

11-10
MAINTENANCE
L13
L17 L4 USED WITH

WHEEL GEAR
L15 L16 L27 --- X--- L28--R
24- G I
-L45 NAV. LTS.
L29 L30- G
N34,
L8
L
L23- L21
WIRES TAPED AND STOWED
Figure 11-14. Light Circuit - 47G

11-11
A1O
A54
-A3 ---- A7
A4
A9 --- A5
A46 A6 A 0
A12A X A 12
rG--W
A13A- -A13
A45 A8
CONTROL STICK A8
GRIP HANDLE
E-3_I A5
A 46 -
Figure 11-15. Electrical Equipment Circuit - 47D-1
A46
Figure 11-16. Electrical Equipment - 47G

11-12
MAINTENANCE
Diagram - 47G-2 (Sheet 1of 3)

Figure 11-17. Wiring L13-18
P3-10
MAINTENANCE
5253 64
|| | --PP4A-4 PP4B-----
IRON
'-
l1-14 / N74
Figure 11-17. Wiring Diagram - 47G-2 (Sheet 2 of 3)

11.14
MAINTENANCE
1. Instrument Panel (View from Rear) 43A. R/H Navigation Light (Used with Wheel
2. Circuit Breaker R/H Hopper Motor (Ref.) Gear When Installed)
3. Circuit Breaker L/H Hopper Motor (Ref.) 44. Receptacle - Hopper (Ref.)
4. Circuit Breaker Radio (Ref.) 45. Thermocouple on No. 2 Cylinder
5. Circuit Breaker Engine Instruments 46. R/H Magneto
6. Bus Bar (Ref.) 47. Magneto Ground Harness - Aft
7. Bus Bar (Ref.) 48. Plug (Ref.)
8. Resistor (Ref.) 49. L/H Magneto
9. Ammeter 50. Receptacle - Hopper (Ref.)
10. Instrument Panel Light 51. L/H Navigation Light (Red)
11. Cylinder Head Temp. Gage 51A. L/H Navigation Light (Used with Wheel
12. Engine Gage Switch Gear When Installed)
13. Altimeter (Ref.) 52. Plug (Ref.)
14. Relay - Hopper (Ref.) 53. Receptacle and Adapter (Ref.)
15. Claristat 54. Plug (Ref.)
16. Starter Switch 55. Receptacle and Adapter (Ref.)
17. Hopper Selector Switch (Ref.) 56. Junction Box Assembly
18. Fuel Primer Switch 57. External Power Relay
19. Ignition Switch 58. Starter Relay
20. Carburetor Air Temp. Gage 59. Shunt
21. Circuit Breaker Generator Switch 60. Voltage Regulator
22. Circuit Breaker Battery Switch 61. Reverse Current Relay
23. Engine and Rotor Tachometer Indicator 62. Generator
24. Fuel Quantity Switch 63. Receptacle and Adapter (Ref.)
25. Engine Gage 64. Plug (Ref.)
26. Fuel Level Gage 65. Starter Motor
27. Instrument Lights Rheostat 66. Engine Tachometer Generator
28. Bus Bar (Ref.) 67. Engine Oil Temperature Bulb
29. Circuit Breaker Blower - Heater 68. R/H Fuel Level Transmitter
30. Circuit Breaker Starter 69. Generator
31. Circuit Breaker Navigation Lights 70. Transmission Oil Temperature Bulb
32. Circuit Breaker Instrument Lights 71. Engine Ground Wire (Ref.)
33. Circuit Breaker Landing Lights 72. Oil Dilution Valve (Ref.)
34. Compass 73. Fuel Primer
35. Receptacle and Adapter (Ref.) 74. Primer Pump
36. Plug (Ref.) 75. Battery
37. L/H Landing Light 76. L/H Fuel Level Transmitter
38. Cockpit Light 77. Rotor Tachometer Generator
39. Connector Assembly - Thermocouple Lead 78. Carburetor Air Temperature Bulb
40. Magneto Ground Harness - Forward 79. Battery Relay
41. Receptacle (Ref.) 80. External Power Receptacle
42. Pilot's Stick Grip Switches 81. R/H Tail Light (White)
43. R/H Navigation Light (Green) 82. L/H Tail Light (White)
Figure 11-17. Wiring Diagram - 47G-2 (Sheet 3 of 3)

11-15
MAINTENANCE
TOSTARTERMOTOR
P3A-10 P3B-10 P34A-16-A A
P56-18 B B -- P56A-18
P3-10 14 BAT
1. Instrument Panel Assembly 11. External Power Relay

2. Battery Switch 12. Starter Relay
3. Generator Switch 13. Bus Bar
4. Ammeter 14. Reverse Current Relay
5. Bus Bar 15. Shunt
6. Circuit Breaker 16. Receptacle & Connector
7. Receptacle & Connector 17. Generator
8. Receptacle & Connector 18. Battery, 11 Amp-Hr.
9. External Power Receptacle 19. Battery Relay
10. Voltage Regulator 20. Junction Box Assembly
Figure 11-18. Battery and Generator Circuit - 47G-2

