TECHNICAL

BULLETIN

No. 212-84-84

Bell Helicopter TEXTRON

DATE 2-29-84

DATE
REV.

Post

Office Box 482

For

Worth Texas 76101

PAGE NO.

MODELAFFECTED:

212

SUBJECT:

FLIGHT CONTROL CYLINDER, P/N 212-076005-7, -11, -101, PISTON HEAD SEALS,
REPLACEMENT OF

HELICOPTERS AFFECTED:

Model 212 helicopters, serial numbers

30501 through 31216, 31218 through

31231,

31234,

31235,

and 31247.

[Helicopter serial numbers 31217,

31232,

31233, 31236 through31246, and 31248

and subsequent will have the intent of

this bulletin accomplished prior to
delivery.]
COMPLIANCE:

Part 1:

Part II:

At the next Preflight Check of the

Hydraulic System and each Preflight
Check thereafter until compliance
with Part II.
Recommend at the next overhaul or
repair of the flight control cylinder.

DESCRIPTION:
Reports from helicopter operators indicate early deterioration
of the piston head seals used in flight control cylinder
assembly, P/N 212-076-005-7,
-11, and -101. This condition may
result in cylinder motoring, sluggish operation or erratic
control.
The attached HR Textron Service Bulletin,FMTC No. 260, provides
instructions for installing modification kit KC48088996UN.
This kit replaces the existing piston head seals with a new
seal, P/N S30772-124G20N,
or P/N CEC6601-124-75.
The kit
installation will result in extended seal wear life and
improved service life of the flight control cylinder.
FAA APPROVAL:
The engineering design aspects reflected in the attached HR
Textron Service Bulletin FMTC No. 260 are FAA approved.

AN APPROPRIATE
ENTRY
SHOULD
MADE IN THE AIRCRAFT LOG BOOK UPON ACCOMPLISHMENT
IF OWNERSHIP OF AIRCRAFT HAS CHANGED PLEASE FORWARD TO NEW OWNER

T.B. 212-84-84
Page

2 of

MANPOWER:
Manhours are based on "hands-on" time.
accomplish the required maintenance task
manpower and facilities available.
Part

I.

No

appreciable

additional

time

perform cylinder operational

Hydraulic Preflight Check.
Part

II.

Elapsed time to
may vary due to
is

checks

required

to

during the

Approximately five (5) manhours are required to

accomplish Part II of this bulletin. If seals are
replaced during flight control cylinder overhaul,
no
additional
time
is
required for their
installation.

MATERIAL:
See attached HR Textron Service Bulletin.
SPECIAL TOOLS:
See attached HR Textron Service Bulletin.
WEIGHT AND BALANCE:
Not affected.
ELECTRICAL LOAD DATA:
Not affected.
REFERENCES:
Flight Control Cylinder Assembly Overhaul Manual, HR Textron
Part Number 41000470
(BHT P/N 212-076-005).
HR Textron Service Bulletin FMTC No. 260.
Model 212 Maintenance Manual.
Model 212 Flight Manual (ALL).
BHT Technical Bulletin No. 212-80-45.
PUBLICATIONS AFFECTED:
Flight Control Cylinder Assembly Overhaul Manual,
Part Number 41000470 (BHT P/N 212-076-005).

HR Textron

T.B. 212-84-84
Page

3 of

ACCOMPLISHMENT INSTRUCTIONS:
Part

1.

I.

Perform the Preflight Check of the helicopter Hydraulic

System in accordance with the appropriate Model 212 Flight
Manual.
While performing the check, attentiveness should
be given to the detection of any abnormal control motions
due to improper flight control cylinder operation. If
cylinder motoring, erratic control, or sluggish operation
is detected, remove cylinder(s) from service and accomplish
Part II.

Part II.

1.

Remove cyclic and collective flight control cylinders from

the helicopter in accordance with the Model 212 Maintenance
Manual, Chapter 27.

2.

Replace the piston head seals in the flight control

cylinder assemblies, P/N 212-076-005-101, and all other
previous dash numbers that have been modified per Technical
Bulletin No. 212-80-45, in accordance with the attached HR
Textron Service Bulletin FMTC No. 260.

3.

