BHT-ALL-SRM

CHAPTER 1 GENERAL INFORMATION

TABLE OF CONTENTS
Paragraph
Number

Page
Number

Title
GENERAL INFORMATION

1-1
1-2
1-3
1-4
1-5
1-6
1-7
1-8
1-9
1-10
1-11
1-12
1-13
1-14
1-15
1-15-1
1-15-2
1-15-3
1-15-4
1-15-5
1-15-6
1-15-7
1-16
1-17
1-17-1
1-17-2
1-17-3
1-17-4
1-18
1-18-1
1-18-2
1-18-3
1-18-4
1-19
1-19-1
1-19-2
1-20

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Introduction .........................................................................................................
Scope of This Manual .........................................................................................
How to Use This Manual.....................................................................................
Supplemental Type Certificate (STC) .................................................................
Consumable Materials ........................................................................................
Ordering Repair Materials...................................................................................
Special Tools ......................................................................................................
Standard and Special Torque Requirements......................................................
Warnings, Cautions, and Notes ..........................................................................
Use of Procedural Words....................................................................................
Damage/Repair Limits ........................................................................................
Standard Practices..............................................................................................
Replacement Parts and Assemblies ...................................................................
Structures, Doors, Cowls, and Fairings Description.......................................
Reference Lines..................................................................................................
Reference Lines Introduction ....................................................................
Reference Lines Datum ............................................................................
Reference Lines Fuselage Station ............................................................
Reference Lines Boom Station .................................................................
Reference Lines Fin Station......................................................................
Reference Lines Waterlines ......................................................................
Reference Lines Buttock Station...............................................................
FAA/TCCA Approved Repair Data......................................................................
Repair Categories ...............................................................................................
Repair Categories Negligible ....................................................................
Repair Categories Generic........................................................................
Repair Categories Typical.........................................................................
Repair Categories Specific........................................................................
Repair Methods...................................................................................................
Repair Methods Parts Replacement .........................................................
Repair Methods Welded............................................................................
Repair Methods Riveted, Composite, or Cold Bonded .............................
Repair Methods Wet Lay-up .....................................................................
Repair Deviations................................................................................................
Repair Deviations Minor............................................................................
Repair Deviations Major............................................................................
Repair Limitations ...............................................................................................

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1-4
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1-5
1-5
1-5
1-5
1-6
1-6
1-6
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1-7
1-7
1-7
1-7
1-7
1-7
1-7
1-7
1-7
1-8
1-8
1-8
1-8
1-8
1-8
1-8
1-9
1-9
1-9
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GENERAL INFORMATION
1-1.

INTRODUCTION

This Structural Repair Manual (BHT-ALL-SRM) provides generic information to owners/operators for the repair of
fuselage structural components installed or used on Bell Helicopter Textron commercial products.

1-2.

SCOPE OF THIS MANUAL

This manual contains generic information, processes, techniques, technical data, and typical approved repair
procedures for both the metallic and fiber reinforced composite components used on Bell Helicopter Textron
commercial products. Owners/operators of Bell Helicopter Textron commercial products can refer to this manual to
find recommended processes and techniques, and possible repair procedures that may be applicable when all the
restrictions are met.