11-16
MAINTENANCE
N3 8 -1 6 - -P23-16 P22-16 P21-16- --- P24-4
16 P6-4
-K3A-18 K4A-18
STA 70 . NK6-4 PK1A-4

35.75
K4B-18
K4B-18- D K4C-18
NP3-18 NK5-18-
PP5A-18 A - PP5B-18-
PP4A-4 B PP4B-4
A21 Al PK1A-4
NP2A-4-
P25-4 P24-4-
+
BATT
16. Starter Switch

65. Starter Motor
Figure 11-19. Starter Circuit - 47G-2
LEFT 19
N9-16
J 1-16 J3-16
J4-16
STA 49
35.75
19. Ignition Switch

46. R/H Magneto
49. L/H Magneto
Figure 11-20. Ignition Circuit - 47G-2

11-17
MAINTENANCE
N15-20
N14-20 -- N13-20
A - E32-20
B -E33-20°
E 14-20 E15-20
E12-20 E13-20
67
-E10-20 N15-20
B E11-20 E15-20
N14-20
N13-20
*---E12-20 E13-20 B
N23-20 - N24-20
*-E 14-20
N24-20
E33-20 E34-20 - B
-E10-20
E32-20
E1-20 TO FUEL LEVEL GAGE
5. Circuit Breaker - Engine Instruments

12. Engine Gage Switch
20. Carburetor Air Temperature Gage
25. Engine Gage
67. Engine Oil Temperature Bulb
70. Transmission Oil Temperature Bulb
78. Carburetor Air Temperature Bulb
Figure 11-21. Temperature Bulb Circuit 47G-2
E21-20
E23-20
A -E20-20 E21-20 E25-20 C
B -E22-20
E24-20 E25-20
23
-E26-20 -E27-20
B -E28-20X E29-20
C -E30-20-)E31-20- E31-20 C
E29-20- A 66
STA E27-20 B
35.75
23. Engine and Rotor Tachometer Indicator

77. Rotor Tachometer Generator
Figure 11-22. Dual Tachometer Circuit - 47G-2

11-18
76
RIGHT -
26. Fuel Level Gage

76. L/H Fuel Level Transmission
68. R/H Fuel Level Transmission
Figure 11-23. Fuel Level Transmitter Circuit - 47G-2
STA
35 75 L28-18-
r- - L12-18- 81
43. R/H Navigation Light 70 L-1

43A. R/H Navigation Light - Used with Wheel Gear
37. L/H Landing Light
51. L/H Navigation Light
51A. L/H Navigation Light - Used with Wheel Gear
81. R/H Tail Light
82. L/H Tail Light
Figure 11-24. Light Circuit - 47G-2

11-19
Models 47D-1, 47G & 47G-2 BELL HELCOPTER COMPANY Section XI
TO STARTERMOTOR
P37-16 BAT K4B-18
P50A-8
P56 -18
N38-16
P36-16-
P17-18 A .
XP58-
BAT.
10. Ammeter
36. External Power Receptacle

43. External Power Relay
44. Voltage Regulator
45. Reverse Current Relay
46. Shunt
48. Starter Relay
49. Generator
55. BatteryRelay
56. Battery
65. Main Electrical Junction Box
Figure 11-26. Battery and Generator Circuit(2556

47G-2 - 2570)
11-21
MAINTENANCE
RIGHT
J2A-16
N9-16 27
J3A-16- C J3B-16
K9A-18
RET
GRD
13 6. Ignition Switch
13. Starter Switch
18. Circuit Breaker (Starter) 5 Amp
K3A-18 27. Induction Vibrator
33. Magneto (Right Mag.) L H Side
34. Magneto (Left Mag.) R H Side (Dual Breaker)
47756-47
Figure 11-27. Ignition Circuit 47G-2 (2556 - 2570)
I
13
K3A-180 P24-4
K4A-18 K4A-18 K4B-18 K4B-18
Al 43 A2 Al 48 A2
36 NK5-18
K7A-18
13. Starter Switch

14. Fuel Primer PK1A-4
Switch
18. Circuit Breaker P24-4-A2 56
(Starter) 5 Amp NK6-4
27. Induction Vibrator 55
36. External Powerx2
Receptacle
43. External Power Relay P6-4
45. Reverse Current Relay TO IGNITION
SWITCH
48. Starter Relay P22-16
50. Starter Motor
55. Battery Relay
56. Battery
65. Main Electrical Junction Box 47756-51
Figure 11-28. Starter Circuit 47G-2 (2556 - 2570)

11-22
MAINTENANCE
RIGHT
RIGHT E7-20 E4-20
IGN E1-20-
E35-20 E36-20
RESISTOR LEFT
20
5. Fuel Level Gage

20. Circuit Breaker (Instruments) 5 Amp
53. Fuel Level Transmitter (L H Tank)
60. Fuel Level Transmitter (R H Tank)
47756-50
Figure 11-29. Fuel Level Transmitter Circuit 47G-2 (2556 - 2570)
E20-20 E21-20 E23-20- A

ROTOR B -- E22-20- bI -E23-20- -- E21-20- B 54
E24-20--c E25-20 E25-20- C
A -- E26-20-- E E27-20 E29-20- A

ENGINE B E28-20-- DI E29-20 E27-20- B 61
C E30-20-- C -- E31-20 E31-20
2. Engine and Rotor Tachometer Gage

54. Rotor Tachometer Generator
47756-49
Figure 11-30. Dual Tachometer Circuit 47G-2 (2556 - 2570)

11-23
MAINTENANCE
N15-20
N14-20 N13-20
A -E32-20
B - E33-20
C -N23-20
C N23-20 E14-20 B E15-20
E12-20 E13-20-
-E 11-20-
C - N14-20
63
TRANS N13-20
- E12-20 E13-20
1 r -E32-20
E1-20 }- TO FUEL LEVEL GAGE
1. Carburetor Air Temp. Ind.

