ISLAMIC REPUBLIC OF IRAN ARMY AVIATION TRAINING CENTER

ARMY AVIATION ACADEMY

ISFAHAN-IRAN

TECHNICAL INSTRUCTION GROUP

BOOK 2
SINGLE ROTOR SINGLE ENGINE AIRCRAFT
 ‫بسمه تعالي‬

‫کتاب شماره دو (‪ )2‬دوره تک ملخ تک موتور‬ ‫عنوان کتاب‪:‬‬

‫ستوان فني هوایي محمذرضا صیاد‪ -‬ستوان فني هوایي علیرضا عبذالونذ‬ ‫گردآورنذگان‪:‬‬

‫سرهنگ فني هوایي علیرضا موسوي‬ ‫بازنگري کننذه‪:‬‬

‫سرگرد فني هوایي فضلعلي مرادي‬ ‫ویرایش علمي‪:‬‬

‫سرگرد فني هوایي علیرضا اسذي‬ ‫ویرایش ادبي‪:‬‬

‫ستوان فني هوایي محمذرضا صیاد‬ ‫روان نویسـي‪:‬‬

‫سرهنگ فني هوایي علیرضا موسوي‬ ‫ناظر تخصصي‪:‬‬

‫سرهنگ خلبان نویذ یارمنذ‬ ‫کنترل نهایـي‪:‬‬

‫سرگرد خلبان امیذ سیاح البرزي‬ ‫نمونه خوانـي‪:‬‬

‫ستوان دوم اداري احمذ صالحي‬ ‫ویراستار ‪:‬‬

 FILE NO: 25191X
SINGLE ROTOR SINGLE ENGINE
TABLE OF CONTENTS
CHAPTER TITLE PAGE
8 Main rotor system 8-1
8-1 General description of 206 main rotor assembly 8-1
8-2 Main rotor hub and blade assembly 8-4
8-3 Main rotor hub 8-6
8-4 Vibration analysis (206 helicopter) 8-10
8-5 205 main rotor hub and blade assembly 8-11
8-6 Tracking main rotor blades 8-15
8-7 Main rotor system, description, purpose and components of 214
main rotor system 8-17
9 Swashplate and support system 9-1
9-1 Swashplate support assembly (Rotary control) 9-1
9-2 Swashplate components 9-4
9-3 Swashplate friction measurement 9-10
9-4 205 collective hub and sleeve assembly 9-11
9-5 Swashplate assembly 9-11
9-6 214 main rotor control 9-13
9-7 214 swashplate and support assembly 9-14
9-8 Scissors and sleeve assembly 9-17
10 Transmission and mast 10-1
10-1 206 Transmission and mast 10-1
10-2 206 Transmission 10-4
10-3 206 Transmission oil system 10-7
10-4 206 Main mast 10-13
10-5 214 Main transmission and mast 10-14
10-6 Main transmission oil system 10-20
10-7 Main transmission mounts 10-24
10-8 Mast assembly 10-25
I
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CHAPTER TITLE PAGE
10-9 205 Transmission assembly 10-26
10-10 Mast assembly 10-32
11 Powertrain system 11-1
11-1 206 Drive train system (Powertrain) 11-1
11-2 206 Main drive shaft 11-2
11-3 206 Freewheeling unit 11-3
11-4 206 Tail rotor drive shaft 11-6
11-5 206 Oil cooler fan and shaft 11-8
11-6 206 tail rotor gearbox and pitch change mechanism 11-9
11-7 214 Main drive shaft 11-12
11-8 Intermediate (42º) gearbox 11-19
11-9 Tail rotor (90º) gearbox 11-21
11-10 205 Powertrain system 11-23
11-11 Main drive shaft 11-23
11-12 205 tail rotor drive shafts 11-24
11-13 Hanger bearings (4) 11-24
11-14 Intermediate gearbox (42 degree) 11-24
11-15 Tail rotor gearbox (90 degree) 11-25
12 Tail rotor system 12-1
12-1 General description of 206 tail rotor 12-1
12-2 Tail rotor hub and blade components 12-3
12-3 Tail rotor hub 12-5
12-4 General description of 205 tail rotor blade 12-8
12-5 Tail rotor 12-9
12-6 Tail rotor blade assembly 12-9
12-7 The tail rotor hub assembly is made up of the following components 12-9
12-8 Tail rotor trunnion 12-10
12-9 Trunnion bearing housings 12-10
12-10 Tail rotor yoke 12-10
II
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CHAPTER TITLE PAGE
12-11 Tail rotor blade grips 12-11
12-12 Tail rotor bearings 12-11
12-13 Description of 214 tail rotor 12-13
12-14 Blade assembly- All metal construction 12-16
12-15 Cross head assembly 12-17
13 Hydraulic system 13-1
13-1 General description of 206 hydraulic system 13-1
13-2 Hydraulic system components 13-2
13-3 Hydraulic test stand 13-8
13-4 Inspect hydraulic system 13-8
13-5 205 Hydraulic system components 13-9
13-6 214 Hydraulic system 13-15
13-7 System components 13-16

APPENDIX A COMPREHENSION CHECK PAGE

Main rotor system A-1
Swash plate and support system A-2
Transmission and mast A-3
Power train system A-4
Tail rotor system A-5
Hydraulic system A-6

III
 ISLAMIC REPUBLIC OF IRAN ARMY AVIATION TRAINING CENTER
ARMY AVIATION ACADEMY
ISFAHAN-IRAN

TECHNICAL INSTRUCTION GROUP

FILE NO: 25191X

TRAINING OBJECTIVES
SINGLE ROTOR SINGLE ENGINE

a. TASK: The student will be able to:

(1) Explain the operation of the Main rotor, Swashplate ,XMSN and
Mast,Powertrain ,Tail rotor and Hydraulic system of 206,205 and 214.
(2) Identify and locate the equipment’s and parts of the 206, 205 and 214 Main
rotor, Swashplate ,XMSN and Mast,Powertrain ,Tail rotor and Hydraulic
system.
(3) Inspect, remove and install components and parts of the 206, 205, and 214
Main rotor, Swashplate ,XMSN and Mast, Powertrain ,Tail rotor and
Hydraulic system.

b. CONDITION: In the classroom with the aid of the student outline or related book
and in the hangar under supervision of an instructor with the aid of an instructor
assistant.

c. STANDARD: 70% Accuracy.

IV
 FILE NO: 25191X-8-54
CHAPTER 8
SINGLE ROTOR SINGLE ENGINE
MAIN ROTOR SYSTEM
8-1 General description of 206 main rotor assembly:
(a) The main rotor assembly is a two bladed, semi-rigid, under slung, see-
saw type,feathering axis.

8-1
 FILE NO: 25191X-8-54
(b) It employs preconing to insure smooth operation, greater stability and
ease of maneuver in all flight operation.
(c) The main rotor assembly consist of:
1 Two all metal blades.
2 The blades are connected to a common yoke through blade grips
3 The grips are retained on the yoke by means of tension torsion
straps.(T.T.S)
4 The rotor assembly is attached to the mast through a trunnion
mounted on pillow blocks to provide a flapping axis and is
secured to the mast by a retaining nut.(Mast nut)

8-2
 FILE NO: 25191X-8-54
5 A set of split cones installed in a groove on the mast supports
the trunnion and rotor assembly.
6 A flap restraint kit is installed on top of the trunnion assembly.
7 Flap restraint kit incorporates counter weights and springs .
8 it prevents excessive flapping of the main rotor during starting
and shut-down but allows flapping at normal operation RPM.

8-3
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8-3A
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8-2 Main rotor hub and blade assembly:
(a) Main rotor blades:
1 The main rotor blade are all metal, five pieces assembles:
a Main spar.
b Honeycomb core.
c Trailing edge (Aluminum alloy).
d Butt plates and doublers.
e Skin sheets.
f Trim tab.
g Tracking tip.

8-4
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2 Blades bonded under heat and pressure.
3 There are four weights installed on the blade:
a Brass tip weight.
b Lead span wise (Mid span weight).
c Factory span wise (Balance weight).
d Factory chord wise (Balance weight).

4 Field repairs:
a Blades can be cleaned with hot, soapy water.
b Blades can be waxed with hard polish.
c They can be repaired in accordance with -2,-3 TM.

8-5
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8-5A
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8-3 Main rotor hub:
(a) Description:
1 Driven by power plant through transmission.
2 1 rotor rotation equal 15.22 engine rotations.
3 394 rotor RPM to 6000 engine output RPM.
4 Two grips.(blade grip)
5 Semi-rigid.
6 See-saw.
7 Under slung feathering axis.
8 Hub attached to main rotor drive shaft.(Mast)
9 Main rotor retention nut.(Mast nut)
10 Split cone set.

8-6
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(b) Components.
1 Trunnion:
a Made of steel.
b Flat on top.
2 Pillow block made of aluminum alloy:
a Pillow block serviced with 10W-30 oil, service to half full.
3 Yoke:
a Made of steel.
b Has two Spindles and preconed 2 ½ degrees up.

4 Tension torsion strap :(T.T.S)

a Made of approximately three Miles of fine steel wire.
b Wire is covered with urethane coating to protect against
corrosion.
c Has a steel fitting with hole in the fitting at each end.
d Tension torsion straps take the direct tensional loading of
the main rotor blades.
5 Latches
a Latch pin(Latch Bolt) made of steel.
b Two latches.
c Two latch springs.
d Two latch nuts.
e Trailing edge latch nut is loosened for blade removal.
8-7
 FILE NO: 25191X-8-54

7 Blade grip: made of aluminum alloy.

8 Pitch change horn:
a Bolted to grip with three bolts.
b Reservoir is serviced with 10W-30 oil to half full.
9 Pitch trunnion bearing:
a Attached to pitch horn on leading edge.
b Two kinds:
(1) Teflon self-aligning bearing. Does not require
lubrication.
(2) Lubricated bearing, requires lubrication every 100
flight hours, has needle nose grease fitting on top
of bearing.

8-8
 FILE NO: 25191X-8-54
10 Blade retention bolts:(retaining bolt)
a Made of steel.
b Hollow for span wise weights.

11 Static stop: made of aluminum alloy:

a Bolted to bottom of yoke.

8-9
 FILE NO: 25191X-8-54
8-4 Vibration analysis (206 helicopter):
(a) The only sources of vibrations are the rotating or moving part on the
helicopter.
(b) Other parts may vibrate in related with the rotating or moving parts.

(c) All types of vibrations are caused by the rotor or dynamic controls.
(d) There is always a small amount of vibration present on the helicopter:
1 Flight experience is necessary to learn the normal vibration
levels.
2 Even experienced pilots sometimes make the mistake of
concentrating on feeling one specific vibration.

(e) Type of main rotor vibration:

1 Vertical vibration- it is caused by out of track rotor system:
a Vertical vibration is sensitive to air speed.

2 Lateral vibration- it is caused by out of balance condition:

a Lateral vibration is divided in two methods span wise and
chord wise unbalance.
b Lateral vibration is sensitive to RPM.

8-10
 FILE NO: 25191X-8-54
8-5 205 main rotor hub and blade assembly:
(a) Description- semi-rigid under slung feathering axis:
1 Trunnion and split cones master splined flapping axis for main
rotor hub mounts, main rotor hub on mast cones, align and
support main rotor hub to mast.
2 Pillow blocks- allow flapping of the hub with needle bearings,
attach hub to trunnion self contained lube system.

8-11
 FILE NO: 25191X-8-54
3 Yoke made of steel and serve as the feathering axis for main
rotor grip.
4 Grips and bearings- grip houses 2 sets of needle bearings blade
attachment point self contained tube system allows feathering of
blades.

8-12
 FILE NO: 25191X-8-54
5 Tension torsion strap and retention nut holds grip to yoke.
Tension torsion strap used for tension on main rotor blade for
angle of attack as pitch is increased and aids in return when
pitch is decreased.

6 Oil reservoir and seal- inboard side, Plexiglass with filler, serves
as sight glass, serviced with MIL-L-7808 or MIL-L-23699.

7 Drag brace- adjustable turnbuckles, are used to hold blade in

alignment.

8 Main rotor blades:

a Blades- honeycombed aluminum.
b D-Spar-determines contour of leading edge and is main
strength member of blade.
c Nose block- for mass balance and absorbs shock.

(b) Inspection of main rotor hub and blades inspect for nicks, scratches,
dents, cracks in plating of metal parts, seals for leaks, cleanliness of
lubricant, sight gages for cracks and security, safeties, etc.

