MAINTENANCE MANUAL VOLUME 1 GENERAL INFORMATION

_______________________________________________________________________ Position: __________________________ Telephone No.: _______________________ Company: _______________________________ Fax No.: _______________________ Reference No. (your initials and date): _____________________________________ (If you choose to mail this form, fold in thirds with address exposed, tape and mail.) TAPE HERE TAPE HERE From POSTAGE NECESSARY PRODUCT SUPPORT ENGINEERING 12,800 rue de l’Avenir Mirabel Québec, Canada, J7J 1R4 FOLD ON DOTTED LINES AND TAPE IMPORTANT HELICOPTER SALE NOTICE Please complete this Form and return by Mail or FAX (450-433-0272, Attention: CPDC) to Bell Helicopter Textron. This will ensure that the New Owners receive updates to their Bell Helicopter Technical Manuals and Bulletins. Model of Helicopter Sold or Purchased ____________________________________________ ___________________________________________________________________________ Bell Serial Number ____________________________________________________________ ___________________________________________________________________________ Registration Number __________________________________________________________ ___________________________________________________________________________ Company or Individual who purchased Helicopter____________________________________ ___________________________________________________________________________ Address ____________________________________________________________________ City________________________________________________________________________ State_______________________________________________________________________ Zip Code ___________________________________________________________________ Country ____________________________________________________________________ FAX No. ___________________________ Telephone No. ___________________________ TAPE HERE TAPE HERE From NO POSTAGE NECESSARY IF MAILED IN THE UNITED STATES COMMERCIAL PUBLICATION DISTRIBUTION CENTER P.O. BOX 482 FORT WORTH, TEXAS 76101-0482 FOLD ON DOTTED LINES AND TAPE BUSINESS REPLY MAIL FIRST CLASS PERMIT NO. 1744 FORT WORTH, TEXAS BHT-206L4T-MM-1 16 SEP 2009 Rev. 6 Warranty SPARE PARTS WARRANTY ONE YEAR/1,000 HOURS PRORATED WARRANTY AND REMEDY: Seller warrants each new helicopter part or helicopter part reconditioned by seller to be free from defect in material and workmanship under normal use and service and if installed on Bell model helicopters. Seller’s sole obligation under this warranty is limited to replacement or repair of parts which are determined to Seller’s reasonable satisfaction to have been defective with 1,000 hours of operation or one (1) year after installation, whichever occurs first and reimbursement of reasonable freight charges. After 200 hours of use, there will be a prorated charge to the Purchaser for replacement parts (prorating the hours of total use against the then applicable part life or 2,000 hours, whichever is the lesser). Defective parts must be reported in writing to the Seller’s Warranty Administration within 90 days of being found defective. Replacement of parts may be with either new or reconditioned parts, at Seller’s election. Warranty adjustment is contingent upon the Purchaser complying with the Warranty Remedies as described in the Commercial Warranty Information brochure and the Seller’s Warranty Administration disposition instructions for defective parts. Failure to comply with all of the terms of this paragraph may, at Seller’s sole option, void this warranty. NOTE: Parts, components and assemblies of all new helicopters may have been restored or reworked due to mars, blemishes, dents or other irregularities during the manufacturing process. Such restoration and/or rework is permitted under Seller’s approved manufacturing and engineering processes