4. Engine Gage
20. Circuit Breaker (Instruments) 5 Amp
62. Carburetor Air Temperature Bulb
63. Transmission Oil Temperature Bulb
64. Engine Oil Temperature Bulb
47756-53
Figure 11-31. Temperature Bulb Circuit 47G-2 (2556 - 2570)

11-24
MAINTENANCE
STRAIGHTOR FLOATSKID
-L29-18----- -L30-18-- 39
L^19 BEACON
STRAIGHTOR FLOATSKID-
L.H.NAV.LT.
R.H. TAIL LT.
29 -L23-14-- -L21-14- L 1 2- 18 - /
58
N29-14 L9-18 -L10-18
L.H. LDG. LT.
30 L1-18 -- 59
L1-18 L.H. TAIL LT.
COCKPIT LT.
31
L26-18 - COMPASS
LT.
11. Light Dimming Rheostat 31. Compass Light

15. Circuit Breaker (Landing Light) 15 Amp 37. Beacon (Lower)
16. Circuit Breaker (Instrument Lights) 10 Amp 38. Navigation Lights RH and LH (Curved Skid Gear)
17. Circuit Breaker (Navigation Lights) 10 Amp 39. Navigation Lights RH and LH
19. Circuit Breaker (Heater) 20 Amp (Straight or Float Gear)
24. Circuit Breaker (Beacon) 10 Amp 57. Beacon (Upper)
29. Landing Light LH 58. Tail Light (RH)
30. Cockpit Light 59. Tail Light (LH)
47756-48
Figure 11-32. Light Circuit 47G-2 (2556 - 2570)

11-25
o
.
RADIO INSTALLATION DIAGRAM AND EQUIPMENT LIST
1. Antenna - Type A-12
2. Receiver - R-19
3. Transmitter - T-11B (No. 2)
6. Control Panel - 47-769-078-3
7. Control Panel - SB-327/ARC-44
8. Control Panel - SB-329/AR (Signal Distribution - Co-Pilot)
9. Box Assembly - 47-763-055-11

10. Control Panel - Type C-56
11. Control Panel - SB-329/AR (Signal Distribution)
12. Plug and Jack - Pilots and Co-Pilots Headset
13. Group Antenna - AN/ARA-31 (Homing Group)
14. Radio - ARC-44
15. Transceiver - RT-294/ARC-44-FM
16. Keyer - KY-149/AR
17. Dynamator - DY-107/AR
18. Mounting - MT-1267/AR
19. Mounting - MT-1268/AR
20. Antenna - AT-454/ARC
21. Intercommunication Switch
22. R.F. Filter - Type FA203

23. Foot Switch
24. Radio Circuit Breakers
25. Junction Box
26. Mike and Phone Pad Installation
27. Pilots and Co-Pilots ICS Relay (AN3311-2)
28. Terminal Strip
Figure 11-33. Electronic Installation - A.R.C. Type 12 and AN/ARC-44 Radio 47G-2 (2556-2570) (Sheet 2 of 3)
11-27
MAINTENANCE
0 NIMIC.
KEY B-RC1O4A20 -- CONTROLH RC126A20'o RZ-2BIS --- -RFD-.BLACK -6 L---RZ75CrI--- I I pLu-r PAN1
GROUND D RC105A20N- Q RC127A20 275 V DCSUPPLY A
Models 47D-1, 47G & 47G-2 BELL HELICOPTER COMPANY i
MAINTENANCE Index
* Alphabetical Index
SUBJECT PAGE SUBJECT PAGE
A C
Access and Inspection Provisions, Carburetor - Part .............. .. 5-22B