8-13
 FILE NO: 25191X-8-54

8-13A
 FILE NO: 25191X-8-54

8-13B
 FILE NO: 25191X-8-54
(c) Service:
1 Lubrication- use MIL-L-7808 or MIL-L-23699 turbine engine
oil in pillow blocks and blade grips. Filling pillow blocks full
and blade grips half full (up to bolts).

2 Repair- clean inboard seals, replace faulty or leaking reservoirs,

burnish out nicks, dents, scratches. Flush grips.

3 Replacement- remove and replace when inspection criteria is not

met, excessive leakage at blade grip seals or time change:
a Aids pilot in control of rotor disc.
b Dampens collective and cyclic forces.
c Mounted on trunnion with 8 bolts.

4 Support has pivot point for stabilizer bar:

a Bolt heads are inboard.
b Pivot bearing allows flapping of stabilizer bar.

5 The frame is 2 piece aluminum alloy:

a Has attachment point for damper rods.
b Has attachment point for mixing levers and tubes.

6 The mixing levers receive control forces from control tubes,

control stabilizer bar and transmit control forces to pitch
change links.

7 The pitch change links control feathering of main rotor blades

by transmitting push-pull motion from mixing levers to pitch horn.

8-14
 FILE NO: 25191X-8-54

8-14A
 FILE NO: 25191X-8-54
8 Stabilizer bar tubes are constructed of chrome moly steel, holds
weights:
a Weights are steel, weight about 4 pounds.
b Weight lock nut, safetied with safety wire.
c A safety cable is inside the tube assembly.
d It is bolted on inboard end of tube.
e Used in event of tube failure to prevent loss of weight.

9 Control tubes- transmit cyclic and collective control-1 from

scissors assembly to mixing levers.

10 Damper rods- attach to stabilizer bar frame and dampers:

a Inspect for nicks, scratches, cracks security, etc.
b Maintenance- replace components or intire bar.

8-6 Tracking main rotor blades:

“Run-up of helicopter shall be performed by authorized personnel”:
(a) Both trim tabs at trail.
(b) Coat the tracking tips of each blade with grease pencil, using different
color on each blade tip.

(c) Take a low speed blade track (6,000 RPM).

(d) Correct a low speed out-of-track condition by rolling up the low blade
as follows:
1 Loosen barrel nuts on pitch change link on low blade.
2 Turn pitch link barrel one flat at a time to shorten pitch change link.
3 One flat rotation of barrel will result in approximately 3/8 inch
in blade track.
4 Tighten jam nuts and lock wire barrel to nuts.
5 Recheck track, continue adjustment until blades are in track.
8-15
 FILE NO: 25191X-8-54

8-15A
 FILE NO: 25191X-8-54

8-15B
 FILE NO: 25191X-8-54
(e) Take high speed track check at 6,600 RPM:
1 Designate one blade “A” and the other blade “B”. Use these to
keep a running account of adjustments.

2 Vertical vibration (6,000 low track):

a If vertical vibration is felt after good low track, make roll
adjustment.
b Roll high blade “A” down.

c Continue roll of high blade down until air speed is 70

knots or above (1/4 flat increments).
d Tab low blade “B” up until flight track is acquired (see
tab table).

3 Lateral vibration:
a Place two wraps of 2 inch tape on either blade.
b If better continue adding tape until satisfactory.
c If worse remove tape and place on other blade.

d Continue adding tape until satisfactory.

e Remove tape from blade and count wraps.
f Remove cap from retaining bolt on taped blade.

g For every complete wrap of two-inch wide masking tape

add 3.4 ounces of lead in bolt.
h Reinstall and lock wire cap.

8-16
 FILE NO: 25191X-8-54

8-16A
 FILE NO: 25191X-8-54
8-7 Main rotor system, description, purpose and components of 214 main
rotor system:
(a) Description: The main rotor system is a 50 foot, two (2) bladed, semi-
rigid, see-saw type, under slung and feathering axis:
1 Consists of two (2) rotor blade assemblies, main rotor hub
assembly, and main rotor control assembly.

8-17
 FILE NO: 25191X-8-54
(b) Purpose: Provides the lift and thrust forces for flight of the helicopter:
1 Change a linear control into rotating control.

8-18
 FILE NO: 25191X-8-54
(c) Components: Main rotor blade assemblies (2):
1 Description: The main rotor blades are of an all metal
construction and are interchangeable.

2 They weigh approximately 400 pounds each with 33 inch chord

line.

3 Purpose- produces the lift and thrust forces for the helicopter.
4 Components: Spar:
a Description- constructed of aluminum and forms the
leading edge of the blade.

b Purpose:
(1) The spar is the main supporting member (strength)
of the blade.

(2) Forms the leading edge of the blade.

(3) Provides the attachment point for the rest of the
blade components.

8-19
 FILE NO: 25191X-8-54

8-19A
 FILE NO: 25191X-8-54
c Skin (trailing Edge):
(1) Description- constructed of aluminum and
bonded to the aft end of the spar and to the
honeycomb core.

(2) Purpose- forms the airfoil (blade) section

between the spar and the trailing edge strip.

d Trailing Edge strip:

(1) description- constructed of aluminum and bonded
to aft end of the trailing edge (skin).

(2) Purpose- provides closure and strength to aft end

of the trailing edge (skin).

e Honeycomb core:
(1) Description- constructed of aluminum and bonded
between the skin. (trailing edge).

(2) Purpose- forms and strengthens the skin (trailing

edge).

f Stainless steel strip:

(1) Description- constructed of stainless steel and
bonded to the forward end (leading edge) of the
spar.

(2) Purpose- provides resistance to abrasion for

leading edge of the spar from sand, dirt, etc.

8-20
 FILE NO: 25191X-8-54

8-20A
 FILE NO: 25191X-8-54
g Inboard end:
(1) Description- the inboard end is reinforced with
aluminum doublers, grip plates, and drag plates.

(2) Purpose- provides added strength for inboard end.

h Tip cap:
(1) Description- constructed of aluminum and bonded
to outboard end of the spar and skin (trailing
edge).

(2) Purpose- provides closure of the outboard end of

the blade for a better airflow.

I Factory balance weights:

(1) Description- installed on the tip and inboard end of
the blade during master balancing at the factory.

(2) Purpose- factory balancing provides for main rotor

blade interchange ability.

8-21
 FILE NO: 25191X-8-54

8-21A
 FILE NO: 25191X-8-54
5 Main rotor hub assembly:
a Description- consists of a yoke and trunnion assembly,
two (2) grips and spindle assemblies, and two (2) drag
brace assemblies.
b Purpose- provides the flapping axis and feathering axis
(pitch change) for the main rotor blades.
c Components: Yoke and trunnion assembly:
(1) Description- consists of a yoke, trunnion, and two
(2) trunnion supports (pillow blocks).

8-22
 FILE NO: 25191X-8-54
d Purpose- provides the attaching point for the grip and
spindle assemblies:
(1) Provide the flapping axis for the main rotor blades.
(2) Provides for the attachment of the main rotor
assembly to the mast.

e Description- constructed of titanium:

(1) Forms the attaching points for the trunnion
supports (pillow blocks).
(2) Forms the attaching points for the grip and spindle
assemblies.
(3) Flapping stop bolted to bottom.

f Purpose- provides the attaching points for the trunnion

supports:
(1) Provides the attaching points for the grip and
spindle assemblies.
(2) Provides the flapping stop for main rotor system.

g Description- trunnion constructed of steel:

(1) Master splined to the mast for alignment.
(2) Secure to mast by the mast nut and a split cone set.

h Purpose- provides the alignment of the main rotor hub to

the main rotor controls:
(1) Provides the mounting of the main rotor hub to the
mast.
(2) Provides for mounting of chord wise balancing
weights.

8-23
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8-23A
 FILE NO: 25191X-8-54
I Trunnion supports (pillow blocks):
(1) Description- constructed for steel with elastomeric
bearings:
(a) Elastomeric bearings are for blade flapping.
(b) Elastomeric bearings require no lubrication.
(c) Mounted to the yoke and supports the yoke.

(2) Purpose- provide support for the yoke:

(a) Provides the flapping axis through the
elastomeric bearings.

j Grip and spindle assemblies:

(1) Description- Each grip and spindle assembly
consists of a grip, a spindle, and a tension torsion
strap.
(2) Purpose- provides the attaching point for the main
rotor blades:
(a) Provides feathering axis (pitch change) for
the main rotor blades.

(b) Counteract aerodynamic forces which tend

to change the main rotor blade pitch.

(3) Description- Grip consists of an oil reservoir sight

gage, a magnetic plug, a set of needle bearings, an
elastomeric seal, a pitch horn, and a blade
retention bolt:
(a) Attach to spindle by the tension torsion
strap on a set of needle bearings.

8-24
 FILE NO: 25191X-8-54

8-24A
 FILE NO: 25191X-8-54
(4) Purpose- provides the mounting point for the main
rotor blades:
(a) Provides pitch changing (feathering axis)
for the main rotor blades.

(5) Components- oil reservoir sight gage:

(a) Description- mounted on each grip,
serviced with 10W-30 weight (MIL-L-
46152) oil until ½ full on the sight gage
(4 quarts).

(b) Purpose- to indicate the account of

lubricating oil in the grip.

(6) Description- magnetic plug mounted on the

bottom of each grip:
(a) A magnetic type plug that will collect metal
particles inspect every 300 flying hours
(normal).

(b) Purpose- indicates needle bearing damage

and / or wear.

(7) Needle bearings- description a set of needle

bearings are installed between the grip and spindle:
(a) Purpose- permits the grip to rotate
independent of the spindle for main rotor
blade pitch change (feathering) axis.

8-25
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8-25A
 FILE NO: 25191X-8-54
(8) Elastomeric seal: Description mounted on the
inboard end of the grip and to the spindle:
(a) Used to retain the oil in the grip and spindle
assembly acts as a dust cover.

(b) Purpose- prevents oil leakage protects the

needle bearing from dust, dirt, etc.

(9) Pitch horn- description attached to the aft end of

each grip inboard end attached to pitch change
link:
(a) Purpose- transmits the movement of the
flight controls from the pitch change link to
the grip.

(10) Blade retention bolt description- Hollow steel bolt

installed from the bottom. Used to hold the main
rotor blades to the grips. Span wise balance
weights are installed in the hollow portion:
(a) Purpose- attaches the main rotor blades to
the grips. Permits span wise balance of the
main rotor.

(11) Spindle description- attached to the yoke and acts

as a pivot for the grip.
(a) Purpose- provides for the attachment of the
grip and spindle assembly to the yoke.
(b) Provides a pivot point for the grip.

8-26
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8-26A
 FILE NO: 25191X-8-54
(12) Tension torsion strap:
(a) Description- installed inside of the attached
to the inboard end of the spindle by a
retaining pin. Attached to the outboard end
of the grip by a retaining pin.

(b) Purpose- provides for the attachment of the

grip to the spindle. Counteracts
aerodynamic forces which tends to change
the main rotor blade pitch.
(13) Drag braces- Description attached to the aft end
of the main rotor blade and aft end of the grip.
Adjustable to provide for main rotor blade
alignment:
(a) Purpose- to adjust and retain the main rotor
blade in alignment.

8-27
 FILE NO: 25191X-9-36
CHAPTER 9
SINGLE ROTOR SINGLE ENGINE
SWASHPLATE AND SUPPORT SYSTEM
9-1 Swashplate support assembly (Rotary control):
(a) Description and location- the swashplate and support assembly encircle
the mast directly above the transmission.
(b) The swashplate is mounted on a pivot sleeve (universal support) which
permits tilting in any direction.
(c) Purpose- changes the non-rotating control of cyclic and collective
movement to main rotor assembly rotating control by lowering or
raising the swashplate.

9-1
 FILE NO: 25191X-9-36
(d) Swashplate assembly:
1 The swashplate and collective sleeve mount on support.
2 The support is mounted on top of transmission.
3 Sets on top of the mast bearing inner plate.
4 Secured to the transmission by eight studs.

9-2
 FILE NO: 25191X-9-36
5 Movement of collective lever operates the collective sleeve.

6 Collective sleeve raises and lowers the inner and outer ring
causing vertical rise and descent of helicopter.

7 Cyclic control causes tilting of the inner and outer ring, Causes
forward, left, and right and rearward movement of the helicopter.