WARNING
ALL REPAIR TECHNIQUES, PROCESSES, AND PROCEDURES PUBLISHED IN THIS MANUAL
ARE INTENDED FOR PARTS OR REPAIR MATERIAL MANUFACTURED BY OR FOR BELL
HELICOPTER TEXTRON, OR PROCURED THROUGH SOURCES APPROVED BY BELL
HELICOPTER TEXTRON. IF PARTS OR REPAIR MATERIALS ARE PROCURED FROM SOURCES
OTHER THAN THOSE APPROVED BY BELL HELICOPTER TEXTRON, THEN THE DATA
PUBLISHED IN THIS MANUAL IS CONSIDERED NOT APPLICABLE. THE USER IS WARNED TO
NOT RELY ON BELL HELICOPTER TEXTRON FOR PARTS, REPAIR MATERIALS, REPAIRS, OR
PROCESSES AND TECHNIQUES NOT APPROVED BY BELL HELICOPTER TEXTRON. BELL
HELICOPTER TEXTRON IS NOT RESPONSIBLE FOR PARTS, MATERIALS, PROCESSES, AND
TECHNIQUES OTHER THAN THOSE THAT IT HAS ITSELF DEVELOPED OR APPROVED. FOR
PARTS OR REPAIR MATERIALS NOT APPROVED BY BELL HELICOPTER TEXTRON, THE USER
IS RESPONSIBLE FOR OBTAINING APPLICABLE INSPECTIONS AND REPAIR METHODS,
PROCESSES, OR TECHNIQUES DIRECTLY FROM THE SUPPLIER OF THE AFFECTED PART.
NEGLIGENCE TO USE PARTS, REPAIR MATERIAL PROCESSES, TECHNIQUES, AND REPAIR
PROCEDURES APPROVED BY BELL HELICOPTER TEXTRON MAY VOID THE WARRANTY
APPLICABLE TO NEW BELL HELICOPTER TEXTRON PRODUCTS.
This manual has been divided into chapters and appendices for ease of use and information retrieval.
Chapter 1 Offers general information about this manual and its usage.
Chapter 2 Provides guidance to determine the type and extent of damage. It also provides instructions on how
to approach Bell Helicopter Textron to get assistance for repair when damage is out of the scope of this manual.
Chapter 3 Provides information on the most useful aspects of accomplishing repairs to metal (aluminum,
corrosion resistant steel, and titanium) structures and components or for aluminum faced bonded panels of various
core types with or without fiberglass edging. This chapter also includes information about generic processes,
techniques, and typical repairs that may be used in most cases. Operators may find applicable repair procedures in
this chapter, which may be performed under some restrictions, following the discovery of structural damage to their
helicopter. Operators may find additional repair information from the model-specific SRM if repair data in this
manual is not found to be applicable.
Chapter 4 Provides information on accomplishing wet lay-up repairs to fiber reinforced composite structures and
components using fiberglass or carbon material. Structures addressed in this chapter may be monolithic or

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sandwich panel construction and may have a metallic or non-metallic core. This chapter also includes information
about generic processes, techniques, and typical repairs. Operators may find applicable repair procedures in this
chapter, which may be performed under some restrictions, following the discovery of structural damage to their
helicopter. Operators may find additional repair information in the model-specific SRM if repair information in this
manual is not found to be applicable.
The appendices list useful information relating to structural repair of Bell Helicopter Textron commercial products.
The information is divided as follows:

1-3.

Appendix A Provides information on miscellaneous bonding adhesives/sealants and curing time

required to perform the repairs described in this manual.

HOW TO USE THIS MANUAL

This manual is divided into chapters and appendices, as described in paragraph 1-2.
NOTE
If the information or data you need cannot be found in this manual, refer to the model-specific SRM or
contact Product Support Engineering for assistance.
Tables that provide quick repair selection, based on the type of structure to be repaired and the damage
type and size, are found at the beginning of Chapter 3 and Chapter 4.
To find a general subject, refer first to the table of contents at the beginning of each chapter or appendix, then to
the list of paragraphs. Go to the paragraph that provides the information you need to determine if this information or
procedure is applicable.

1-4.

SUPPLEMENTAL TYPE CERTIFICATE (STC)

Repair processes, techniques, and procedures for Supplemental Type Certificate (STC) installations are not
included in this manual. When a STC installation is incorporated in the helicopter, the area of the structure affected
by the installation shall be maintained in accordance with the maintenance program or Instructions for Continuing
Airworthiness (ICA) supplied by the STC holder.
STC certification data is normally not reviewed by Bell Helicopter Textron. A STC installation on a Bell Helicopter
product can affect the system interface, operating characteristics, or fatigue life of certain components and the
information we provide in this manual may not qualify for the modified section of the helicopter. Therefore, it is
suggested to contact the owner of the STC certification data for repair assistance.

1-5.

CONSUMABLE MATERIALS
NOTE
Handling and storage of consumable material shall be in accordance with manufacturer's instructions,
unless otherwise noted in the applicable chapter or appendix of this manual.