and guidelines. The restoration and/or rework so completed does not render such items defective in material or workmanship. THIS WARRANTY IS GIVEN AND ACCEPTED IN PLACE OF (i) ALL OTHER WARRANTIES OR CONDITIONS, EXPRESS OR IMPLIED, INCLUDING BUT NOT LIMITED TO THE IMPLIED WARRANTIES OR CONDITIONS OF MERCHANT ABILITY AND FITNESS FOR A PARTICULAR PURPOSE AND (ii) ANY OBLIGATION, LIABILITY, RIGHT, CLAIM OR REMEDY IN CONTRACTOR IN TORT (DELICT), INCLUDING PRODUCT LIABILITIES BASED UPON STRICT LIABILITY, NEGLIGENCE, OR IMPLIED WARRANTY IN LAW. This warranty is the only warranty made by Seller. The Purchaser’s sole remedy for a breach of this warranty or any defect in a part is the repair or replacement of helicopter parts and reimbursement of reasonable freight charges as provided herein. Seller excludes liability, whether as a result of a breach of contract or warranty, negligence or strict product liability, for incidental or consequential damages, including without limitation, damage to the helicopter or other property, costs and expenses resulting from required changes or modifications to helicopter components and assemblies, changes in retirement lives and overhaul periods, local customs fees and taxes, and costs or expenses for commercial losses or lost profits due to loss of use or grounding of helicopters or otherwise. Seller makes no warranty and disclaims all liability in contract or in tort (delict), including, without limitation, negligence and strict tort (delictual) liability, with respect to work performed by third parties at Purchaser’s request and with respect to engines, engine accessories, batteries, radios, and avionics, except Seller assigns each manufacturer’s warranty to Purchaser to the extent such manufacturer’s warranty exists and is assignable. This warranty shall not apply to any helicopter part which has been repaired or altered outside Seller’s factory in any way so as, in Seller’s judgment, to affect its stability, safety or reliability, or which has been subject to misuse, negligence or accident, or which has been installed in any aircraft which has been destroyed unless that helicopter has been rebuilt by Bell. A list of destroyed aircraft is obtainable from Bell Product Support. Repairs and alterations which use or incorporate parts and components other than genuine Bell parts or parts approved by Bell for direct acquisition from sources other than Bell itself are not warranted by Bell, and this warranty shall be void to the extent that such repairs and alterations, in Seller’s sole judgment, affect the stability, safety or reliability of the helicopter or any part thereof, or damage genuine Bell or Bell-approved parts. No person, corporation or organization, including Bell Customer Service Facilities, is authorized by Seller to assume for it any other liability in connection with the sale of its helicopters and parts. NO STATEMENT, WHETHER WRITTEN OR ORAL, MADE BY ANY PERSON, CORPORATION OR ORGANIZATION, INCLUDING BELL CUSTOMER SERVICE FACILITIES MAY BE TAKEN AS A WARRANTY NOR WILL IT BIND SELLER. Seller makes no warranty and disclaims all liability with respect to components or parts damaged by, or worn due to, corrosion. Seller makes no warranty and disclaims all liability for consumables (wear items) which are defined as items required for normal and routine maintenance or replaced at scheduled intervals shorter than the warranty period. “Consumables” include but are not limited to engine and hydraulic oil, oil filters, packings and o-rings, anti-corrosion and/or sealing compounds, brush plating material, nuts, bolts, washers, screws, fluids, compounds, and standard aircraft hardware that is readily available to aircraft operators from sources other than Seller. All legal actions based upon claims or disputes pertaining to or involving this warranty including, but not limited to, Seller’s