Install cyclic and collective flight control cylinders in

the helicopter in accordance with the Model 212 Maintenance
Manual, Chapter 27.

HR
SERVICE

BULLETIN

REPLACEMENT OF PISTON HEAD SEALS CEC5071-124-55

ON FLIGHT CONTROL CYLINDER ASSEMBLY
41000470-005, -009, -011, OR -013
FAA 4861

1.

FMTC NO. 260

Planning Information
A.

Effectivity

This Service Bulletin affects flight control cylinder assembly

BHT 212-076-005-101 (HRT 41000470-013), and all other previous dash
numbers that have been modified in accordance with Service Bulletin FMTC
No. 247.
B.

Reason

Recent field reports indicate a deterioration and disintegration of the

piston head seal, causing motoring, erratic control, and/or sluggish
operation.
C.

Description
HR Textron,

has available

upon request,

a new replacement

seal,

S30772-124G20N or CEC6601-124-75. During each preflight check, if any

motoring, erratic control or sluggish operation is detected, the flight
control cylinder assembly should be removed from the helicopter and
modified in accordance with this Service Bulletin.
D.

Approval

HR Textron Engineering:
E.

Manpower

Approximately 1.5 manhours are required to modify one shipset.

F.

Material

Modification Kit KC48088996UN for replacement of piston head seals may be

obtained from HR Textron, 25200 W. Rye Canyon Road, Valencia, CA 91355,
Attention: Product Support Department.
G.

Tooling

Installation Tool T556-33 and Sizing Tool T557-14.

Oct 31/83

Page

1 of 6

25200 West Rye Canyon Road * Valencia, California 91355 * 805/259-4030 * TWX 910/336/1438 * TELEX 65/1492

HR

FAA 4861

H.

NO. 260

FMTC

Weight and Balance

Not affected.

I.

Electrical

Load Data

Not affected.
J.

References

Flight Control Cylinder Assembly Overhaul Manual 41000470

(BHT 212-076-005).
K.

Publications Affected
Flight Control Cylinder Assembly Overhaul Manual 41000470
(BHT 212-076-005).

2.

Accomplishment Instructions:
A.
B.

Remove lockwire securing four screws (1, figure 1).

Remove

four screws

(1) and end cap (2) from piston

(3).

Do not disturb

components on end cap (2).

C.

Slide cylinder (5) towards upper servo head assembly (6) to expose piston
head

D.

seal

(4).

Remove and discard existing piston head seal. Using Seal Installation
Tool T556-33, carefully install and properly seat and form new piston head
seal

(4), Part Number

S30772-124G20N

(or alternate

CEC6601-124-75)

groove on piston (3), prior to using sizing tool.

Tool
E.

T557-14,

Slide cylinder

size and form

(5) back over

new piston
piston

head

seal

head seal

into

Using Sizing
(4).

(4), using

care

not to cut

or deform piston head seal (4).

F.
G.

Install end cap (2) over piston (3) and onto cylinder (5).
Install

and secure

four

screws

(1).

Torque

screws

to 50 inch-pounds.

Safety wire four screws together per MS33540 using lockwire MS20995C32.
H.

Remove lockwire securing four screws (7, figure 1).

Oct 31/83

Page

2 of 6

FAA 4861

FMTC NO. 260

I.

Remove four screws (7) and slide end cap (8) from lower servo head.
not remove end cap (8) from piston (9).

J.

Remove piston (9) from lower servo head assembly (10).

K.

Remove and discard existing piston head seal. Using Seal Installation
Tool T556-33, carefully install and properly seat and form new piston head
seal (4), Part Number S30772-124G20N (or alternate CEC6601-124-75) into
groove on piston (9), prior to using sizing tool. Using Sizing
Tool T557-14,

L.

size and form new piston

seal

(4).

Slide piston (9) back into lower servo head assembly (10), using care not
to cut or deform

M.

head

Do

piston

head

seal

(4).

Slide end cap (8) into lower servo head assembly (10), and secure with
four screws (7). Torque screws to 50 inch-pounds. Safety wire four

screws together per MS33540using lockwire MS20995C32.

N.

Identify modification plate (12) with applicable serial numberand the

letter G, and install around center of lower servo head assembly (10).
Carefully form modification plate to contours of lower servo head assembly
and secure with RTV 3145.