8 Swashplate consists of the following parts:

a Drive link.
b Protective boot.
c Outer ring.
d Inner ring.
e Collective sleeve.
f Collective lever.
g Compensating links.
h Support.

9-3
 FILE NO: 25191X-9-36

9-3A
 FILE NO: 25191X-9-36
9-2 Swashplate components:
(a) Drive link- has three major parts:
1 Mast drive collar set:
a Two piece.
b Internally splined to mast.
c Has top and bottom.
d Bottom has extended groove lip for safety of rubber boot.
e Drives idler link.
f Has two steel flanged bushings.
g Two halves held together by two bolts.
h Driven by second set of mast splines.
2 Idler Lever:
a Forged aluminum alloy.
b “H” shaped.
c Has four (4) Teflon lined bearings.
d Connects drive link to collar set.
3 Idler link assembly:
a Forged aluminum alloy.
b Provides drive for the outer ring.
c Two steel flanged bearings.
d One Teflon outer race self-aligning bearing.

9-4
 FILE NO: 25191X-9-36

(b) Protective boot:

1 Installed between collar set and outer ring cap.
2 Acts as dust and water shield for uniball pivot sleeve and uniball
pivot sleeve bearing.
3 Pleated rubber construction.
4 Attached to collar set and outer ring by safety wire.

9-5
 FILE NO: 25191X-9-36
(c) Outer ring:
1 Aluminum alloy forging.
2 Two Teflon lined self-aligning bearings.
3 Tilts with the inner ring but rotates with mast.
4 Driven by the swashplate drive link.
5 Needle nose grease fitting under one have.

9-6
 FILE NO: 25191X-9-36
(d) Inner ring:
1 Aluminum alloy forging.
2 Tilts but does not rotate.
3 Contains:
a Inner ring cap.
b Upper uniball (pivot sleeve) Teflon bearing.
c Lower uniball (pivot sleeve) Teflon bearing.
d Uniball (pivot sleeve) friction adjustment shims.

9-7
 FILE NO: 25191X-9-36
(e) Collective sleeve: (pivot sleeve)
1 One piece aluminum forging.
2 Machined to its shape.
3 Upper portion called uniball (pivot sleeve):
a Uniball (pivot sleeve) is a hard anodized surface.
b Upper and lower uniball (pivot sleeve) bearing ride on
this surface.
4 The inner ring tilts in all directions on the uniball.
5 The inside diameter has two Teflon lined bearings:
a Ride on the hard anodized surface of the swashplate support.
b Allow free vertical movement.

6 Uniball (pivot sleeve) has two milled vertical slots. Slots furnish
track for two Teflon lined blocks:
a Blocks are bolted by special bolts to the inner ring.
b Blocks keep inner ring from rotating.

(f) Collective lever:

1 Aluminum alloy forging.
2 Attaches support through the compensating link.
3 Has Teflon bearing.
4 Attaches collective sleeve through trinnion pins.
5 Airframe control attaches through Teflon self-aligning bearings.

(g) Compensating link:

1 Aluminum alloy forging.
2 Teflon inner liner.
3 Steel sleeve bearing.
4 Must be connected at bottom end to properly install swashplate
support to transmission.
9-8
 FILE NO: 25191X-9-36
(h) Support:
1 One piece aluminum forging.
2 Vertical machined surface is hard anodized.
3 Base machined to receive 8 studs from transmission upper case.

9-9
 FILE NO: 25191X-9-36
9-3 Swashplate friction measurement:
(a) Obtain 0 to 50 pound spring scale.
(b) Remove pitch links.
(c) Disconnect drive link.
(d) Place swashplate control plate level position.
(e) Attach 0 to 50 pound sparing scale to one arm on outer ring.
(f) Pull up. This will cause swashplate to pivot on uniball.
(g) Note amount of force required to move uniball after breakaway.
(h) Turn outer ring 120 degrees and repeat.
(i) Friction must be 24 to 32 pounds within 2 pounds at each point.

9-10
 FILE NO: 25191X-9-36
9-4 205 collective hub and sleeve assembly:
(a) Description- the primary purpose of the collective hub and sleeve
assembly is to transmit the desired collective setting necessary for
flight from the pilots control to the main rotor. This unit changes non-
rotating push-pull motion to rotating motion and back to rotating push-
pull motion.
1 Slider- moves up and down around mast and is non-rotating.
2 Collective levers receive push-pull motion from the collective
servo and pivot shaft moves sleeve up and down.

3 Hub and bearing- moves up and down with sleeve and changes
push-pull motion to rotating motion.

4 Scissors and sleeve-bolted to hub, changes rotating motion to

rotating push-pull motion moving the mixing levers thru the
control tubes attached on the forward end, the trailing end of the
scissors is attached to drive links.

5 Drive links- drive the rotating portion of swashplate and

transmits cyclic control to the mixing levers thru scissors and
control tubes.

9-5 Swashplate assembly:

(a) Description- made in 4 parts and used for cyclic control of aircraft by
changing push-pull motion from the cyclic servo into titling rotating
motion and back to push pull motion.
1 Support assembly- bolted to the top of transmission and serves
as attachment for the gimbol ring.
2 Gimbol ring- acts as universal, attaches inner ring support and
allows tilting of inner ring.
9-11
 FILE NO: 25191X-9-36

9-11A
 FILE NO: 25191X-9-36

9-11B
 FILE NO: 25191X-9-36

3 Inner ring- stationary –3 preloaded trunnion bearing, 2 cyclic

servos and synchronized elevator, tilts and push-pull motion.
4 A new pre-loaded bearing feels rough.
5 Outer ring- rotates, changing push pull motion (tilting) to
rotating push-pull motion through a bearing.
9-12
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9-12A
 : FILE NO: 25191X-9-36
9-6 214 main rotor control
(a) Description:
1 Consists of two (2) pitch change link assemblies, a swashplate
and support assembly and a scissors and sleeve assembly.
2 Located between the dual actuators (collective and cyclic) and
the pitch horns.
3 Used to change a linear control movement into rotating control
movement.

9-13
 FILE NO: 25191X-9-36
(b) Purpose- to change the collective and cyclic linear control movement
into a rotating control system for the main rotor blades.
(c) Components:
1 Description of pitch change link assembly:
a Adjustable links used for adjustments of the flight control
system.
b Connected to the pitch horns at the top end.
c Connected to the scissors at the lower end.

2 Purpose- of pitch change link:

a Transmits rotating control movement from the scissors to
the pitch horns.

b Provides adjustments for the flight control system and the

autortation RPM.

9-7 214 swashplate and support assembly:

(a) Description:
1 Consists of a support assembly and swashplate assembly.
2 Use for cyclic control system.
3 Mounted to the top of the transmission.

(b) Purpose inner ring:

1 Transfers cyclic linear control movement into a rotating control.
2 Transmits cyclic fore and aft control movement to the elevator
control system.

(c) Components:
1 Description of the support assembly:
a Bolted to the top of the transmission at the lower end.
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9-14A
 FILE NO: 25191X-9-36
b An anodized steel uniball mounted to the top allows the
swashplte to be tilted in any direction.
c Side opening, at the bottom, for installation of the
collective lever to the collective sleeve.
d Teflon- lined bearing inside for alignment of the
collective sleeve.

2 Purpose:
a Permits the swashplate assembly to tilt in any direction.
b Allows installation of the collective lever to collective sleeve.
c Alignment of the collective sleeve.

3 Description of the swashplate assembly:

a Consists of inner ring and an outer ring separated by a set
of a duplex ball (thrust) bearings.

b Mounted to support assembly by a set of contoured

Teflon lined bearings.

4 Purpose inner ring::

a Transfer a cyclic linear control movement into a rotating
control movement.
b Transmit cyclic fore and aft movement to the elevator
control system.

5 Components:
a Description of the inner ring:
(1) A non-rotating ring.
(2) Mounted to the support assembly’s uniball by a set
of contoured Teflon lined bearings.
9-15
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9-15A
 FILE NO: 25191X-9-36
(3) The two (2) forward horns are for attaching the
cyclic dual actuators.
(4) The aft horn is for attaching the anti drive link.
(5) The anti-drive link prevents the inner ring from
rotating.
(6) The anti-drive will move the elevator control
system when the cyclic control movement is in the
fore and aft position.

6 Purpose, of inner ring:

a Provide the attaching point for the cyclic dual actuators.
b Provides tilting of the swashplate assembly through the
set of contoured Teflon bearings.
c Transmits the cyclic fore and aft movement to elevator
control system.

7 Description of outer ring:

a Rotating ring driven by the two (2) drive links.
b Mounted to the inner ring by a set of duplex ball (thrust)
bearings.

c The duplex ball (thrust) bearing allows the outer ring to

rotate.
d The outer ring will tilt with the inner ring.

8 Purpose- changes a linear movement into a rotating control

movement for the cyclic control system.

9-16
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9-16A
 FILE NO: 25191X-9-36
9-8 Scissors and sleeve assembly:
(a) Description- consists of a scissors, drive plate, sleeve, collective hub,
collective lever, two (2) drive links and friction collate.

(b) Purpose:
1 Transfers a linear movement into a rotating control movement
for the collective control system.

2 Transmits cyclic and collective rotating control movements to

the pitch change links.

(c) Components:
1 Description of scissors:
a Two (2) levers bolted in the center to the collective hub.
Connected at one end to the pitch link assemblies.
b Connected at other end to the drive link.

2 Purpose- transmits both cyclic and collective rotating control to

pitch change link assemblies.

3 Description of sleeve:
a Located between the support assembly and the mast.
b The collective lever attaches to the bottom.
c The collective hub attaches to the top of the sleeve
through a set of bearings.
d The sleeve moves vertically (up and down) only.
e Purpose- transmits collective control movement from the
collective lever to the collective hub.

9-17
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9-17A
 FILE NO: 25191X-9-36
4 Description of collective hub:
a Mounted to the top of collective sleeve by a set of ball
bearings and retaining nut.
b Driven by the drive plate.
c The scissors are bolted to the collective hub.
d The collective hub drives the scissors.
e The collective hub will rotate but the sleeve will not.
f Purpose of collective hub:
(1) Provides attachment point for the scissors.
(2) Changes linear movement of the collective control
into a rotating control movement.
(3) Allows a pivot point for scissors in the cyclic
control.

5 Description of collective lever:

a A split lever assembly.
b Connected on the inboard end to the sleeve.
c Connected on the outboard end to dual collective
actuator.

d An idler link is connected to the center.

e Purpose- transmits collective control movement from the
dual collective actuator to the sleeve.

6 Description of drive plate:

a Master splined to the mast.
b Connected to the top of the collective hub by six (6) bolts
and nuts.
c The friction collet is connected to the top.
d Purpose:
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9-18A
 FILE NO: 25191X-9-36
(1) Drives the collective hub at the mast RPM.
(2) Provide an attachment point for the friction collet.

7 Description of friction collet.

a A Teflon coated collet set riding vertically on a bearing
surface on the mast.
b Has a clamp ring that attaches it to the top of the drive
plate.

c A rubber boot acts as a dust cover for friction collet.

d A three (3) piece clamping set for adjusting friction to the
collet set.

e Purpose- applies friction to the collective control to

prevent control feedback.

8 Description of drive links:

a The top of the drive links attaches to the scissors.
b The bottom of the drive links attaches to the outer ring.
c Purpose:
(1) Drives the outer ring of the swashplate assembly at
the scissors RPM.

9-19
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9-19A
 FILE NO: 25191X-10-48
CHAPTER 10
SINGLE ROTOR SINGLE ENGINE
TRANSMISSION AND MAST
10-1 206 Transmission and mast:
(a) General description:
1 The transmission provides a two stage reduction of 15.22 to 1.0
(6000 to 394).

10-1
 FILE NO: 25191X-10-48
2 The transmission consists of:
a Top case assy.
b Ring gear.
c Planetary gear assy.
d Sun gear.
e Spiral bevel gear and gear shaft.
f Input quill.
g Accessory drive quill.
h Main case.
(b) Lubrication is provided by a system which includes:
1 Pump.
2 Relief valve.
3 Filter.
4 Spray jets.
5 Temperature bulb.
6 Oil cooler.
7 Oil level sight gage.

10-2
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10-2A
 FILE NO: 25191X-10-48
(c) The mast transmits rotary motion from the transmission to the main
rotor.
(d) It has three sets of splines.