Section I, Part I ................. 1-6 Carburetor - Lycoming 2556 thru
Accessory Drive Gear - Transmission .. 4-9 2570 - Part .................. 5-40
Adjusting Angular Relationship of Blade Carburetor - Mixture and Heat Controls
Grips - Part .................. 2-25 Part II - Lycoming 2556 & Subs ...... 5-35
Adjusting - Autorotation Speed - Carburetor - Mixture & Heat Controls
Main Rotor .................... 2-7 Lycoming - PartII ............... 5-19
Adjusting Counterweights - Main Cables - Tail Rotor Controls ......... 7-51
Rotor - PartII .................. 2-4 Cables - Sprag System - Part I ........ 5-11
Air Filter - Part I ................. 5-12 Cables - Sprag System - Lycoming -
Air Induction System - Part I ......... 5-12 Part 1 ....................... 5-15
Air Induction System - Lycoming Cambox - Lycoming Engine 1459 thru
PartII ....................... 5-17 2478- PartII .................. 5-19
Adjusting Manifold Pressure Gage ...... 8-5 Cambox - Lycoming Engine 2556 thru
Adapter Plate and Engine Mount - 2570 - Part II .................. 5-20 A
Part I ........................ 5-6 Centrifugal Clutch - Transmission...... 4-14
Adjusting Stabilizer - Dampers ........ 3-8 Checking Centerframe & Tail Boom -
Adjusting Trim Tab - Main Rotor ....... 2-5 Alignment ..................... 10-12
Alignment - Checking Centerframe Checking Cross Tube Deflection ........ 10-9
and Tail Boom .................. 10-12A Center of Gravity Locating - Main
Aligning - Main Rotor Blades - Part I .... 2-3 Rotor - Part I .................. 2-10
Alignment - Main Rotor Blades - 47G-2 Chordwise Balance Check - Rotor
S/N 2454 & Subs - Part .......... 2-5 Installed - 47G-2 S/N 2454& Sub-Part II 2-4
Alignment - Main Rotor Blades Part II . . 2-5 Cleaning - Hydraulic Boost - System
Aligning Tail Rotor Pitch Change - Part II ...................... 7-27
Drum - Part II .................. 7-15 Cold Air Intake - Part I ............. 5-12
Aligning - Tail Rotor Pitch Change Collective Pitch & Throttle Control
Drum ........................ 7-15 Assembly - Standard - Part I........ 7-1
Assembly - Main Rotor Hub - Part I ..... 2-22 Collective Pitch & Throttle Control
Assembly - Hydraulic - Part II....... 7-17
B Collective Pitch & Throttle Control
Assembly - Standard 2556 & Sub -
Balancing - Main Rotor - 47G-2 S/N 2454 Part II ...................... 7-52
and Subs - Part II ................. 2-6 Collective Pitch Control System -
Balancing - Main Rotor - Part I ........ 2-2 Rigging - Hydraulic - Part II ........ 7-1
Balancing - Main Rotor - Part II ....... 2-6 Collective Pitch Control System - Part II. 7-15
Balancing - Tail Rotor .............. 6-3 Collective Pitch Control System -
Battery ........................ 9-4 Rigging - Standard - Part I.......... 7-1
Battery Relay .................... 9-5 Control Disc - Standard - Part I........ 7-15
Bellcranks ...................... 7-15 Controls - Throttle - Part I.......... 5-15
Blade Grips - Part II ............... 2-15 Controls - Throttle - Lycoming- Part .. 5-19
Blades - Main Rotor - Part I .......... 2-9 Control Pedals - Tail Rotor - Hydraulic -
Blade Aligning- Main Rotor - Part II .... 2-3 Part II ....................... 7-48
Blade Repair - Main Rotor - Part I ..... 2-10 Controls - Heat & Mixture - Part I ...... 5-17
Blades - Tail Rotor ................ 6-13 Control Cables - Tail Rotor - Part I ..... 7-20
Bleeding Oil Pressure Gage Line ....... 8-5 Control Pedals - Tail Rotor - Standard -
Body and Landing Gear .............. 10-1 Part I ........................ 7-16
Cooling Fan - Part I................ 5-19
C Cooling Fan Drive Assembly .......... 4-24
Cooling Shroud - Part I ............. 5-23
Cabin Assembly .................. 10-1 Cooling Shroud & Baffles - Part II ...... 5-29
Cabin Doors .................... 10-7 Cooling System - Part I ............. 5-19
Cables - Dynamic Stop .............. 3-5 Cooling System - Lycoming - Part II..... 5-25
Carburetor - 1459thru 2478 - Part I .... 5-14 Cyclic Control Dampers - Part II ....... 7-35
Index 1
Alphabetical BELL HELICOPTER COMPANY Models 47D-1, 47G & 47G-2
Index MAINTENANCE & OVERHAUL INSTRUCTIONS

C G
Cyclic Control Jackshaft - Standard - Gearbox - Tail Rotor ............... 6-27

Part I ........................ 7-14 General Information - Part I .......... 1-1
Cyclic Control Stick - Hydraulic - Part II.. 7-19 Generator ....................... 9-5
Cyclic Control Stick - Standard - Part I... 7-12 Generator Drive Assembly . ...... 4-20
Cyclic Control Systems - Part II ....... 7-19 Ground Handling- Part I ............ 1-4
Cyclic Control System - Hydraulic - Ground Operating Instruction - Part I .... 1-7
Part ....................... 7-19 Ground Handling Wheels . ........ 10-12
D H
Dampers - Cyclic Controls . ....... 7-35 Hand Cranking - Lycoming Engine -