O.

Testing.

Three Optional Testing Methods:

Option 1.

Utilization of a test stand capable of supplying 2250 psi.

This is the preferred option.

Option 2.

External hydraulic supply connected to helicopter after

installation of actuators.

Option 3.

Utilization of the helicopter hydraulic supply after

installation of actuators. This option should be used only as
a last resort

or emergency

situation.

A satisfactory

installation of the seal cannot be verified with this option

during ground test.
P.

Testing Procedure Options:

Option 1.

Connect flight control cylinder assembly to test stand.

(a)

Connect both systems pressure and return lines.

500 psi to pressure

(b)

Oct 31/83

Apply

ports.

Cycle actuator five full stroke cycles to ensure actuator

and system are free of air.

Page 3 of 6

HR

FAA 4861

FMTC NO. 260

(c)

Block return line and apply 2250 psi proof pressure.

Hold input lever in neutral, full extend, and full
retract positions for a minimum of 1 minute in each

position.
Requirement - There shall be no evidence of external
leakage, permanent deformation or loosening
of parts.
(d)

Connect

a drip

1000 psi.
input

lever

spout

to each

return

port and apply

Monitor leakage out each return port with

at neutral,

full extend,

and full retract.

Requirement - Leakage shall not exceed 80 cc/min in

either position.
(e)

times to monitor external leakage from

Cycle actuator 50
end caps.

Requirement - Leakage shall not exceed four drops from

either seal.
(f)

Verify

seal leakage

in the innerconnect

housing

(11) by

extending piston (9) to full extend position and hanging

actuator in vertical position with lower servo head
assembly (10) down, for 15 minutes.
vent hole in end of piston (9).

Check

for leakage

at

Requirement - Leakage shall not exceed four drops from

the vent hole.
(g)

Apply 500 psig to PRESS ports and cycle unit several

times to purge all air, then close PRESS and RETURN ports
so that all ports

are blocked

and unit

is full of fluid.

Shift input lever to full extend, then full retract and

note amount of force required at the pilot input to
manually move actuator through full excursions (extend to
retract, then retract to extend).
Requirement - With input lever shifted to full extend or
full

retract,

actuator

shall

be capable

of

being manually moved through full excursion

with a force not exceeding 31 pounds.
(h)

If actuator

meets

all of the above

requirements,

it is

considered acceptable.

Oct 31/83

Page 4 of 6

FAA 4861

FMTC NO. 260

Option 2.

Install actuator on helicopter and connect hydraulic ground

power
(a)

cart.
Adjust

external

hydraulic

supply to 1000 psi system

pressure.
(b)

Move cyclic and collective controls through full

stroke. Observe actuator for leakage and monitor for
motoring, erratic control or sluggish operation.
Reference hydraulic system check in BHT Flight Manual.

(c)

Further
checked
Option

verification
of satisfactory assembly can be
by removing return lines and test per Step (d) in
1.

Requirement - If there is no motoring, erratic control or

sluggish operation and/or the leakage
requirements are within limits, the
actuator is considered acceptable.
Option 3.

This option should only be performed in an emergency.

(a)

Install

(b)

Move cyclic

actuator

on helicopter.

and collective

controls

through

travel

as

described in BHT Flight Manual, hydraulic system check.

Check for motoring, erratic control and/or sluggish
operation.
Requirement - If any of the above conditions exist,
remove actuators and repair as required.

Oct 31/83

Page 5 of 6

HR

FAA 4861

FMTC NO. 260

SCREw 1
END CAP 2

3 PISTON

*PISTON HEADSEAL4
PART NUMBER
30772-124G20N
(OR ALTERNATE
CEC6601-124-75)

-5

CYLINDER-

11 INTERCONNECT HOUSING

6 UPPER
SERVIC
HEAD ASSEMELY

LOWERSERVO 10
HEAD ASSEMBLY

12 MODIFICATIONPLATE

*PISTON HEADSEAL4PART NUMBER

S30772-124G20N
(OR ALTERNATE
CEC6601-124-75'

9 PISTON

END CAP8

Figure 1.

Oct 31/83

Piston Head Seal Installation Data

Page 6 of 6