denial of any claim or portion thereof under this warranty, must be filed in the courts of general jurisdiction of Tarrant County, Texas or in the United States District Court for the Northern District of Texas, Ft. Worth Division located in Ft. Worth, Tarrant County, Texas. In the event that Purchaser files such an action in either of the court systems identified above, and a final judgment in Seller’s favor is rendered by such court, then Purchaser shall indemnify Seller for all costs, expenses and attorneys’ fees incurred by Seller in defense of such claims. In the event Purchaser files such a legal action in a court other than those specified, and Seller successfully obtains dismissal of that action or transfer thereof to the above described court systems, then Purchaser shall indemnify Seller for all costs, expenses and attorneys’ fees incurred by Seller in obtaining such dismissal or transfer. January 2007 FAA APPROVED BHT-206L4T-MM-1 4-00-00 27 OCT 2009 Rev. 7 Page 1 ECCN EAR99 TABLE OF CONTENTS Paragraph Chapter/Section Page Number Title Number Number CHAPTER 4 — AIRWORTHINESS LIMITATIONS SCHEDULE AIRWORTHINESS LIMITATIONS SCHEDULE 4-1 Airworthiness Limitations Schedule. .............................................. 4-00-00 3 FIGURES Figure Page Number Title Number 4-1 Tailboom Upper Left Attachment Fitting (P/N 206-032-409-001) — Recurring 100-Hour Inspection ...................................................................... 9 TABLES Table Page Number Title Number 4-1 Airworthiness Limitations Schedule .................................................................... 4 4-2 Inspection Limitations Schedule ......................................................................... 8 BHT-206L4T-MM-1 FAA APPROVED 4-00-00 Page 2 Rev. 7 27 OCT 2009 ECCN EAR99 REVISION NO. DATE OF SIGNATURE APPROVAL SIGNATURE Original 19 July 1994 Rev. 1 4 December 1995 N/A Rev. 2 12 August 1996 N/A Rev. 3 18 February 1998 N/A Rev. 4 12 February 1999 Rev. 5 N/A N/A Rev. 6 16 September 2009 Rev. 7 27 October 2009 FAA APPROVED BHT-206L4T-MM-1 4-00-00 27 OCT 2009 Rev. 7 Page 3 ECCN EAR99 AIRWORTHINESS LIMITATIONS SCHEDULE 4-1. AIRWORTHINESS LIMITATIONS SCHEDULE WARNING A L L R E P A I R A N D O V E R H A U L PROCEDURE LIVES PUBLISHED BY B E L L H E L I C O P T E R T E X T R O N , INCLUDING COMPONENT RETIREMENT LIFE, ARE BASED SOLELY ON THE USE O F B E L L A P P R O V E D P A R T S A N D P R O C E S S E S . I F P A R T S O R P R O C E S S E S D E V E L O P E D O R APPROVED BY PARTIES OTHER THAN BELL HELICOPTER ARE USED, THEN THE DATA PUBLISHED OR OTHERWISE SUPPLIED BY BELL HELICOPTER ARE N O T A P P L I C A B L E . T H E U S E R I S W A R N E D T O N O T R E L Y O N B E L L HELICOPTER DATA FOR PARTS AND PROCESSES NOT APPROVED BY BELL H E L I C O P T E R. A L L A P P L I C A B L E INSPECTIONS AND REPAIR METHODS M U S T B E O B T A I N E D F R O M T H E S U P P L I E R O F T H E P A R T S O R PROCESSES NOT APPROVED BY BELL HELICOPTER. BELL HELICOPTER IS NOT RESPONSIBLE FOR PARTS OR PRO CE S SE S OTH ER T HAN T HO SE WHICH IT HAS ITSELF DEVELOPED OR APPROVED. The mandatory Airworthiness Limitation Schedule (Table 4-1) summarizes the mandatory maximum life, in hours, years or by Retirement Index Number (RIN) of components with a limited airworthiness life. Parts that are not on the schedule have an unlimited airworthiness life. The Inspection Limitations Schedule (Table 4-2) summarizes the mandatory inspection interval in hours. NOTE The airworthiness life for any part number contained in this schedule applies to all the successive dash numbers for that component unless otherwise specified. Refer to the engine manufacturer’s publications for the airworthiness limitations of the power plant components. WARNING S O M E P A R TS A R E I N S TA L L E D A S O R I G I N A L E Q U I P M E N T O N B O T H M I L I T A R Y A N D C O M M E R