Dampers - Stabilizer Bar . ...... 3-7 Part I ........................ 1-8
Determining Battery Location - 47G & Heated Air Intake - Part I ......... 5-13
47G-2 - Part I .................. 1-11 Heat Control Valve - Part I ........... 5-14
Determining Center of Gravity - Part I ... 1-10 Heat & Mixture Controls - Lycoming -
Dimensions- Principal - Part I ..... 1-1 Part ................. ..... 5-19
Drive Shaft - Tail Rotor . ....... 6-19 Hoisting - Part I .................. 1-5
Dynamic Stop Cables ............... 3-5 Horizontal Stabilizer - Standard -
Part I ........................ 7-22
E Hub - Main Rotor ................. 2-19
Hydraulic Boost System - Part ....... 7-20
Electrical System ................. 9-1 Hydraulic Boost System - Cyclic
Electrical System - 2556 & Subs ....... 9-9 Controls - Part II ................ 7-20
Electrical System- Equipment......... -3 HydraulicIrreversible Valve- Part . .... 7-24
Electrical System - Troubleshooting ..... 9-1 Hydraulic Power Cylinders - Fore & Aft
Engine Mount & Adapter Plate - Part I ... 5-6 Cyclic Controls - Part II ........... 7-31
Engine MountingSystem - Lycoming - Hydraulic Power Cylinder & Support -
Part II ....................... 5-9 Lateral Cyclic Controls - Part ...... 7-40
Engine Sprag Mounts - Lycoming -
PartII . ...................... 5-13 I
Engine Sprag Mounts - Part I ......... 5-10
External Power Receptacle .... ..... 9-7 Inspection Daily - 47D-1 - Part I ....... 1-41
Exhaust Stacks - Part I ............. 5-18 Inspection - 50 Hour - 47D-1 - Part I .... 1-45
Exhaust Stacks - Lycoming - Part II ..... 5-17 Inspection - 100 Hour - 47D-1 -
Extension Shaft & Housing Assembly ..... 6-24 Part I ....................... 1-49/1-50
Inspection - 300 Hour - 47D-1 -
Part I ....................... 1-51
Inspection - 600 Hour - 47D-1 -
Part I .......... ............. 1-55
Fan Belts - Part I ................. 5-22 Inspection - Special - 47D-1 - Part I .... 1-61
Fan Belts - Lycoming- Part II ...... 5-28 Inspection- Daily- 47G- Part II ....... 1-1
Firewall .... ....... 10-5 Inspection - 50 Hour - 47G - Part II ..... 1-7
Flight Controls- Hydraulic- Part II..... 7-1 Inspection- 100Hour- 47G- Part . ... 1-12
Flight Controls- Standard- Part I .... 7-1 Inspection- 300Hour- 47G- Part II . . .. 1-13
Floor Assembly .................. 10-7 Inspection - 600 Hour - 47G - Part II .... 1-17
Fore & Aft Cyclic Control Jackshaft - Inspection - 1200 Hour - 47G - Part I . . . 1-21
Hydraulic- Part . ............... 7-30 Inspection- Special- 47G- Part II...... 1-27
Fore & Aft Cyclic Control System - Inspection - Daily - 47G-2 - Part II ..... 1-1
HydraulicPart .................. 7-29 Inspection- 50 Hour- 47G-2- Part III.. 1-9/1-10
Fore & Aft Cyclic Control System - Inspection - 100 Hour - 47G-2 - Part III. 1-11
Rigging Standard - Part I ... ..... 7-5 Inspection - 600 Hour - 47G-2 - Part . 1-13
Fore & Aft Cyclic Control System - Inspection - 1200 Hour - 47G-2 -
Rigging - Hydraulic - Part II ........ 7-3 Part III ...................... 1-17
Freewheeling Unit - Transmission ...... 4-6 Inspection - Special - 47G-2 - Part m... 1-23
Fuel System - Part ............... 5-28 Ignition System ........... . 9-8...
-8
Fuel Level Transmitters ........... 9-9 Information - General ............. 1-1
Fuel Strainer - Part I.... ......... 5-30 Instruments ........... 8...
8-1
Fuel Shut-Off Valve - Part I . ...... 5-30 Inspection - Maintenance - 47D-1, 47G &
Fuel System- Lycoming- Part ....... 5-23 47G-2- Part ................. 1-29
Index 2
Models 47D-1, 47G & 47G-2 BELL HELICOPTER COMPANY Alphabetical
MAINTENANCE Index
I M
Inspection - Overhaul Main Rotor Main Rotor Blades - Part II........... 2-8
Blades - Part I ................ 2-9 Main Rotor Hub - Part I............. 2-19
Installing - Collective Pitch & Throttle Main Rotor Hub - Part II............. 2-11
Control Assembly - Part II......... 7-18 Main Rotor Hub - 47G-2 S/N 2454 & Subs -
Installing - Fore & Aft Cyclic Part II ....................... 2-11
Controls - Part II ............... 7-30 Main Rotor Hub - Inspection - Part I .... 2-12
Installing - Fore & Aft Cyclic Control Main Rotor Hub - Reassembly - Part II ... 2-12
Jackshaft - Part II .............. 7-31 Maintenance Inspection - Part I........ 1-29
Installing - Hydraulic Boost System - Main Rotor Installation - 47G-2 S/N
Part II ...................... 7-27 2454& Subs- Part .............. 2-1
Installing - Lateral Cyclic Controls with Main Rotor Tie Down - Part I ......... 1-5
Franklin Engine - Part II .......... 7-38 Main Rotor System - Part I ........... 2-1
Installing - Lateral Cyclic Controls with Major Assemblies - Transmission ...... 4-3
Lycoming Engine - Part II ......... 7-38 Mandatory Retirement Schedule -
Installing - Power Cylinder & Support - 47D-1 - Part I ................ 1-65/1-66
Fore and Aft Cyclic Controls - Mandatory Retirement Schedule -
Part II ...................... 7-34 47G - PartII .................. 1-31/1-32
Installing - Power Cylinder & Support - Mandatory Retirement Schedule -
Lateral Cyclic Controls with Lycoming 47G-2 - Part II ................ 1-27/1-28
Engine - Part II ................ 7-42 Manifold Pressure Gage - Adjusting ..... 8-5
Installation - Main Rotor - 47G-2 S/N Mast Assembly ................... 3-17
2454 & Subs - Part I............. 2-7 Mast Controls .................... 3-1
Installation - NewSkid Landing Gear .... 10-12 Mast Repair Limits ................ 3-20
Introduction .................... i Mooring - Part I .................. 1-6
Mounts - Engine Sprag - Part I ........ 5-10
J Mounts - Engine Sprag Lycoming- Part II. 5-13
N
Jacking - Part I .................. 1-5
Jackshaft - Tail Rotor Controls -
Hydraulic - Part II ............... 7-50
Junction Box - Assembly ............. 9-5 Oil Cooler - Franklin - Part I ......... 5-26
Oil Cooler - Lycoming - Part II ........ 5-32
K Oil Filter - Part I ................. 5-27
Oil Pump - Part I ................. 5-28
L Oil System - Part I ................ 5-25
Oil System - Check Valve - Part I ...... 5-27
Landing Gear .................... 10-7 Oil System - Lycoming - Part II ........ 5-30
Lateral Cyclic Control System - With Oil System - Relief Valve - Part I ...... 5-28
Franklin Engine - Installing - Part II ... 7-36
Lateral Cyclic Control System - With
Lycoming Engine - Installing - Part II .. 7-39 Pitot tatic System ................ 8-5
Lateral Cyclic Control System - Rigging Plexiglass Repairs................. 10-3
Standard - Part I ............... 7-3 Power Cylinders - Hydraulic - Fore &
Lateral Cyclic Control System - Part II.. . 7-60 Aft
Aft Cyclic
Cyclic Controls
Controls -- Part Part II.........
II......... 7-31
7-31
Legs ................................ 10-12 Power Cylinders - Hydraulic Lateral
Leveling - Part I .............. ......... 1-5 Cyclic Controls - Part II ........... 7-40
List of Lubricants - Part I ........... 1-16 Power Plant - Part I ............... 5-1
Lower Case Assembly - Transmission ... 4-14 Power Plant -Part . 5-1
Lower Spider - Transmission ......... 4-10 - Lycoming 2556thru
Lower Sun Gear - Transmission ........ 4-12 Power
2570 Plant - Lycoming 2556 thru
.........................
2570......................... 5-34
5-34
Lubrication - Part I ................ 1-13 Principal Dimensions - Part I . .... 1-2
Pushing or Towing- Part I ........... 1-4
M
Q
Magnetos- Part I ................. 5-24
Main Rotor Balancing - Part I ......... 2-2 R
Main Rotor Blades - Part I ........... 2-9
Main Rotor Blades - 47G-2 S/N 2454 Range Markings - Dual Tachometer ..... 8-4
and Subs - Part II ................ 2-8 Range Markings - Instruments ......... 8-4
Index 3
Alphabetical BELL HELICOPTER COMPANY Models 47D-1, 47G & 47G-2
MAINTENANCE
R R
Reassembly - Main Rotor Hub - 47G-2 Rigging - Synchronized Elevator