10-3
 FILE NO: 25191X-10-48
10-2 206 Transmission:
(a) Location:
1 It is mounted on the cabin roof of the forward section in front of
the engine.
2 The transmission is supported and isolated from the airframe by
two pylon support links, one on each side.

3 A drag link is secured to the bottom of transmission and bolted

to the isolation mount.
4 The isolation mount keeps the transmission in alignment.

5 A drag pin extends down from the drag link and fits into a hole
of the stop plate.
6 The stop plate provides for a positive stop of the pylon.
10-4
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10-4A
 FILE NO: 25191X-10-48
(b) The transmission receives driving RPM from the powerplant through
the freewheeling unit and main drive shaft.

(c) Component description:

1 Top case:
a Is made of magnesium casting.

2 Main case:
a Is made of magnesium casting.
b Serves as the transmission oil system reservoir.

3 Input quill:
a Is made of steel pinion gear.
b Receives drive from the engine through an input shaft
and in turn drives the spiral gear.

10-5
 FILE NO: 25191X-10-48

4 Spiral bevel gear:

a Is made of steel.
b Drives the accessory drive quill and sun gear.

5 Accessory drive quill:

a Drives transmission oil pump.

6 Sun gear:
a Purpose: Drives planetary assy.

7 Planetary assy:
a Is consist of three pinions and one spider gear.
b The spider is internally splined and drives the mast.

10-6
 FILE NO: 25191X-10-48

10-3 206 Transmission oil system:

(a) Type of oil system: The oil system is wet sump type and it is serviced
with MIL-L-7808 or areoshell 500, MIL-L-23699.

10-7
 FILE NO: 25191X-10-48
(b) Component description:
1 Oil pump:
a Location: Is mounted on forward left side of
transmission.
b Type: The oil pump is a vane type constant volume.
c It is driven by the accessory gear inside the transmission,
it delivers 4.5 gallons per minute at 4500 RPM.
d Purpose: Is to provide oil under pressure, to the internal
gears and bearing.
e The oil pump drives the hydraulic pump.

10-8
 FILE NO: 25191X-10-48
2 Oil pump screen:
a Located on forward right side of transmission.
b Purpose is to clean the oil before it goes through the pump.
c The screen is removed, cleaned and inspected 100 flight
hours.
3 Oil filter head and filter:
a Located and bolted to left side of transmission.
b Incorporated in the filter head is a thermo switch filter
bypass valve and oil monitor.
c The filter bypass valve lets the oil bypass if it becomes
clogged.
d The filter is a replaceable cartridge type, changed every
100 flight hours.
e The thermo switch will cause a caution light illuminate if
oil gets too hot.

10-9
 FILE NO: 25191X-10-48
4 Oil cooler:
a Located aft left of upper case on the transmission.
b The oil cooler incorporates a bypass valve.
c The oil bypass valve closes at 140ºF (60ºC) forcing the
hot oil through the cooler.
d The oil cooler is a flat radiator type cooler.

5 Pressure regulator valve:

a Located on the left side of transmission.
b The pressure regulating valve bleeds excessive pressure
off the oil system and back into the sump.
c Purpose: regulating valve regulates system oil pressure.
d The oil pressure must be adjusted with the engine
running.
e Adjust the oil pressure to 45 PSI at 6000 RPM:
(1) Turn screw adjuster to increase pressure.
(2) Turn screw adjuster counter clockwise to decrease
pressure.
(3) After adjusting pressure, lock the screw adjuster in
place with lock nut.
10-10
 FILE NO: 25191X-10-48

6 Spray jets:
a Two spray jets are used in the transmission to lubricate
the internal components.
b Number 1 jet:located above the oil filter of main case.
c Number 2 jet is located above the pressure relief valve on
the upper case.
d Purpose of the spray jets are to lubricate the internal gears
and bearings.
7 Filler vent cap:
a Located on the top right side of transmission.
b The filler cap is vented to prevent pressure build-up
inside the transmission.
c The filler cap has a mesh screen to prevent foreign
material from entering the transmission.

10-11
 FILE NO: 25191X-10-48
8 Drain plug chip detector:
a Located on the lower right side of transmission.
b The magnetic chip detector is part of drain plug.
c The chip detector can be removed, cleaned and inspected
without draining the oil.
d It must be removed every 25 flight hours, cleaned and
inspected.
e Purpose of the chip detector is to indicate if there are
metal particles in the oil system.
f On newer helicopters, there will be another chip detector
below the oil pump screen.

10-12
 FILE NO: 25191X-10-48
10-4 206 Main mast:
(a) The mast transmits rotary motion from the transmission to the main rotor:
1 The mast has three sets of splines.
2 The lower set is the driven source from the transmission.
3 The middle set drives the outer ring while the upper set drives
the main rotor.
4 The mast is machined to accommodate a double thrust ball
bearing.
(b) The bearing(retainer plate) and liner hold mast into the transmission:
1 The mast is made of 4340 steel.

10-13
 FILE NO: 25191X-10-48
2 The lower portion of mast has a machined surface that fits into a lower
seat roller bearing at bottom of transmission. It acts as an alignment
bearing.

10-13A
 FILE NO: 25191X-10-48
10-5 214 Main transmission and mast:
(a) Description:
1 The transmission is a mechanical reduction gearbox in which the
main rotor mast is mounted, power transmitted from the engine
through the engine gearbox assembly and main drive shaft
drives the transmission. In addition, the XMSN drives the main
rotor, tail rotor drive, #1 and #2 hydraulic pumps, main
generator, rotor tachometer generator, and transmission oil pump.

2 The main transmission has six (6) cases:

a Top case-magnesium.
b Ring case-steel.
c Main case-magnesium.
d Lower main case-magnesium.
e Tail rotor case-magnesium.
f Sump case-magnesium.

(b) Accessories driven by main transmission:

1 Accessory gear case:
a Located on forward main case.
b Drives the main generator which supplies DC power, 28
volts 200 amps.
c Drives the #2 hydraulic pump, which provides 3000 PSI
to hydraulic system #2.
d Drives the rotor tachometer generator, which senses the
main rotor RPM.
e A vent is located on the top right corner of the case.
f An electric chip detector is located on bottom right corner
of the case, which turns on a light on the annunciator
panel, in the event of impending internal failure.
10-14
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10-14A
 FILE NO: 25191X-10-48
2 Hydraulic pump #1:
a Located on the forward top of the sump case.
b Provides 3000 PSI to #1 hydraulic system.

10-15
 FILE NO: 25191X-10-48
3 Tail rotor drive quill:
a Located aft on tail rotor case.
b Drives the tail rotor shaft.

10-16
 FILE NO: 25191X-10-48
4 Transmission oil pump:
a Located in the bottom of the sump case.
b Provides pressurized oil to lubricated the, main
transmission.

10-17
 FILE NO: 25191X-10-48
(c) Input drive quill:
1 Description:
a The input drive quill drives the main XMSN, located on
aft main case.
b The input drive quill contains a freewheeling unit, which
allows for autorotation.

10-18
 FILE NO: 25191X-10-48
(d) Tail rotor drive quill:
1 Description: The tail rotor drive quill has a bevel gear, and is
driven by the XMSN. The quill, in turn, drives the tail rotor
shaft.

10-19
 FILE NO: 25191X-10-48
10-6 Main transmission oil system:
(a) Description: The oil system is a wet sump, pressure type system, which
uses lines, internal passages, jets, filters, valves, oil cooler, and a pump.
(b) Purpose: The oil system lubricates, cleans and cools the internal
components of the main XMSN.
1 External oil filter:
a Located on the lower right side of the XMSN.
b It is an additional filter to clean the oil.
c The filter is a 10 micron paper pleated, throw away type,
changed every 300 hours.
d A red indicator button will pop up when an impending
filter clogged condition exists.

10-20
 FILE NO: 25191X-10-48
2 Oil manifold:
a Located on the transmission main case on the right side
of main input drive shaft.
(1) Temperature bulb, senses oil temperature and
sends signal to the transmission oil indicator.
(2) Thermo switch, senses oil temperature and sends
the signal to the transmission oil temperature
segment light on the annuciator panel.
b Supports and supplies the #3 oil jet with oil to lubricate
the input gear mesh.
c Supplies the oil pressure manifold with oil.
3 Oil pressure manifold- located above the oil manifold,
connected to the oil manifold by an external tube. The oil
pressure manifold supports the following items:

10-21
 FILE NO: 25191X-10-48
a Oil pressure transmitter- senses oil pressure and sends a
signal to the XMSN oil pressure indicator.

b Pressure switch- senses the oil pressure in the XMSN and

turns on the light on the annunciator panel

10-22
 FILE NO: 25191X-10-48
4 Oil filler cap- is located on the top front of the top case and is
used as a means of servicing the transmission. The cap also
allows air to enter the transmission.

5 Sight gage- located on the right side of sump case and allows the
repairman to observe the oil level in the transmission:
a Made of acrylic plastic.
b Has a full and add line on the case.

6 Electric chip detectors- there are 5 detectors located on the main

transmission which warn of impending internal failure, by
turning on a segment light on the annunciator panel:
a Mast bearing assembly.

b Forward planetary gear.

c Aft planetary gear.

d Bottom accessory drive case.

e Bottom of sump case.

10-23
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10-23A
 FILE NO: 25191X-10-48
10-7 Main transmission mounts:
(a) Description:
1 The transmission is supported by, and attached to the airframe
by a nodalized beam on each side of the transmission.

2 The beam- on each side is 4 piece which include the support,

clevis, weight support and torsion arm assemblies.

3 The beam sections are connected together by elastomeric

bearings and bolts.

(b) Three restrain assemblies (vibration dampers) reduce and isolate

transmission movements, made by vibrations of the main rotor:

1 Two restrain assemblies are mounted on the left and right side of
transmission and are for fore and aft movement of the
transmission.

2 One restraint assembly is located aft of the transmission and is

for lateral movement of the transmission and is for lateral
movement of the transmission.

10-24
 FILE NO: 25191X-10-48

10-24A
 FILE NO: 25191X-10-48
10-8 Mast assembly:
(a) Description:
1 The mast is a hollow steel shaft with three splined section.
2 Only the top two sets of splines are master splined:
a Top spline- mounting for the main rotor.
b Center spline-drives the collective hub..
c Lower spline-drives the mast from the upper planetary
gear inside transmission.

10-25
 FILE NO: 25191X-10-48
10-9 205 Transmission assembly:
(a) Description:
1 The transmission is connected to the engine by main drive shaft
and provides drive angle change and gear reduction, to drive
main rotor mast.

2 A freewheeling clutch in the input drive quill coupling

disengages to allow for autorotation purposes.
3 Secondary gear trains drives tail rotor shaft, DC generator.

4 Five main cases:

a Top-magnesium.
b Planetary case (ring gear)- steel.
c Main case- magnesium.
d Support case- magnesium.
e Sump case- magnesium.

(b) Mounting:
1 Isolation mounts:
a Purpose- restrains the rocking motion of the transmission.
b Location- one on each corner, one between the AFT two
mounts, attached to the support beam, a total of (5)
isolation mounts.

c Maintenance:
(1) Inspect mount boots for proper installation, rips or cuts.
(2) Remove and replace.

10-26
 FILE NO: 25191X-10-48

10-26A
 FILE NO: 25191X-10-48

10-26B
 FILE NO: 25191X-10-48
2 Friction dampers:
a Purpose- supports the isolation mounts in restraining
rocking motion of the transmission.
b Location- under the AFT two isolation mounts.

3 Lift link:
a Purpose- attach transmission to fuselage.
b Construction- forged steel, not adjustable.
c Location- attached to the bottom center of transmission
and top of support beam.

(c) Freewheeling unit:

1 Purpose- provides the authoritative feature in the helicopter.
2 Location- in the input drive quill assembly of the transmission.

(d) Accessory drives (3):

1 Main generator:
a Purpose- produces the DC electricity used in the
helicopter.
b Location- front center of main case.

2 Hydraulic pump and rotor tachometer drive:

a Pressurized the hydraulic system and shows the pilot the
RPM of the main rotor.
b Location- right side of pump case.

(e) Lubrication- two sight gages indicates oil level, use MIL-L-7808 or
MIL-L-23699 (Do Not Mix):
1 Type- wet sump, pressure type.
2 Oil pump:
10-27
 FILE NO: 25191X-10-48

10-27A
 FILE NO: 25191X-10-48

10-27B
 FILE NO: 25191X-10-48
a Purpose delivers oil to the system under pressure, 40-60
PSI +10.
b Location- bottom of sump case.