Consumable materials that are required to perform repairs are called out in the text by nomenclature and C-code
number (e.g., drycleaning solvent (C-304)). Each number is associated with a cross-reference number available
from Bell Helicopter Textron approved supply centers or commercially, as indicated. The Standard Practices
Manual (BHT-ALL-SPM) provides information on the consumable materials required to perform the repairs
described in this manual.

1-4

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If there is ever a difference between the Structural Repair Manual (BHT-ALL-SRM) and the BHT-ALL-SPM, the
manual that has the latest date of issue or revision, as applicable, shows the preferred material. However, either
material may be used for the repair task, unless otherwise specified.

1-6.

ORDERING REPAIR MATERIALS

The various materials required for the repairs described in this Structural Repair Manual are procurable directly
from any Bell Helicopter approved supply center. Occasionally, different or more advanced materials could be
delivered from a supply center, as guided by Bell Helicopter Textron engineering. If an alternate or replacement
material is delivered from our supply center, both the new and previously specified material may be utilized, unless
otherwise specified.

1-7.

SPECIAL TOOLS

Certain procedures or repairs require the use of special tools, workaids, or templates. Special tools, workaids, or
templates are described in an appendix of the model-specific SRM. Some could be rented from Bell Helicopter
Textron or simply be manufactured locally.
NOTE
Bell Helicopter Textron does not support repairs done using a stationary fixture that does not carry a
valid and current BHT certification tag at the time the repair is performed.
Additional, more complex, and stationary Bell Helicopter approved repair fixtures (with current certification tags)
are located at approved Customer Service Facilities (CSF). The list of Bell Helicopter approved CSF can be found
in the annual Customer Support and Services Directory or on the Bell Helicopter Web site at http://
www.bellhelicopter.com/en/support/.

1-8.

STANDARD AND SPECIAL TORQUE REQUIREMENTS

Standard torque values for various types of fasteners are found in the Standard Practices Manual (BHT-ALL-SPM).
Where applicable, special torque values will be identified within the text with a symbol ( T ). Torque values are
listed only in the installation section of the procedure and on the applicable repair figure (illustration). When more
than one torque value is listed on an illustration, the torque symbol ( T ) will carry a number. The torque value will
be listed next to the numbered torque symbol in the legend of the illustration.

1-9.

WARNINGS, CAUTIONS, AND NOTES

WARNING
A PROCEDURE, PRACTICE, ETC., WHICH IF NOT STRICTLY OBSERVED, COULD RESULT IN
PERSONAL INJURY OR DEATH.

CAUTION
A PROCEDURE, PRACTICE, ETC., WHICH IF NOT STRICTLY OBSERVED, COULD RESULT IN
DAMAGE TO EQUIPMENT OR TO THE HELICOPTER.

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NOTE
A note provides supplemental information about the procedure, practice, condition etc. for the required
task.
Warnings, cautions, and notes are used throughout this manual to emphasize important and critical instructions.
They normally appear ahead of the procedure they apply to.

1-10.

USE OF PROCEDURAL WORDS

The procedural words used throughout this manual and their intended meanings are as follows:
"Shall" is used when the application of a procedure is mandatory.
"Should" is used when the application of a procedure is recommended.
"May" is used when the application of a procedure is optional.
"Will" is used to indicate futurity, not to indicate a mandatory procedure.

1-11.

DAMAGE/REPAIR LIMITS

CAUTION
THE METRIC EQUIVALENTS TO U.S. STANDARD WEIGHTS AND MEASURES ARE PROVIDED IN
THIS MANUAL. HOWEVER, USE ONLY THE U.S. STANDARD VALUES WHEN YOU TAKE A
MEASUREMENT TO ESTABLISH A SPECIFIC DIMENSION OR TO FIND THE SERVICEABILITY OF
A COMPONENT.
Throughout this manual, wear, damage, and repair limits are provided to determine if the parts are serviceable.
Parts showing evidence of wear or physical damage shall be checked dimensionally.

1-12.

STANDARD PRACTICES

Standard practices and procedures not described within this manual are contained in the Standard Practices
Manual (BHT-ALL-SPM).

1-13.