S/N 2454 & Subs - Part II........... 2-12 Hydraulic - Part II ............... 7-11
Reassembling - Tail Rotor Control Rigging - Synchronized Elevator -
Pedals - Part ................. 7-50 Standard- Part I................ 7-5
Refinishing - Metal Main Rotor Blades - Rigging - Synchronized Elevator -
47G-2 S/N 2454 & Subs - Part II ...... 2-8 Standard - 2556 & Subs - Part I ...... 7-59
Refinishing - Main Rotor Blades - Part I . . 2-16 Rigging - Tail Rotor Controls - Part II . . . 7-59
Refinishing - Metal Main Rotor Blades - Rigging - Tail Rotor Controls -
Part .II.............. 2-8 Hydraulic- Part ............... 7-11
Relay - Battery ................... 9-5 Rigging - Tail Rotor Controls -
Removing - Hydraulic Boost System - Standard - Part I ................ 7-7
Part ....................... 7-27 Rigging - Tail Rotor Controls -
Removing - Lateral Cyclic Controls with Standard - 2556 & Subs - Part II ...... 7-59
Franklin Engine - Part II ........... 7-36 Rotor Tachometer Drive Assembly ...... 4-22
Removing - Lateral Cyclic Controls with
Lycoming Engine - Part II .......... 7-37 S
Removal - Main Rotor 47G-2 S/N 2454 &
Subs-- Part
Subs Part II
..................
II. ................ 2-7 servicing
S2-7 - PartI ................. 1-7
Repairing Centerframe Elongatedervicing & Testing - Hydraulic Boost
Attachment
Repair Holes
or Replacement Fore & Aft 10-18 System
Servicing -&Part II -...............
Testing 7-29
Hydraulic Boost
Cyclic
Repair orControls
Replacement II ...........
- Part- Fore & Aft 7-30 System- Part
Servicing II................. 7-60
Repair or Replacement - Lateral System& TestingII
- Part - Hydraulic Boost
.................
Setting & Ranges of Movement - Part I ... 7-60
1-2
Cyclic Controls - Part ........... 7-37 Skids 10 A
Replacing Weather Strip Ring on Doors . . 10-5 Special Tools..
Rigging - Collective Pitch Control
Rigging Special Tools
Spanwise ....................
Balance Check - Rotor 1-18
System (Alternate Method)- Part II .... 7-56 - 47G-2S/N 2454
Installed &
Rigging - Collective Control System - 2-3
Part
Part II
II....................... .....................
7-52
7-52 Sprag Safety Cables - Part I .......... 5-11
Rigging Fore & Aft Cyclic Control Sprag Safety Cables - Part II..... 5-15
System - Part II .................. 7-56 Stabilizer Bar.......... 3-3
Rigging - Collective Pitch Control 3-3
System - Hydraulic - Part ........ 7-1 Stabilizer Bar Dampers 3-7
PitchCollective
Controltabilizer Bar Dampers - Adjusting ..... 3-8
System - Standard
Rigging
System - Standard Pitch
- Part
II. 7-1
- Collective
Control - Part ..........
Starting System
Straightening - Part
Cross I .............
Tube with Fixture ....
5-2
5-23
10-10
Rigging - Collective Pitch Control Straightening Cross Tube with Helicopter
System - Standard - 2556 & Subs -Straightening Cross Tube with
Part ....................... 7-56 ............... 10-9
Rigging - Fore & Aft Cyclic Controls Swashplate Assembly ............. 3-
Hydraulic - Part II ............... 7-3 Synchronized Elevator- -2556
Swashplate Assembly Part &IISubs ..... 7-42
3-28
Rigging - Fore & Aft Cyclic Controls Synchronized Elevator
Standard - Part I ................ 7-5 Synchronized Elevator Rigging -
Rigging - Fore & Aft Cyclic Controls Standard - Part I 7-5
Standard - 2556 & Subs - Part II ...... 7-56 Synchronized Elevator - Standard -
Rigging - Lateral Cyclic Controls
Standard - Part I ................ 7-6 Synchronized Elevator - Rigging
Rigging - Lateral Cyclic Controls Hydraulic - Part 7-11
Hydraulic- Part ............... 7-10
Rigging - Lateral Cyclic ControlT
System - Part II ................. 7-56
Rigging - Lateral Cyclic Control Tachometer Generators ............. 9-8
System - Franklin Engine - Part II .... 7-6 Tail Rotor ...................... 6-6
Rigging - Lateral Cyclic Control Tail Rotor Blades ................. 6-13
System - Lycoming Engine - Part II .... 7-10 Tail Rotor Control Cables - Standard
Rigging - Synchronized Elevator - Part I ........................ 7-20
Part II1 ....................... 7-59 Tail Rotor Control Cables - Hydraulic
Rigging Synchronized Elevator - Part II ....................... 7-51
Part II ...................... .7-11 Tail Rotor Controls- PartII .......... 7-48
Index 4
Models 47D-1, 47G & 47G-2 BELL HELICOPTER COMPANY Alphabetical
MAINTENANCE
& OVERHAULINSTRUCTIONS Index
T T
Tail Rotor Control Jackshaft - Transmission - Disassembly - Lower