3 Thermal by-pass valve:

a Purpose- when oil is cool, valve routes the oil through the
system, when oil is hot valve routes the oil to oil cooler,
then to system.
b Location- rear wall, cargo sling compartment.

4 Cooler and drain (2):

a Purpose- cools both engines and transmission oil drains
oil from each oil cooler radiator, also a drain at bottom of
transmission sump case.
b Location- AFT baggage compartment.

5 Oil filters- two types:

a Internal oil filter:
(1) Wafer disc type- with by-pass valve if filter is
clogged.
(2) Purpose- filters transmission oil.
(3) Location- Aft right side of sump case.

(f) External oil filter- located in cargo sling throw-away, plated paper type,
filter compartment on right side hand wall equipment and has a by-pass
valve set to open at 18 to 22 PSI differential pressure:
1 Removal (every 100 flying hours).
2 Oil manifold- located top aft right side of transmission:
a Purpose- provides the mounts for following components:
(1) Thermo switch:
10-28
 FILE NO: 25191X-10-48

10-28A
 FILE NO: 25191X-10-48
(a) Purpose- turns on the XMSN oil hot light
on caution panel.
(b) Location- top left side of manifold.

(2) Thermo bulb:

(a) Purpose- provides oil temperature
indication to transmission oil temperature
gage.
(b) Location- top right side of oil manifold.

(3) Oil pressure relief valve (spring loaded):

(a) Purpose- regulates transmission oil system
pressure 40-60 PSI.
(b) Adjustment- turn adjusting screw into
increase pressure, out to decrease pressure.
(c) Location- center of oil manifold.

(4) Oil jet No.3:

(a) Purpose- sprays oil onto the input bevel gear.
(b) Location- bottom of oil manifold.

(5) Oil jet No.7:

(a) Purpose- sprays oil onto the bearings of the
input drive gear assembly.
(b) Location- between thermo switch and the
thermo bulb on the manifold.

3 Pressure tap manifold:

a Purpose- provides the mount for the following
components:
10-29
 FILE NO: 25191X-10-48

10-29A
 FILE NO: 25191X-10-48
(1) Pressure switch:
(a) Purpose- turns on the XMSN oil press light
on the caution panel, when oil pressure
drops bellow 25 PSI.

(b) Location- left side of the pressure tap

manifold.

(2) Pressure transmitter:

(a) Purpose- provides an indication to the oil
pressure gage 28 volt AC.
(b) Location- right side of pressure switch.

4 Magnetic plug (chip detector):

a Purpose- attracts metal chips, completes the circuit
between pole and ground, turning on the chip detector
light on the caution panel warns pilot of internal failure.
b Location- right side of sump case.

5 Oil jets (10 each):

a Purpose- delivers aimed spray of oil onto the gears and
bearings in the transmission.
b Description:
(1) No.1 Jet:
(a) Purpose- sprays the mast upper bearing,
mast drive spline area and upper stage
planetary pinion bearings.
(b) Location- right aft on top case.

10-30
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10-30A
 FILE NO: 25191X-10-48
(2) No.2 Jet:
(a) Purpose- sprays spur gear and pinion
bearings on both planetary stages, supplies
oil to two auxiliary jets.
(b) Location- right aft on ring gear case, two
auxiliary 120 degrees apart on ring gear
case.

(3) No.4 Jet:

(a) Purpose- sprays the accessory drive gears
and the tail rotor drive quill.
(b) Location- left side of the sump case.

(4) No.5 Jet:

(a) Purpose- sprays the input quill gears.
(b) Location- Aft, left main case.

(5) No.6 Jet:

(a) Purpose- sprays inboard bearing of the
input drive quill and bearings of the free-
wheeling unit.

(b) Location- right side of the main case, near

the oil manifold.

(6) No.7 Jet:

(a) Purpose- sprays the bearing of the internal
gear quill.
(b) Location- top of oil manifold.

10-31
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10-31A
 FILE NO: 25191X-10-48
(7) No.8 Jet:
(a) Purpose- additional lubrication for the
upper mast bearing and mast driving spline
area.
(b) Location- right side of the retainer plate.

10-10 Mast assembly:

(a) Purpose- drives the main rotor and supporting units.
(b) Description:
1 Contracted of tubular steel.
2 Has a screw-on retaining cap with an eye on top for removing
the mast or lifting the helicopter.
3 Four sets of splines on mast.
4 Three are master splined.
5 Two sets of bearings.

(c) Location- top of transmission.

(d) Inspection:
1 Inspect mast seal for leaks, if leakage is present, seal must be
replaced.
2 Inspect mast assembly for deep scratches and corrosion.

10-32
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10-32A
 FILE NO: 25191X-11-48
CHAPTER 11
SINGLE ROTOR SINGLE ENGINE
POWERTRAIN SYSTEM

11-1 206 Drive train system (Powertrain):

(a) Identification of drive train system:

1 The drive train on the 206 consists of a freewheeling unit,

engine to transmission drive shaft, tail rotor drive shafting and
their components.

2 The drive train is driven by the power plant through the

freewheeling unit.

(b) Purpose, operation and location of the drive train: Tail rotor drive shaft
is located on the tail-boom.

11-1
 FILE NO: 25191X-11-48
11-2 206 Main drive shaft:
(a) The main drive shaft is located between freewheeling unit and input
quill of transmission.

(b) The main drive shaft consists of two flexible couplings with a spring
inside each coupling.

(c) The springs centers the shaft during operation.

(d) The main drive shaft is removed, cleaned and inspected every 300
flight hours.

(e) It is packed by hand with 204-040-755-3, a special lubricant.

(f) The main drive shaft can be installed in either direction.

(g) When cleaning the couplings, use only clean rags.

11-2
 FILE NO: 25191X-11-48
11-3 206 Freewheeling unit:
(a) The freewheeling unit is located at bottom of accessory case on the
power plant.

11-3
 FILE NO: 25191X-11-48
(b) It is driven by the power take-off gear shaft in the accessory gear case.
(c) As the powerplant is running, the freewheeling unit is driving the main
drive shaft on forward and the tail rotor drive shaft on aft end.

(d) Operation:
1 Engine power is transmitted to the outer race of the freewheeling
unit, then through the Sprague elements of the unit which couple
the engine power to the transmission drive shaft.

11-4
 FILE NO: 25191X-11-48
2 The forward section of tail rotor shafting connects to a splined
adapter on aft end of freewheeling shaft.

3 During autorotation, the main rotor drives the main drive shaft.
a The freewheeling so that rotation forces of main rotor are
free to drive transmission, tail rotor drive shaft and other
accessory items on transmission.

4 During autorotation, the main rotor drives XMSN and

freewheeling unit.
a The freewheeling unit has a vent that opens at increasing
RPM of 2500, and closes at decreasing RPM of 1500.

b It vents the freewheeling unit thus allowing oil to

return to transmission.

(e) The freewheeling unit is lubricated by the transmission oil system.

11-5
 FILE NO: 25191X-11-48
11-4 206 Tail rotor drive shaft:
(a) The tail rotor drive shaft.

(b) There are four sections of tail rotor drive shafting.

(c) The front two short sections are made of steel.

(d) The aft two sections are made of aluminum.

(e) The drive shaft sections are connected with the use of flexible Thomas
couplings and splined adapters.

(f) There are five Thomas couplings and on each coupling are 10 steel
laminated discs.

11-6
 FILE NO: 25191X-11-48
(g) The steel laminated discs are installed 90º to each other.
(h) When the Thomas couplings are installed, there are 10 special beveled
washers installed with each coupling.
(i) The second section of drive shaft supports and drives the oil cooler fan assembly.

(j) The long section of tail rotor drive shaft is connected to the tail rotor
gearbox by a splined adapter:
1 The long section is supported by five hangar assemblies.
2 The hanger assemblies are interchangeable.

11-7
 FILE NO: 25191X-11-48
11-5 206 Oil cooler fan and shaft:

(a) Mounted on the intermediate section behind the rear firewall.

(b) It is driven by the second section of tail rotor drive shaft.

(c) Supplies air to cool engine oil, transmission oil and hydraulic fluid.

11-8
 FILE NO: 25191X-11-48
11-6 206 tail rotor gearbox and pitch change mechanism:
(a) General description:
1 The tail rotor gearbox (90º gearbox) is made of magnesium
alloy, and it is located on the aft end of tail-boom by four studs.

2 Two spiral bevel gears provide speed reduction of 2.35 to 1.0

(6000 to 2550 RPM).

3 The gearbox is serviced with MIL-7808 or Area shell 500.

4 The capacity is (0.375 pints) or 0.18 litters.

5 The pitch change mechanism is located on the tail rotor gearbox,

and it change angle of tail rotor blade.

11-9
 FILE NO: 25191X-11-48
(b) Functions of tail rotor gearbox and pitch change mechanism:
1 Provide a-90 degree change or drive.
2 Provide for mounting of tail rotor hub and blade assembly.

(c) Tail rotor gearbox components:

1 Gearbox housing:
a Attached to tail-boom with 4 studs.
b Vent type filler cap on top right side.
c Vent cap removed by pressing down turning ¼ of an inch.
d Sight glass located on aft end of gearbox housing.
11-10
 FILE NO: 25191X-11-48
e Chip detector located on aft end of gearbox housing.
f Chip detector must be removed and replace the oil every
100 flight hours.
2 Front cap assembly:
a Front cap attached to gearbox housing with three studs.
b There is a packing (“O-ring”) which is provided a seal for
gearbox housing and front cap assembly.
3 Output shaft assembly:
a It is hollow to accept pitch change rod.
b Has set of threads for mounting of tail rotor hub and
blade assembly.

11-11
 FILE NO: 25191X-11-48
11-7 214 Main drive shaft:
(a) Description:
1 The main drive shaft is located between the engine gearbox and
the main transmission input drive quill.

2 The shaft is a hollow steel tube with splined coupling assemblies

on each end to provide flexibility.

3 The shaft couplings are attached by bolts to the engine gearbox

adapter and the transmission input drive quill adapter.

4 Cleaning:
a Clean exterior of drive shaft and couplings with a clean
cloth dampened with dry cleaning solvent,
b Clean the interior of drive shaft and couplings with clean
dry cloth.

11-12
 FILE NO: 25191X-11-48

11-12A
 FILE NO: 25191X-11-48
(b) Tail rotor drive shafting and components:
1 Tail rotor dive shafts:
a Description:
(1) There are 6 shaft section, 4 are the same length #2
and #5 are not interchangeable.
(2) The shafting is anodized aluminum alloy tubes.
(3) Steel triangle 3 bolt flange is on each end.
(4) Internal balance strips are in the end caps.

2 Inspection- inspect for nicks, dents, scratches and out of round

condition.

11-13
 FILE NO: 25191X-11-48
(c) Tail rotor quill couplings:
1 Description:
a Two flex couplings allow for the longitudinal movement
and flexing of the tail-boom in flight.
b Location- one coupling on each end of No.1 section of
drive shafting.
2 Lubricate every 300 hours .

11-14
 FILE NO: 25191X-11-48
(d) Hanger bearings:
1 Description:
a There are four hanger assemblies on the tail rotor
shafting, which connect and support the drive shafting
and provide a means of mounting the shafting to the
tail-boom.

b Each hanger assembly has a zerc fitting for lubrication.

Lubricate every 300 hours with MIL-G-81322.

11-15
 FILE NO: 25191X-11-48
(e) Adjustable coupling:
1 Description:
a It is a splined coupling with a bolt flange on each end,
located between #5 section of shafting and 42º gearbox.
b The coupling has a sleeve nut for adjustment and a
through bolt.
c The coupling is used to adjust the overall length of the
shaft assembly and remove any end play in the shaft.
2 Adjustment:
a Any time a part is replaced between the transmission tail
rotor output quill assembly and the intermediate gearbox
assembly, which effects the stack up length, the
adjustable coupling assembly must be, readjusted.

11-16
 FILE NO: 25191X-11-48
(f) Disc assembly:
1 Description- there are five flexible stainless steel, hexagonal
disc assemblies, having 18 discs in each assembly. They allow
for longitudinal movement and flexing of the tail-boom in flight.

2 Location- one disc assembly is located at the aft end of number

2,4,5 and 6 tail rotor drive shaft sections.