C I A L H E L I C O P T E R S A N D M A Y H A V E A LOWER AIRWORTHINESS LIFE AND/OR OVERHAUL SCHEDULE WHEN USED O N A M I L I T A R Y H E L I C O P T E R. I N A D D I T I O N , C I R C U M S T A N C E S SURROUNDING THEIR USE MAY CALL FOR OPERATION OF THE MILITARY H E L I C O P T E R O U T S I D E O F T H E A P P R O V E D C OM M E R C I A L F L I G H T ENVELOPE. CONSEQUENTLY, PARTS THAT HAVE BEEN USED ON MILITARY HELICOPTERS SHOULD NOT BE USED ON COMMERCIAL HELICOPTERS. CAUTION AIRWORTHINESS LIFE OF SOME KIT COMPONENTS IS NOT COVERED IN T H I S S C H E D U L E . R E F E R T O APPLICABLE SERVICE INSTRUCTION ( S I ) O R M A I N T E N A N C E M A N U A L S U P P L E M E N T ( M M S ) F O R K I T COMPONENT SCHEDULES. NOTE The retirement life given, or the failure to give a retirement life to a component, does not constitute a warranty of any kind. The only warranty applicable to the helicopter or any component is the warranty included in the Purchase Agreement for the helicopter or the component. The airworthiness lives given to the components and assemblies are determined by experience, tests, and the judgment of Bell Helicopter engineers. The lives cannot be changed without the approval of the FAA. BHT-206L4T-MM-1 FAA APPROVED 4-00-00 Page 4 Rev. 7 27 OCT 2009 ECCN EAR99 Prior to disposing of unsalvageable aircraft parts and materials, caution should be exercised to ensure that the parts and material are disposed of in a manner that does not allow them to be returned for service. Refer to FAA Advisory Circular 21-38 for guidance on the disposal of unsalvageable aircraft parts and materials. Table 4-1. Airworthiness Limitations Schedule COMPONENT PART NUMBER RETIREMENT LIFE (YEARS/HOURS/RIN) MAIN ROTOR HUB AND BLADES Main Rotor Trunnion 206-011-120-103 24,000 RIN Pin, Strap Retention 206-011-125-001 1200 hours Main Rotor Grip 206-011-132-113 4800 hours Fitting, Strap Retention 206-011-150-105 2400 hours Tension Torsion Strap 206-011-147-007 1200 hours/24 months Tension Torsion Strap 206-011-154-103/-107 1200 hours/24 months Latch Bolt 206-011-260-101 1200 hours Main Rotor Blade 206-015-001-001/-103/-105 3600 hours Main Rotor Blade 206-015-001-107/-109/-111/-113/ 115/-117/-119/-121 3600 hours Main Rotor Blade 206-015-001-125/-127/-129/-131 2300 hours SWASHPLATE AND SUPPORT Tube, Lower Cyclic 206-001-193-001 4800 hours Support Assembly, Swashplate 206-010-445-113 4800 hours Link, Collective Idler 206-010-446-105 1200 hours Link, Collective Idler 206-010-446-107 4800 hours Lever, Collective 206-010-447-105 1200 hours Lever, Collective 206-010-447-109 4800 hours Sleeve Assembly, Collective 206-010-454-107 4800 hours Sleeve Assembly, Collective 206-010-454-109 4800 hours POWER TRAIN Duplex Bearing, Tail Rotor Gearbox 206-040-410-003/-005/-101 3000 hours Mast, Main Rotor 206-040-535-105 5000 hours/44,000 RIN Sun Gear 206-040-662-101 Driveshaft, Main 206-340-300-101 5000 hours TAIL ROTOR HUB AND BLADES Yoke, Tail Rotor 206-011-819-105/-109 5000 hours Blade, Tail Rotor 206-016-201-001/-107 2400 hours 1 21 22 11 11 17 31 31 31 24 25 9 21 23 14 32 FAA APPROVED BHT-206L4T-MM-1 4-00-00 27 OCT 2009 Rev. 7 Page 5 ECCN EAR99 TAIL ROTOR HUB AND BLADES (CONT) Blade, Tail Rotor 206-016-201-113 2400 hours Blade, Tail Rotor 206-016-201-127/-131 2500 hours Blade, Tail Rotor 400-016-100-109/-113 5000 hours Yoke, Tail Rotor 406-012-102-107/-113 5000 hours AIRFRAME Horizontal Stabilizer 206-023-119-167 MISCELLANEOUS KITS Crosstube, Landing Gear, High Gear 206-053-109-ALL Crosstube, Landing Gear, Standard 206-053-119-ALL Reservoir, Pressure Vessel 1271226 15 years Reservoir, Emergency Floats 206-073-848-121 15 years POWER PLANT Turboshaft Engine 250-C20R Refer to Rolls Royce 250-C20R Series Operation and Maintenance Manual, GTP5232-2 NOTES: Airworthiness limitation for part number listed applies to all successive dash numbers for that component