Standard - Part I ................ 7-18 Sun Gear ...................... 4-12
Tail Rotor Control Jackshaft - Hydraulic - Transmission - Reassembly - Major
PartII ....................... 7-50 Assemblies .................... 4-17
Tail Rotor Control Pedals - Standard - Transmission - Diassembly Upper
Part ........................ 7-16 Spider ........................ 4-6
Tail Rotor Control Pedals - Hydraulic - Transmission - Removal............ 4-1
PartII ....................... 7-48 Transmission - Troubleshooting........ 4-1
Tail Rotor Control System - Rigging - Transmitters - Fuel Level ........... 9-9
Standard - Part ................ 7-7 Trim Tab Adjusting - Main Rotor -
Tail Rotor Drive Assembly ........... 4-26 Part I ........................ 2-5
Tail Rotor Drive Shaft .............. 6-19 Troubleshooting - Engine Franklin -
Tail Rotor Gearbox ................ 6-27 Part I ........................ 5-1
Tail Rotor Pitch Change Drum - Troubleshooting - Engine Lycoming -
Aligning - Part II ................ 7-15 Part II ....................... 5-1
Tail Rotor Controls - Rigging - Troubleshooting - Hydraulic Boost
Hydraulic- Part ............... 7-11 System- Part II ................. 7-24
Tail Rotor System ................. 6-1 Troubleshooting - Main Rotor - 47G-2
Temperature Bulbs ................ 9-7 S/N 2454 & Subs - Part II ........... 2-1
Throttle Controls - Part I ............ 5-15
Throttle Controls - Lycoming 1459 thru U
2478 - Part II .................. 5-19
Throttle Controls - Lycoming - 2556 Universal Joint ................... 6-22
thru 2570 - PartII ............... 5-36 Upper Spider - Transmission ......... 4-6
Tie-Down - Main Rotor............. 1-5
Torque Tube - Lateral Cyclic Control - V
Part II ....................... 7-38
Towing and Pushing ................ 1-4 Ventral Fin - Part I ................ 7-20
Tracking - Tail Rotor Blades .......... 6-1 Ventral Fin - Part II ............... 7-46
Tracking - Main Rotor - Part I ........ 2-5 Voltage Regulator ................. 9-6
Tracking - Main Rotor - 47G-2 S/N
2454 & Subs - Part II.............. 2-2 W
Transmission Assembly ............. 4-1
Transmission - Disassembly Acessory Warm -Up-Franklin Engine ........... 1-9
Drive Gear .................... 4-9 Warm-Up and Ground Test - Lycoming
Transmission- Disassembly - Centrifugal Engine ....................... 1-9
Clutch ........................ 4-14 Weight and Blance - Part I ........... 1-10
Transmission - Disassembly Major Wiring Data ..................... 11-1
Assemblies .................... 4-5 Wiring Data - 2556 thru 2570 .......... 11-20
Transmission - Disassembly - Wiring - Electric Installation - 2556
Freewheeling Unit ................ 4-6 thru 2570 ..................... 11-28
Transmission - Disassembly - Lower Case 4-14
Transmission- Disassembly- Lower
Spider ........................ 4-10 X Y Z
Index 5/Index 6