11-17
 FILE NO: 25191X-11-48
(g) Tail rotor bearing cooling duct:
1 Description- A fiberglass duct that is attached to the oil cooler
blower and goes through the tail-boom to direct air onto the #2,
#3, and #4 hanger bearings for cooling.
2 Inspection- inspect the duct for looseness cracks and air
blockage in the duct.
3 Maintenance- replace and cracked fiberglass ducting, tighten
any loose clamps.

11-18
 FILE NO: 25191X-11-48
11-8 Intermediate (42º) gearbox- the gearbox provides a 42º change in direction of
the tail rotor drive shafting with a gear The gearbox is located on the tail-
boom at the base of the vertical fin.

(a) Components of gearbox:

1 The input quill coupling is not flexible, but the output coupling
is flexible for drive shaft attachment.

2 Oil filler cap with breather incorporated in it.

3 Oil sight gage- left side of gearbox, used to check oil level.

4 Oil pump- “G” rotor type capable of producing 20 PSI, (pounds

per square inch) driven by the output quill.

5 Oil jet- on right side of gearbox and lubricates mating gear teeth
of quills.

6 Electric chip detector- on aft right side of gearbox activates a

warning light segment on the annunciator panel to warn of
impending internal failure.

7 Thermos witch- located aft center of the gearbox above the chip
detector, activates a warning light segment on the annunciator
panel .

11-19
 FILE NO: 25191X-11-48

11-19A
 FILE NO: 25191X-11-48
8 Pressure switch- located to right of gearbox, activates a warning
light segment on annunciator panel .
9 Oil pump screen- aft left side of gearbox.
10 Inspection cover- left side of gearbox used to inspect meshing of
quill gears.

(b) Gearbox oil system- wet sump, pressure type system:

1 Servicing- capacity is 3.5 pints of MIL-L-23699 oil.

3 The pump (under pressure) forces oil through internal passages

and jet assembly to input and output quill gears .

CAUTION: Do not disturb or attempt to remove shims installed on tail-boom under

gearbox assembly.

CAUTION: To prevent damage to output coupling grease seal, do not lift or handle
gearbox output coupling fan assembly.

11-20
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11-20A
 FILE NO: 25191X-11-48
11-9 Tail rotor (90º) gearbox- the gearbox provides a 90º change in direction of
drive with gear The gearbox is located at the top of the vertical fin and
provides a mounting point for the tail rotor:
(a) Components of the gearbox:
1 Input and output quills, input quill has an adapter for attachment
of driveshaft.

11-21
 FILE NO: 25191X-11-48
2 Oil pressure manifold on left side of gearbox incorporates a
thermos witch and a pressure switch.
3 Oil filler cap has a breather incorporated in it.
4 Oil pump- G rotor type.
5 Two oil jets- on manifold, #12 lubricates input and output quills,
#11 lubricates output quill and oil pump drive gear.

6 Electric chip detector- on the aft left of gearbox, activates a

warning light segment on annumciator panel.
7 Oil sight gage- located left side of gearbox. Used to check oil
level.

8 Thermos witch- located on manifold activates a warning light

segment on annunciator panel .
9 Pressure switch- located on manifold activates a warning light
segment on annunciator panel .

(b) Gearbox oil system- wet sump pressure type system:

1 Servicing- capacity 3.5 pints of MIL-L-23699 oil.
2 Operation- the oil pump forces oil through internal passages,
transfer tubes, and jet assemblies to lubricate input and output
quills

11-22
 FILE NO: 25191X-11-48

11-22A
 FILE NO: 25191X-11-48
11-10 205 Powertrain system- the powertrain is a system of shafts and gearboxes
through which the engine drives the main rotor, tail rotor and accessories such
as DC generator, hydraulic pump and tachometer generator. The system
cossets of a main drive shaft, a main transmission which includes input and
output drives, main rotor mast and a series of drive shafts with (2) gearboxes
through which the tail rotor is driven.

11-11 Main drive shaft:

(a) Description:
1 Is a steel hollow shaft which is installed between an adapter on
the engine output shaft and the freewheeling coupling of
transmission input drive quill.

2 Two (2) coupling clamp sets of spit “V” band type, hold mating
curve faces of couplings in secure contact, 90 degree apart.

3 Flexibility of couplings is provided by crowned tooth couplings

sliding, in splined teeth of outer coupling to accommodate
movement of transmission on pylon mounts.

4 A spring in each coupling assists centering of shaft during

operation and tends to hold shaft assembly in place if clamp are removed.

(b) Service- lubricate main drive shaft with Androl L-786 every 600 flying
hours.

(c) Maintenance- always refer to TM 55-1520-210-20 for safe and proper

sequence for maintenance.

11-23
 FILE NO: 25191X-11-48

11-23A
 FILE NO: 25191X-11-48

11-23B
 FILE NO: 25191X-11-48
11-12 205 tail rotor drive shafts:
(a) Description:
1 Six sections, five same length, one short.
2 Anodized aluminum alloy tube.
3 Curve couplings riveted to each end.
4 Metal strips for balance static.
(b) Inspection- inspection of drive shafts consists of inspecting for nicks,
scratches and out of round condition.
11-13 Hanger bearings (4):
(a) Purpose- provides a means of attaching the drive shafting together to
transmit power to tail rotor.
(b) Permanently lubricated.
(c) Location- secured to top of the tail-boom.
11-14 Intermediate gearbox (42 degree):
(a) Purpose- changes angle of drive.
(b) Location- base of vertical fin.
(c) Description:
1 Filler cap allows for servicing with oil.
2 Vent allows for internal pressure to scope.
3 Sight gage provides means of checking oil level.
4 Drain plug with magnetic plug provides a means of draining the
gearbox oil and checking for an internal failure, 9 chip detectors.

11-24
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11-24A
 FILE NO: 25191X-11-48
11-15 Tail rotor gearbox (90 degree):
(a) Purpose- changes the angle of drive 90 degree and has a 2.6 reduction
in speed and houses pitch change mechanism.
(b) Location- At the top of the vertical fin.
(c) Description:
1 Filler cap allows for servicing with oil, cap vented to
atmosphere to prevent build up.
2 Sight gage provides the means of checking oil level, use MIL-L-
7808 or MIL-L-23699 (DO NOT MIX).
3 Drain plug with magnetic plug provides means of draining
gearbox and for checking internal failure (chip detector).
4 Filler caps must not be interchanged, could cause a failure of the
90 degree gearbox due to pressure build-up.
5 Quill removal and replacement is the same as for the 42 degree
gearbox.

11-25
 FILE NO: 25191X-11-48

11-25A
 FILE NO: 25191X-12-43
CHAPTER 12
SINGLE ROTOR SINGLE ENGINE
TAIL ROTOR SYSTEM
12-1 General description of 206 tail rotor:
(a) The tail rotor is a semi rigid, two bladed type.
(b) The tail rotor hub and blades assembly is mounted on the 90 degree
gearbox output shaft.
(c) 12 pound (5.44g) weight hub and blades assembly.
(d) Each time a part of the tail rotor assembly is replaced, the tail rotor
assembly must be balance.

12-1
 FILE NO: 25191X-12-43
(e) The tail rotor consists of:
1 Two aluminum tail rotor blades.
2 Tail rotor hub.
3 Forged aluminum yoke.
4 Tail rotor trunnion.

12-2
 FILE NO: 25191X-12-43
12-2 Tail rotor hub and blade components:
(a) Tail rotor blades:
1 Location- located on the output shaft of the pitch change
mechanism.
2 Purpose- is to counteract the main rotor torque.
3 Made of metal with an aluminum alloy they are reinforced by a
honeycomb filler.
4 Stainless steel leading edge.
5 Aluminum block(Retention block) inboard end extends 6 inches.
6 Two spherical Teflon bearings mounted in the retention block
take centrifugal loads.
7 Tip of blades have phonolic block is used to mount tip weights.

12-3
 FILE NO: 25191X-12-43
8 Removal of tail rotor actuator cause change in pitch change
horn.(Item 5 below figure)
9 New type pitch change horn is round, with added counterweigh
washer to counteract tail rotor pedal forces.
10 Pitch horn bolted to butt of blade with pitch link stud to leading edge.

12-4
 FILE NO: 25191X-12-43
12-3 Tail rotor hub:
(a) The hub is made of forged aluminum.
(b) There are two types of hubs:
1 206-011-810 earlier type.
2 206-011-801 Newest type
(c) Yoke: ONE piece aluminum forging at each end of the yoke is a blade
grip to hold the tail rotor blade.
(d) Trunnion:
1 Made of aluminum.
2 Master splined to output shaft.
3 Has stud on each end of trunnion for centering trunnion.

12-5
 FILE NO: 25191X-12-43
(e) Pitch change horns:
1 Made of steel.
2 Attached to butt of tail rotor blade.
3 Counterweights(washers)attached to new type pitch change horns.
(f) Spacer:
1 Made of steel.
2 Located on T/R output shaft inboard of trunnion.
3 Purpose: centers hub on output shaft splines.
(g) Shims:
1 Laminate steel.
2 Located just outboard of hub trunnion.
3 Purpose is to limit flapping angle of tail rotor assembly 12
degrees + 1degree.
4 Maintain minimum tail-boom clearance 1.50 inches.
(h) Static stop:
1 Made of steel.
2 Provides a positive stop for tail rotor flapping angle.
(i) Bumper:
1 Made of rubber.
2 Located between static stop and tail rotor yoke.
3 Prevents metal to metal contact.

(j) Safety washer:

1 Made of steel.
2 Located between static stop and hub retention nut.
3 Locks retention nut on output shaft.

(k) Retention nut:

1 Made of steel.
2 Hold tail rotor hub onto output shaft.
12-6
 FILE NO: 25191X-12-43
(l) Knurled nut:
1 Located on the end of tail rotor output shaft.
2 Centers the pitch change shaft in the output shaft.
3 Tightened finger tight and safetied to safety lock washer.
(m) Cross head:
1 Made of steel.
2 Attached at end of pitch change shaft.
3 Inside diameter is tapered and grooved for attachment to pitch
change shaft.

12-7
 FILE NO: 25191X-12-43

12-7A
 FILE NO: 25191X-12-43
12-4 General description of 205 tail rotor blade:
(a) Description:
1 Two bladed controllable pitch.
2 At the present time, located left side of tail rotor gearbox.
3 Composed of two assemblies:
a Blades- all metal construction and attached by bolts in
blade grip.
b Hub-hinge mounted to provide automatic equalization of
thrust on advancing and retreating blades.
4 Control links provide equal and simultaneous pitch change to
both blades.
5 Tail rotor counteracts togue of the main rotor and provides
directional control.
(b) Information (data):
1 Disc diameter –8 feet 6 inches.
2 Hub weight –17 pounds.
3 Blades- all metal bonded, phenulic block root-end, has place for
balance weights

12-8
 FILE NO: 25191X-12-43

12-8A
 FILE NO: 25191X-12-43

12-5 Tail rotor- The tail rotor assembly consists of a tail rotor hub assembly and a
tail rotor assembly.
(a) Location- Attached to the output shaft of the 90 degree gearbox on the
left hand side of the helicopter.
(b) Purpose- Counteracts torque of the main rotor.
(c) Balance- The tail rotor is balanced with the marvel balancing kit.

12-6 Tail rotor blade assembly:

(a) Description- Tail rotor blade assembly is an all metal air-foil. With an
aluminum alloy span, aluminum alloy honeycomb core (center), and
aluminum alloy skin. The inboard end has aluminum alloy doubles and
grip plate.

(b) Location- Attached to the tail rotor hub blade grips by two blade
retention bolts.

(c) Purpose- By changing pitch the tail rotor blades counteract the torque
of the main rotor.

12-7 The tail rotor hub assembly is made up of the following components:
(a) Tail rotor trunnion.
(b) Trunnion bearing housings.
(c) Tail rotor yoke.
(d) Tail rotor blade grip.
(e) Tail rotor bearings.

12-9
 FILE NO: 25191X-12-43

12-9A
 FILE NO: 25191X-12-43
12-8 Tail rotor trunnion:
(a) Description- The tail rotor trunnion is made of steel, there is a spindle
on each side of the trunnion to attach it to the trunnion bearings. The
trunnion is centered by shimming the trunnion bearing housings.
The trunnion has a hole in the center to mount onto the 90 degree
gearbox output shaft. The trunnion is splined so the output shaft can
turn the trunnion.