REPLACEMENT PARTS AND ASSEMBLIES

WARNING
THE STRUCTURAL ENGINEERING ASPECT OF THE PROCESSES, TECHNIQUES, AND REPAIRS
DESCRIBED IN THIS MANUAL IS APPROVED FOR PARTS OBTAINED THROUGH SOURCES
APPROVED BY BELL HELICOPTER TEXTRON ONLY.
Replacement parts and assemblies required for the applicable repairs are listed in the repair procedure of the
model-specific Illustrated Parts Breakdown (IPB) manual. The IPB provides complete nomenclatures, part
numbers, effectivity, and ordering information.

1-6

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1-14.

STRUCTURES, DOORS, COWLS, AND FAIRINGS DESCRIPTION

Complete descriptions of the BHT helicopter models are found in the model-specific SRM. For helicopters not
described within these manuals, contact Product Support Engineering.

1-15.

REFERENCE LINES
NOTE

The layouts of the various helicopter reference lines are found in the model-specific SRM. For
helicopters not described within these manuals, contact Product Support Engineering.
1-15-1. REFERENCE LINES INTRODUCTION
Reference lines are a useful tool to identify or locate a precise location on the airframe. A location is given by
specifying the intersection in space of various lines known as datum, Fuselage Station lines, Boom Station lines,
Fin Station lines, Waterlines and Buttock Lines.
1-15-2. REFERENCE LINES DATUM
The datum is an imaginary vertical plane from which all horizontal measurements are taken. This point may or may
not be on the part or assembly.
1-15-3. REFERENCE LINES FUSELAGE STATION
Fuselage Station lines (FS, STA, or station) are vertical reference lines, as viewed from the side of the helicopter.
They express the distance in inches from the datum line (FS 0.0) to a given point.
1-15-4. REFERENCE LINES BOOM STATION
Boom Station lines (BS or BSTA) are similar to Fuselage Station lines but are applicable to the tailboom. They
express the distance in inches from the datum line (BS or BSTA 0.0) to a given point. They are not vertical but are
normal to the tailboom's horizontal centerline.
1-15-5. REFERENCE LINES FIN STATION
Fin Station lines (FS or FSTA) are similar to Fuselage Station lines but are applicable to the vertical fin. They
express the distance in inches from the datum line (FS or FSTA 0.0) at the gearbox attachment point to a given
point, as seen with the medium helicopter fleet.
1-15-6. REFERENCE LINES WATERLINES
Waterlines (WL) are horizontal reference lines, as viewed from the side or front of the helicopter. They express the
distance in inches above the datum (WL 0.0) to a given point.
1-15-7. REFERENCE LINES BUTTOCK STATION
Buttock Lines (BL) are vertical reference lines, as viewed from the back of the helicopter. They express the
distance in inches from the centerline (BL 0.0) of the helicopter to a given point. Dimensions given left of centerline
are referred to as Left Buttock Line (LBL), when looking forward; dimensions given right of the centerline are
referred to as Right Buttock Line (RBL).

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1-16.

FAA/TCCA APPROVED REPAIR DATA

WARNING
USE OF THIS DATA ON PARTS OBTAINED THROUGH SOURCES OTHER THAN BELL
HELICOPTER TEXTRON IS STRICTLY FORBIDDEN.
NOTE
The FAA/TCCA approved data contained in this manual was developed following the requirements of
the United States Department of Transportation, Federal Aviation No. 43, TCCA Canadian Air
Regulation 571.06 and Bell Helicopter Textron engineering.
Only the structural engineering aspects of the repairs described in this manual are FAA/TCCA approved for parts
obtained through sources approved by Bell Helicopter Textron. The TCCA/FAA (ODA) approval of the repairs is
provided on pages C/D and E/F.

1-17.