Manual - 47D1-G-G2 Mo

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Manual - 47D1-G-G2 Mo

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MODELS

47 D-l, G, & G-2

LIST OF EFFECTIVE PAGES

Insert latest revision pages: dispose of superseded pages.

LIST OF EFFECTIVE PAGES (Cont)

Page Revision Page Revision

5-11 - 5-16 (Part 1) ................. 0 10-6A .......... .............................. 0

The information in this manual is provided to help assure

Delchem None Pennsalt Chemicals 4 months from Use in well venti-

1-3. STATION. (Figure 1-1.) Main components are

Stations of the main and tail rotor are measured from

Height (Ground line to top

1-5. MAIN ROTOR.

Main rotor disc diameter 35 ft. 1.50 in.

Tail rotor disc diameter 5 ft. 8.125 in.

1-7. SETTINGS AND RANGES OF MOVEMENT.

1-8. MAIN ROTOR BLADES.

Collective Pitch (Measured at Blade Grip)

Flapping (any direction) 7° 30'

Figure 1-2. Station Diagram - Main and Tail Rotor

1-9. SWASHPLATE. (Measured with protractor.) Right Pedal Forward -

Aft - 47D-1 and G 9° ± 1/2 ° Neutral Down 15 1/2 ° to 16 1/2 °

Left - 47D-1 and G 7 1/2 ° ± 1/2 ° Manufacturer Aircooled Motors, Inc.

MAST COVER NUT

Figure 1-3. Hoisting - Jacking and Leveling Diagram

Figure 1-4. Main Rotor Tie Down

a. Open tie-down assembly and install on end of Note

Figure 1-5. Helicopter Tie Down

f. Pull engine through compression on up-stroke of 1-35. GROUNDTEST - FRANKLIN ENGINE.

CAUTION d. Place a jack, on scales, under each of three jack-

c. Operating at 3100 RPM with collective pitch stick

Figure 1-6. Determining Center of Gravity

d. Using chart (figure 1-7), determine whether CG BATTERYAJUSTMENT EMPTY

CG LOCATION-INCHES AFT OF STATION ZERO 47976-137

Figure 1-7. Required CG Limits

ADJUSTMENT= WEIGHT(AS DELIVEREDCG - ASWEIGHEDCG)

a. When using sprayed solvents or compressed air

Broken arrows indicate lubrication of

Figure 1-8. Lubrication Chart (Sheet 1 of 2)

Note 1 35. Swivel and Link Bearings

Detail B: Main Rotor Hub Area

Figure 1-8. Lubrication Chart (Sheet 2 of 2)

MIL-G-25537 (ALTERNATE MIL-C-23827)

Aero Shell Grease 14 Shell Oil Company

MANU FAC TURER' S MANU FAC TURER'S

TG-4831 Texaco, Inc.

Calol 3934 Standard Oil Company of California

Royco 37 Royal Lubricants Company

Low Temperature Grease EP Texaco, Inc.

Aero Shell Grease 7 Shell Oil Company

RPM Aviation Grease 5 Standard Oil Company of California

TL-7094 Texaco, Inc.

HYDRAULIC FLUID - PETROLEUM BASE

3126 Hydraulic Oil Humble Oil and Refining Company

XSL 7828 Shell Oil Company

TL-5874 Texaco, Inc.

Staufer Aero-Hydrail 500 Staufer Chemical Company

Mobil Aero HFB Mobil Oil Corporation

1-47. FLUORESCENT PENETRANT MATERIALS. (See Table 1-1.)

Table 1-1. Flourescent Penetrant Inspection Materials (Sheet 1 of 5)

The following Post Emulsified Penetrant System materials

(Post Emulsified Penetrant Systems)

FPE-505 Fluorescent Penetrant AutomationIndustries Inc.

Dubl-Chek FP-20 Penetrant Belmont Chemicals, Inc.

FP-93 Penetrant Met-L-Check Company

P-148A Penetrant URESCO Inc.