unless otherwise specified. RESERVED. RESERVED. RESERVED. RESERVED. RESERVED. RESERVED. RESERVED. Selected serial numbers of main rotor mast 206-040-535-105 will have been returned to Bell Helicopter for metallurgical evaluation no later than 31 May 1987. Affected masts inspected at BHT and found to be acceptable have the suffix “U” added to the serial number. Refer to BHT ASB 206L-87-44, dated 23 April 1987 for list of serial numbers affected. Table 4-1. Airworthiness Limitations Schedule (Cont) COMPONENT PART NUMBER RETIREMENT LIFE (YEARS/HOURS/RIN) 1 15 32 15 16 30 32 36 18 18 28 29 1 2 3 4 5 6 7 8 9 BHT-206L4T-MM-1 FAA APPROVED 4-00-00 Page 6 Rev. 7 27 OCT 2009 ECCN EAR99 NOTES: (CONT) RESERVED. Main rotor hub tension torsion straps 206-011-147 and 206-011-154 have airworthiness lives of 1200 hours or 24 months, whichever occurs first. The calendar life of 24 months starts when new straps are installed in a main rotor hub and blade assembly and are subjected to rotation on the aircraft. Refer to BHT ASB 206L-80-12, dated 2 June 1980. RESERVED. RESERVED. Selected serial numbers of sungear 206-040-662-101 must be removed from service. Refer to BHT ASB 206L-90-69 Revision A, dated 15 January 1991 for list of serial numbers affected. Selected serial numbers of tail rotor blades 206-016-201-113/-127 must be removed from service. Refer to BHT ASB 206L-90-70, dated 27 June 1990 for list of serial numbers affected. Selected serial numbers of tail rotor blade 206-016-201-127 will have been returned to Bell Helicopter for evaluation no later than 30 September 1990. Affected blades inspected at BHT and found to be acceptable have the suffix “M” added to the serial number. Refer to BHT ASB 206L-90-71 Revision A, dated 31 October 1990 for list of serial numbers affected. Selected serial numbers of main rotor latch bolt 206-011-260-101 must be removed from service. Refer to BHT ASB 206L-92-86, dated 3 December 1992 for list of serial numbers affected. Landing gear crosstubes 206-053-109-ALL and 206-053-119-ALL (all dash numbers) will have been removed from service no later than 30 September 1994. Refer to BHT ASB 206L-94-93, dated 11 April 1994. RESERVED. RESERVED. Each component with a retirement life sensitive to torque events will be assigned a maximum Retirement Index Number (RIN). This RIN corresponds to maximum allowed fatigue damage resulting from lifts and takeoffs. A TORQUE EVENT is defined as a takeoff (one takeoff plus subsequent landing = one RIN) or a lift (internal or external). For example, if an operator performs six (6) takeoffs and ten (10) slingloads, this would total 16 torque events; (6 takeoffs = 6 events, 10 slingloads = 10 events, 6 + 10 = 16 torque events total). Pilots are to record total number of torque events for each flight. This allows maintenance personnel to convert torque events to RIN by applying the appropriate RIN Adjustment Factor. Refer to BHT ASB 206L-94-99, Revision B, dated 10 August 2001. A new component will begin with an accumulated RIN of zero, that will be increased as lifts and takeoffs are performed. Operator will record number of lifts and takeoffs (torque events), and increase accumulated RIN accordingly. When maximum RIN is reached or retirement flight hours, whichever occurs first, component will be removed from service. Table 4-1. Airworthiness Limitations Schedule (Cont) COMPONENT PART NUMBER RETIREMENT LIFE (YEARS/HOURS/RIN) 1 10 11 12 13 14 15 16 17 18 19 20 21 FAA APPROVED BHT-206L4T-MM-1 4-00-00 27 OCT 2009 Rev. 7 Page 7 ECCN EAR99 NOTES: (CONT) The retirement life of trunnion 206-011-120-103 is based solely on RIN. Retire trunnion when RIN = 24,000. For each takeoff/lift, add one (1) RIN if the trunnion is installed on 206L, 206L-1 or 206L-3 (includes 206L-3 with Increase Power Operation kit installed per Service Instruction 206-2039) and two (2) RIN if the trunnion is