(b) Location- Mounted between the two trunnion bearing housings.

(c) Purpose- Allows flapping action of the tail rotor.

12-9 Trunnion bearing housings:

(a) Description- The trunnion bearing housing is made of steel. Inside the
housings are steel roller bearings.
(b) Location- Attached to the tail rotor yoke.

(c) Purpose- provides (gives) a place to attach the trunnion bearings and
trunnion.
(d) Lubrication-Mil-G-25537 grease.

12-10 Tail rotor yoke:

(a) Description- The tail rotor yoke is made of steel with two spindles one
at each end of the yoke. The spindles hold the tail rotor blade grips and
the tail rotor the trunnion bearings. The center of the youk is hollow to
attach the trunnion bearing housings.

(b) Location- Attached to the trunnion by the trunnion bearing housing.

(c) Purpose- To hold all of the components (parts) of the tail rotor.

12-10
 FILE NO: 25191X-12-43

12-11 Tail rotor blade grips:

(a) Description- The blade grip are hollow aluminum alloy, the outboard
end is made like a clevis to hold the tail rotor blades. The blade grips
mounts over the yoke spindles and bearings, the grips are held (to hold)
to the yoke by a retainer nut. The pitch horm is part of the blade grips.
(b) Location- Mounted over the yoke spindles and bearings.
(c) Purpose- holds the tail rotor blade.
12-11
 FILE NO: 25191X-12-43
12-12 Tail rotor bearings:
(a) Description- The tail rotor bearings are steel ball bearings. These are
four (4) bearings in the tail rotor, two (2) on each spindle.

(b) Location- Mounted on the yoke spindle.

(c) Purpose- Allows the tail rotor blade to pitch.

(d) Lubrication- Mil-G-25537 grease.

12-12
 FILE NO: 25191X-12-43
12-13 Description of 214 tail rotor:
(a) Description- The 214A has a two blade, semi-rigid delta hinge tail
rotor.
(b) Purpose- To provide directional control of helicopter.

12-13
 FILE NO: 25191X-12-43
(c) Components.
1 Yoke:
a Preconed for better use of rotor loads.
b Spherical bearings allow for feathering and flapping of
the tail rotor.
2 Grips- attach blades to yoke and are changed every 2400 hours.
3 Pitch horns-attached to trailing edge of grips and provides a
mounting point for chord wise balance weight.

12-14
 FILE NO: 25191X-12-43
4 Trunnion- mounts hub assembly to shaft. It has split halves, one
side with static stops and is master splined to the shaft.
5 Split halves, one with static stops.
6 Master splined to the support shaft.

12-15
 FILE NO: 25191X-12-43
12-14 Blade assembly- All metal construction:
(a) Corrosion resistant steel skin.
(b) Stainless steel leading edge strips.
(c) Aluminum alloy honeycomb core aft of the spar.
(d) Steel doubles for added strength.

(e) Grip plates- Reinforce root end of blade.

(f) Permanent balance weights.
(g) On butt block trailing edge.
(h) On blade tip.

12-16
 FILE NO: 25191X-12-43
12-15 Cross head assembly:
(a) Cross head- Master splined to the support shaft.
(b) Shield- Protects control shaft from dirt, water and foreign objects.
(c) Retaining nut- Holds hub assembly on tail rotor shaft.
(d) Support- Master splined to the support shaft:
1 Attaching point for counter weight link.
2 Retaining nut is safe tied to it.

(e) Pitch link- Attaches to pitch horn and cross head assembly. Changes
pitch of blades.

(f) Counterweight link- Attaches to support and counter balance bell

crank on cross head assembly .

12-17
 FILE NO: 25191X-12-43
(g) Bearing- Supports outboard end of cross head on control shaft.
(i) Nut retainer- Protects cross head bearing.

12-18
 FILE NO: 25191X-13-44
CHAPTER 13
SINGLE ROTOR SINGLE ENGINE
HYDRAULIC SYSTEM
13-1 General description of 206 hydraulic system:
(a) The hydraulic system provides the necessary pressure to operate the
flight control system.

(b) It makes easier for the pilot to move the controls.

(c) The hydraulic system consists of a reservoir, pump pressure regulator

valve, solenoid valve, pipe and hose assemblies.

(d) Operation: When the pilot moves the cyclic or collective control stick
the servo actuators will be activated and help the pilot to control the
flight surfaces, by using the hydraulic pressure.

13-1
 FILE NO: 25191X-13-44
13-2 Hydraulic system components:
(a) Hydraulic reservoir:
1 Purpose: The reservoir supplies the hydraulic fluid for the
hydraulic system.
2 Location: It is mounted on the forward side of transmission.
3 Type of fluid which is used in the reservoir is MIL-H-5606.
4 Capacity: 1 pint.
5 Cooling fins and a cooling jacket is used to keep it cool. (using
the air from the blower).
6 Sight glass a ball level sight glass indicates the fluid level
located on the right side of the reservoir.

13-2
 FILE NO: 25191X-13-44
7 Scupper: An opening on top of the reservoir connected to a drain
line used to release excess hydraulic fluid.
8 Baffle: Prevents surging or vortexing of hydraulic fluid.
(b) Pump:
1 Location: It is located on the lower part of the reservoir.
2 Type: Transmission driven, constant delivery gear type pump.
3 Purpose:
a Provides the necessary pressure to operate the hydraulic
system.
b Drives the rotor tachometer generator which is located on
the forward side of pump and reservoir.
4 Pump RPM is 4300 when rotor RPM is %100.
5 Pump delivers two gallons per minute.
6 Pump equipped with a shear shaft as a safety factor.
7 Shear shaft shears at 725 inch lbs.

13-3
 FILE NO: 25191X-13-44
(c) Pressure regulator valve:
1 Location: Mounted on the lower part of the hydraulic pump.
2 Purpose: To pressurize the hydraulic system.
3 Hydraulic system pressure is 600 + 25 PSI.
4 Pressure adjustment:
a Remove pressure regulator valve.
b Separate the housing and sleeve assembly.
c Assemble piston, sleeve and correct number of AN 960-
4L washers.
d Addition of one AN 960-4L washer will increase
hydraulic pressure by 30 PSI.

13-4
 FILE NO: 25191X-13-44
(d) Solenoid valve:
1 Location: Located on the forward side of the transmission on the
cabin roof.
2 A three way two position solenoid valve use to turn the
hydraulic system on and off.
3 Operation:
a Operated by 28 volt D.C.
b System on solenoid valve de-energized allowing pressure
to the pressure line.
c System off solenoid valve, energized allowing pressure to
the return line.

13-5
 FILE NO: 25191X-13-44
(e) Hydraulic filter:
1 Location: The hydraulic filter is located on the right side of the
transmission deck.
2 Purpose: It is used to clean the hydraulic fluid in the hydraulic system.
3 Type: Micronics filter.
4 The filter is changed or cleaned every 100 flight hours.
5 A red pop-out button located on top of the filter is called
differential pressure indicator (D.P.I).
6 70 + 10 PSI differential pressure causes to pop the button out.
7 When the filter bowl is removed and reinstalled must be cleaned
and safety wired to the filter head.
8 If a new filter is not available, the old filter may be cleaned
(with solvent) and blown out with high pressure air.

13-6
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(f) Servo actuator:
1 Location: The servo actuators are located on the forward end of
the transmission deck.
2 Purpose: Increases the pilot input to control flight surfaces with
more accuracy.

3 When the pilot moves flight controls the pilot valve located at
read of the servo actuator moves allowing fluid flow through the
cylinder.
4 If hydraulic pressure is lost due to pump failure or other causes
the pilot can control the helicopter but the control will be hard to move.

5 The servo actuators contain irreversible valves which allow fluid

to flow in one direction.
6 The collective servo is mounted in center position the cyclic
servos are on left and right.

7 The tail rotor servo is located aft and above the baggage
compartment. (AB 206 A).
8 The tail rotor servo actuator has been removed from later model aircraft.

9 A sequence valve is installed in the servo actuator used to:

a Relieve thermal pressure that has been increased when
the hydraulic system is inactive.

b Isolate the servo actuator from hydraulic system, in this

condition the servo actuator can control manually.

c The valve begins to open at 100-180 PSI and

completely open at 250 PSI.
13-7
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13-7A
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13-7B
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13-3 Hydraulic test stand:
(a) Purpose: It is used to flush (clean) or test the hydraulic system.
(b) The test stand has a hydraulic pump to operate the hydraulic system
without operating the engine.
(c) It has micronic filters that clean the fluid passing through the test stand.
(d) The test stand is connected to the Hydraulic system through two quick,
disconnects located in front of the hydraulic filter.
13-4 Inspect hydraulic system:
(a) All pipes for damage, leakage and security.
(b) Components for security.
(c) Correct oil level.
(d) For troubleshoot and rig system refer to a Agusta-Bell maintenance
manual section 3 (E-AB 206-250-2).

13-8
 FILE NO: 25191X-13-44
13-5 205 Hydraulic system components:
(a) Description of the 295 hydraulic system:
1 Pressured system.
2 Uses pump for pressure.
3 Has a filter.
4 Has 4 power cylinders.
(b) Operation:
1 The pump provides pressure.
2 Pressure on cylinders aid pilot in controlling helicopter.
(c) Information data:
1 Pump provides 1000 PSI full flow.

13-9
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13-9A
 FILE NO: 25191X-13-44
2 Cylinder are for cyclic control 2 each, and collective control 1
each, and one anti-torque cylinder for the tail rotor control.
3 Filter is a 25 micron paper type, 100 hrs. change, indicator type
is 1000 hrs. cleaning.
4 The system has a reservoir which hold 5.3 U.S pints.

(d) Major components:

1 Reservoir:
a Description:
(1) Constructed of aluminum.
(2) Capacity is 5.3 U.S pints.
(3) Sight glass-hydraulic fluid must cover the entire glass.
(4) Vent system- screened port on top of the reservoir.

2 Hydraulic pump:
a Description:
(1) Type variable delivery, axial piston.
(2) Capacity- 1000 PSI no flow, 950 PSI full flow.
(3) Drive-shear type.
(4) Ports- suction, pressure, by-pass seal drain.
(5) Location- transmission sump case.
(6) Hydraulic quill- seal drain.

3 Hydraulic filter:
a Description:
(1) Three sections-head, bowl, filter.
(2) Head by-pass provision.
(3) Filter element- paper type.
(4) Location- between the cyclic cylinders in the
pylon island.
13-10
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13-10A
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13-10B
 FILE NO: 25191X-13-44
b Maintenance:
(1) Change filter energy one hundred flying hours, the
red indicator type, every 1000 hours or when the
button will not stay down (70 + 10 PSI).
(2) Filter- for proper installation inlet port connected
to pressure line from pump.
(3) When replacing filter element, replace the seals
and proper safety.

4 Pressure relief valve:

a Description:
(1) Relieves system over pressure 1100 to 1200 PSI.
(2) Type- adjustable.
(3) Location- front of pylon island behind access panel.

5 Solenoid valve:
a Description:
(1) The solenoid valve is an electrically operated
three-way valve.
(2) The valve changes the fluid flow, cutting off
hydraulic aid the power cylinders.
(3) The solenoid valve is located in the pylon island
behind the access panel. It is 28 VDC operated.

6 Pressure switch:
a Description:
(1) The pressure switch is located in the pylon island
behind the access panel.
(2) The switch monitors the system pressure.

13-11
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13-11A
 FILE NO: 25191X-13-44

13-11B
 FILE NO: 25191X-13-44
(3) The switch turns on a light on the caution panel
when the pressure drop below 500 PSI and the
light goes out at 800 PSI.

7 Hydraulic cylinders:
a Description:
(1) Cyclic system has two cylinders.
(2) Collective has one cylinder.
(3) The cylinders are all the same type and are located
in the pylon island behind the access panel.

(4) They aid the pilot in cyclic and collective control.

(5) The tail rotor system has one servo cylinder,
located in the aft access compartment.
(6) The tail rotor servo is used to aid in anti torque control.

b Maintenance:
(1) If seals leak change them.
(2) Replace dust boot if cracked.
(3) If the drag on the cylinder is not in tolerance, the
upper bearing retaining nut must be re-torque to
400 to 450 inch lbs.

(4) If re-torque does not correct the drag, the Teflon

ring must be replaced.
(5) The support mounts must be lubricated every 100
hours with gap 25537 in a grease gun.

(6) The overall length of the cylinders should be:

(a) Left cylinder 53.47 inches.
13-12
 FILE NO: 25191X-13-44

13-12A
 FILE NO: 25191X-13-44

13-12B
 FILE NO: 25191X-13-44
(b) Right cylinder 53.72 inches.
(c) Collective cylinder 48.33 inches.

8 Irreversible valve:
a Description:
(1) The valve is located on the bottom of each
cylinder, attached to the servo valve.
(2) The valve is designed to absorb feedback force
and maintain 500 PSI of hydraulic fluid in the
cylinder in the event of hydraulic pressure loss.

9 Servo valve:
a Description:
(1) The power cylinder servo valve is located at the
base of the cylinder.

(2) The servo valve directs the flow of fluid into and
out of the cylinder to move the cylinder up or down.

10 Anti-torque servo cylinder:

a Description:
(1) Aids the pilot in moving the tail rotor controls.
(2) Located in the aft access compartment.
(3) This servo cylinder has no irreversible valve
bolted to it, but does have irreversible features
built in.

11 Hydraulic test stand D5-B:

a Purpose- The purpose of the test stand is to perform the
necessary test operations on aircraft hydraulic systems:
13-13
 FILE NO: 25191X-13-44

13-13A
 FILE NO: 25191X-13-44
(1) Flush the hydraulic system.
(2) Fill the hydraulic system.
(3) Test aircraft hydraulic system.

b Starting the engine:

(1) Open fluid by-pass valve.
(2) Open fluid feed line.
(3) Pull choke control out.
(4) Pull throttle control 10 ¼ open position.

(5) Set ignition switch on ON position.

(6) Push and hold starter switch until engine starts.
(7) Adjust choke until engine is operating normally
with choke fully open.

(8) Operate engine at 1000 to 1400 RPM for ten to

fifteen (10 to 15) minutes or until the engine
attains normal operating temperature.

13-14
 FILE NO: 25191X-13-44
13-6 214 Hydraulic system:
(a) Description: Two similar but separate hydraulic systems with a
capacity of 1.2 gallons, each provide propered assist of the cyclic,
collective and directional control system. Each system uses identical
pumps and reservoir, module and manifold assemblies. Although both
systems are used to operate the cyclic and collective dual power
actuators, there is no physical connection between the systems. Each
system uses separate passages and piston chambers inside the dual
actuators. If one system is disabled the other system will supply the
necessary hydraulic power for normal helicopter control.

13-15
 FILE NO: 25191X-13-44
13-7 System components:
(a) Pumps (2 each):
1 Location:
a No.1 pump is mounted vertically on the sump case
located on the lower transmission assembly.
b No.2 pump is mounted on the transmission accessory
drive quill adjacent to the rotor tachometer generator.
2 Type-variable delivery pressure compensated.
3 Pressure and flow:
a No.1 pump delivers 3000 PSI at 6.7 GPM.
b No.2 pump delivers 3000 PSI at 7.0 GPM.

13-16
 FILE NO: 25191X-13-44
(b) Dual cyclic actuators (2 each):
1 Location- In the forward pylon area on the left and right hand
sides.
2 Purpose- To assist the pilot in cyclic control of the main rotor.

13-17
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(c) Dual collective actuator:
1 Location- In the left rear pylon area.
2 Purpose- To assist the pilot in collective control of the main rotor.

13-18
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(d) Directional actuator:
1 Location- In the aft heater compartment on the right side.
2 Purpose- To assist the pilot in directional control of the A/C
when moving the pedals.

13-19
 FILE NO: 25191X-13-44
(e) AFCS actuators (3 each):
1 Location:
a The two cyclic actuators are underneath the center floor
panel in the cabin, forward of the pylon area.
b The directional AFCS actuator is forward of the aft heater
compartment accessible through ADF antenna access panel.
2 Purpose- Provide stability control when either SCAS or ATID
modes are selected.

13-20
 FILE NO: 25191X-13-44
(f) Hydraulic switches (2 each):
1 Location- On the miscellaneous control panel on the pedestal.
2 Purpose- Allows pilot to turn off either system .

(g) Caution lights (2 each):

1 Location- On the caution panel, one for each system labeled
HYDR SYS 1 and HYDR SYS 2.
2 Purpose- To warn the pilot that hydraulic pressure in the system
has decreased.

13-21
 FILE NO: 25191X-13-44
(h) Hydraulic temperature and pressure indicators (2 each):
1 Location:
a On the engine instrument section of the instrument panel.
b One for each system.
2 Dual indicating type:
a Temperature on left side.
b Pressure on right side.
3 Purpose- To provide the pilot with a visual indication that the
hydraulic systems temperature and pressure are within proper
limits.
4 Range markings:
a Temperature- Red line at 116º C maximum.
b Pressure:
(1) Red line at 2200 minimum.
(2) Pad line at 3200 maximum.
(3) Green are from 2900 to 3100 PSI normal
operation.

13-22
 FILE NO: 25191X-13-44
(i) Pressure transmitters:
1 Description- Two identical electrically operated pressure
transmitters pressure to gage on instrument panel.

2 Location- Installed in aft fuselage at station 129.00 in lower

transmission compartment.

3 Purpose- To transmit hydraulic pressure of #1 and #2 hydraulic

system to the hydraulic pressure gages located on instrument panel.

(j) Ground test connections:

1 Location- Forward of the aft cabin bulkhead beneath the left
sliding door.
2 Quick disconnect type.

3 Purpose- Allows a means for connecting hydraulic test cart to

the hydraulic system for flushing or ground test operation
without operating the engine.

13-23
 FILE NO: 25191X-13-44
(k) Reservoir, module and manifold assembly (2 each):
1 Location- In the forward pylon area, above the cabin roof, one
for each system.

2 Description- Three major assemblies bolted together to make

one unit.

13-24
 FILE NO: 25191X-13-44
3 Reservoir:
a Type- Spring loaded, pressurized to 75 PSI.
b Purpose- To store a supply of hydraulic fluid for use by
the hydraulic system.
c Capacity- 3.5 pints Mil-H-5606.
d Components:
(1) Sight gage, indicates fluid level.
(2) Bleeder valve, allows bleeding of air from the
reservoir.
(3) Overflow drain, drains excess fluid from reservoir,
if the reservoir is over serviced.
(4) Automatic shutoffs, prevent fluid leakage if the
reservoir is separated from the manifold.

13-25
 FILE NO: 25191X-13-44
4 Manifold:
a Purpose- Provides attachment points for mounting
brackets and all system connections, except for test
connections, bleeder valve and overflow drain on the
reservoir.
b Components:
(1) Filler plug, provides a connection for servicing the
reservoir with hydraulic fluid.
(2) Temperature bulb, measures the temperature of the
hydraulic fluid for the indicator.
(3) Pressure switch, provides the pilot with a visual
indication on the caution panel if the hydraulic
system pressure decreases.

13-26
 FILE NO: 25191X-13-44
(4) Automatic shutoffs, prevents fluid leakage if the
reservoir filter module assembly is separated from
manifold.

13-27
 FILE NO: 25191X-13-44

5 Filter Module Assembly’s:

a Purpose- Performs many different functions .

b Components:
(1) Filters- 2 for each system, total of 4 each:
(a) Type- 10 micron metal mesh.
(b) Purpose- To filter the pressure and return
fluid to prevent contamination of the
hydraulic system.

(2) Visual indicators (4 each):

(a) Type- Spring loaded red button.
(b) Purpose- To warn that the filters have
become clogged or dirty.

(3) Relief valve:

(a) Purpose- Relives excess system pressure.

(4) Filter bypass relief valve:

(a) Purpose- Allows the return fluid to the
reservoir to bypass the return filter should
the return filter become clogged or dirty.

13-28
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13-28A
 FILE NO: 25191X-13-44
(5) Solenoid valve:
(a) Purpose- To turn the hydraulic system on or off.

(6) Pressure operated valve:

(a) Purpose- Directs return fluid to the
reservoir or the hydraulic test cart

(7) Automatic shutoffs- Prevent fluid leakage it the

filter module assembly is separated from the
manifold.

13-29
 FILE NO: 25191X-8-54
APPENDIX A
COMPREHENSION CHECK
SINGLE ROTOR SINGLE ENGINE
MAIN ROTOR SYSTEM

1. What type of blades are used on the 206 helicopter?

2. What drives the main rotor hub?

3. What is the purpose of 206 main rotor tension to slion strap?

4. What is the 206 main rotor trunion made of?

5. What is used to waned the 206 main rotor blades?

6. What is the purpose of nose block of 205 main rotor system?

7. What type of oil is used in 205 main rotor grips?

8. What is the purpose of 214A main rotor system?

9. What is the purpose of 214A M/R spar?

10. What is the tension torsition strap of 214A main rotor located?

A-1
 FILE NO: 25191X-9-36
APPENDIX A
COMPREHENSION CHECK
SINGLE ROTOR SINGLE ENGINE
SWASHPLATE AND SUPPORT SYSTEM

1. How are secured the swashplate to the transmission?

2. What is the purpose of idler link assembly?

3. Where is the protective boot located?

4. What are moved the sleeve in up an down motion?

5. What are the purpose of swashplate in 214 helicopter?

6. Where is the support assembly located?

7. Where is the sleeve located?

8. How are secured the drive plate to the collective hub?

A-2
 FILE NO: 25191X-10-48
APPENDIX A
COMPREHENSION CHECK
SINGLE ROTOR SINGLE ENGINE
TRANSMISSION AND MAST

1. What is the location of 205 lift link?

2. What is the construction of 205 planetary case?

3. Which of the four mast splines on 205 is not master spline?

4. How many types of oil filters are use on 205 main transmission?

5. How many cases are on 214 transmission?

6. What type oil system does the 214 main transmission have?

7. When is the 214 transmission external oil filter be change?

8. What is the purpose of chip detectors in transmission?

9. How many stages reduction are provided for 206 XMSN?

10. How much reduction is provided by the 206 XMSN?

11. How many sets of splines are there on the 206 mast?

12. Where is the location of the 206 XMSN?

A-3
 FILE NO: 25191X-11-48
APPENDIX A
COMPREHENSION CHECK
SINGLE ROTOR SINGLE ENGINE
POWERTRAIN SYSTEM

1. What is use to lubricate the 205 main drive shaft?

2. What are the 205 tail rotor drive shafts made of?
3. What is the purpose of 205 tail rotor drive shafts?
4. What are the 205 tail rotor drive shafts metal strips use for?
5. Where is the location of 205 42º gearbox?
6. What is the purpose of 214 output quill of the 42º gearbox fan?
7. What is the reduction of 214 90º gearbox?
8. How many sections of the 214 tail rotor drive shafting are interchangeable?
9. How is the 206 drive drain driven?
10. Where is the location of the 206 tail rotor drive shaft?
11. How often must the 206 main drive shaft be serviced?
12. How much reduction is provided by the 206 tail rotor GIB?

A-4
 FILE NO: 25191X-12-43
APPENDIX A
COMPREHENSION CHECK
SINGLE ROTOR SINGLE ENGINE
TAIL ROTOR SYSTEM

1. What are the phonolic blocks used for?

2. Why is the inside of cross head tapered?

3. What is the purpose of spacer?

4. What is the static stop made of?

5. What is the purpose of bumper?

6. What is the purpose of safety washer?

7. How many bearings are used in the tail rotor assembly?

8. Where is the blade grip untied?

9. What type bearings are located in the trunnion housing?

10. How many components of the tail rotor assembly are master splined?

11. What is purpose of the steel doubles on the root end of the blade?

A-5
 FILE NO: 25191X-13-44
APPENDIX A
COMPREHENSION CHECK
SINGLE ROTOR SINGLE ENGINE
HYDRAULIC SYSTEM

1. What is the purpose of the 206 hydraulic system?

2. What is the function of the 206 hydraulic reservoir baffle?

3. How much is the capacity of the 206 hydraulic reservoir?

4. Where is the location of the 206 hydraulic pump?

5. How much is the capacity of the 205 hydraulic reservoir?

6. What type filter element is used on the 205 hydraulic system?

7. How often must the 205 filter element be changed?

8. How is the 205 hydraulic system solenoid valve operated?

9. Where is the location of the 214 Dual cyclic actuators?

10. What type reservoir is used on the 214 hydraulic system?

11. How much is the capacity of the 214 hydraulic reservoir?

12. What type filter is used on the 214 hydraulic system filter module?

A-6