installed on a 206L-4. Refer to BHT ASB 206L-94-99 Revision B, dated 10 August 2001. Retire mast 206-040-535-001/-005/-101/-105 when RIN = 44,000. For each takeoff/lift, add one (1) RIN if the mast is installed on 206L, 206L-1 or 206L-3 (includes 206L-3 with Increase Power Operation kit installed per Service Instruction 206-2039) and two (2) RIN if the mast is installed on a 206L-4. Refer to BHT ASB 206L-94-99 Revision B, dated 10 August 2001. Collective idler link 206-010-446-105, serial numbers A-1 through A-27, inclusively, and serial numbers RE-238 through and including RE-270 will be retired from service at 1200 hours service time. Refer to BHT ASB 206-98-110, dated 6 May 1998. Collective lever 206-010-447-105, serial numbers A-1 through A-22, inclusively, will be retired from service at 1200 hours service time. Refer to BHT ASB 206L-98-110, dated 6 May 1998. RESERVED. RESERVED. Reservoir per DOT-3HT specification and Exemption Letter DOT-E-7218. This reservoir is a detail part of reservoir assembly P/N 206-073-848-121. Life starts from date of manufacture. This reservoir assembly includes reservoir P/N 1271226. Tail rotor blade 206-016-201-127 and subsequent, retirement life increased to 2500 hours. Refer to BHT TB 206L-89-147, dated 2 June 1989. Main rotor blade 206-015-001-ALL. It is permissible to use any main rotor blade (mix and match) on helicopter model 206L, 206L-1, 206L-3, 206L-4, provided that all conditions are met. Refer to BHT TB 206L-87-142, dated 1 October 1987, and information letter IL 206L-00-68 Revision A or subsequent. Tail rotor blade 206-016-201-ALL. It is permissible to use any tail rotor blade on helicopter model 206L, 206L-1, 206L-3, 206L-4 provided that all conditions are met. Refer to BHT TB 206L-94-172. RESERVED. RESERVED. RESERVED. Affected horizontal stabilizer 206-023-119-167 must be removed from service no later than 30 September 2008. Refer to ASB 206L-06-141 for list of horizontal stabilizer serial numbers affected. Applicable horizontal stabilizers must be inspected every 600 hours or annually until replaced. Refer to ASB 206L-06-141 for inspection details. Table 4-1. Airworthiness Limitations Schedule (Cont) COMPONENT PART NUMBER RETIREMENT LIFE (YEARS/HOURS/RIN) 1 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 BHT-206L4T-MM-1 FAA APPROVED 4-00-00 Page 8 Rev. 7 27 OCT 2009 ECCN EAR99 Table 4-2. Inspection Limitations Schedule COMPONENT PART NUMBER INSPECTION INTERVAL (HOURS OPERATING TIME) Tailboom Upper Left Attachment Fitting 206-032-409-001 100 hours NOTES: Inspection limitation for the part number listed applies to all successive dash numbers for that component, unless otherwise specified. You must do an inspection of the tailboom upper left attachment fitting P/N 206-032-409-001 every 100 flight hours. Refer to BHT ASB 206L-09-158 for a listing of affected tailbooms. Refer to Figure 4-1 for inspection details. 1 2 1 2 FAA APPROVED BHT-206L4T-MM-1 4-00-00 ECCN EAR99 Figure 4-1. Tailboom Upper Left Attachment Fitting (P/N 206-032-409-001) — Recurring 100-Hour Inspection 206LS MM 04 0001 INSPECTION PROCEDURE: 1. Inspect upper left attachment fitting for cracks, mechanical damage, corrosion damage, loose rivets, and general condition. 2. Refer to ASB 206L-09-158 for wear, damage, and repair limits. 3. Repair fitting in accordance with ASB 206L-09-158. 4. Replace cracked or damaged fitting or loose rivets in accordance with ASB 206L-09-158. 5. If a crack is found, contact Product Support Engineering with details as follows: Bell Helicopter Textron Product Support Engineering Light Helicopters group Tel: 1-800-243-6407 (Continental USA and Canada) 1-800-363-8023 (Continental USA) 1-800-361-9305 (Within Canada) 1-450-437-2862 (All other areas - Call collect) Fax: 450-433-0272 Email: pselight@bellhelicopter.textron.com (DETAILS OMITTED FOR CLARITY) 27 OCT 2009 Rev. 7 Page 9/10