REPAIR CATEGORIES

Bell Helicopter repair information covers four categories of repairs: negligible, generic, typical, and specific.
1-17-1. REPAIR CATEGORIES NEGLIGIBLE
The negligible repair information addresses damage that may remain as is, or may require a simple repair
procedure not necessarily contained in this manual. This information may be found as part of the helicopter
maintenance program, in the corrosion Control Guide CSSD-PSE-87-001, or in any other document published by
Bell Helicopter Textron.
1-17-2. REPAIR CATEGORIES GENERIC
The generic repair information is not specific to a component or part number but has a wide application. It can be
used in many areas or on many parts provided it meets the restriction requirements of the procedure described.
1-17-3. REPAIR CATEGORIES TYPICAL
The typical repair information addresses types of component construction and structure associated with a
particular model. Typical repair information is found in the model-specific SRM.
1-17-4. REPAIR CATEGORIES SPECIFIC
The specific repair information is designed by Bell Helicopter Textron engineering on a case-by-case basis. The
repair information is based on a complete damage description provided by the operator. The specific repair
information includes its own FAA/ODA 8110-3 and 8100-9 approval forms or TCCA Statement of Compliance
(SOC) form AE-100-1, and is valid for one helicopter and/or one serialized component only.

1-18.

REPAIR METHODS

This manual provides various repair methods, techniques, and processes along with generic repair schemes that
can be selected based on the type of damage and the type of structure to be repaired.
The following describes the repair methods covered by this manual.

1-8

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1-18-1. REPAIR METHODS PARTS REPLACEMENT
NOTE
In some cases, Bell Helicopter Textron may issue a specific repair procedure that would serve to
alleviate the labor involved in the replacement of a part.
This is probably the first repair method operators should consider. Parts replacement is the most satisfactory repair,
from the point of view of engineering, when carried out correctly. It ensures the same strength, weight, and
appearance, and could also prevent the down-time that may be involved with specific repair methods. Availability
of the replacement part, workload, and use of a fixture and/or workaid are just a few factors that may guide the
operator to other viable repair methods. The model-specific SRM provides replacement instructions for helicopter
structural components. Other publications from Bell Helicopter Textron may also provide instructions for
replacement of helicopter structural components.
1-18-2. REPAIR METHODS WELDED
No welded repairs are covered in this manual. However, some welded repairs that are described in the applicable
Maintenance Manual (MM) or Components Repair and Overhaul (CR&O) manual may be permitted. A publication
such as the FAA AC-43-13-1B (or subsequent) have approved information concerning steel tubing structure
repairs, which may be acceptable to the Civil Aviation Administration authorities.
1-18-3. REPAIR METHODS RIVETED, COMPOSITE, OR COLD BONDED
A combination of bonded and riveted repairs are covered in this manual. Each repair provides the type of rivet and
the rivet pattern to be used. Rivet pitch and edge distance are also provided. Rivet rows added as part of a repair
procedure are to be aligned with each other and, if possible, with existing rivet rows.
The size of the required doubler may vary, based on the damage area to cover. Applicable overlap of the doubler
with existing part is also defined. In most cases, composite-bond material is noted as the required doubler material.
1-18-4. REPAIR METHODS WET LAY-UP
Wet lay-up processes for fiberglass or carbon fiber material are used for the repair or replacement of composite
plies and laminates.

1-19.

REPAIR DEVIATIONS

Deviation from approved generic repairs described in this manual, deviation from typical repairs found in the
model-specific SRM, or specific repairs covered by Federal Aviation Agency (FAA) Designated Engineering
Representative (DER) approved documents (8110-3), or Transport Canada Civil Aviation (TCCA) Certification
Delegate (CD) approved documents (AE-100-1), shall be analyzed to determine if the change is considered a
minor or major deviation.
1-19-1. REPAIR DEVIATIONS MINOR
Minor deviation from FAA/TCCA approved data can be authorized by Product Support Engineering on a
case-by-case basis. For a minor deviation, FAA document (8110-3) or TCCA document (AE-100-1) will not be
offered, and it will become the responsibility of the operator to obtain concurrence from the local aviation authority.

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1-19-2. REPAIR DEVIATIONS MAJOR

Major deviation from FAA/TCCA approved data will require new engineering approval. Sources of approval are as
follows:

Manufacturer's approval (internal FAA/DER or TCCA/DAR approval forms)

Outside engineering approval by Designated Engineering Representative (DER) in U.S., and Department
Approved Representative (DAR) in Canada

Local aviation airworthiness authority

1-20.

REPAIR LIMITATIONS

WARNING
THE FOLLOWING INFORMATION IS TCCA/FAA APPROVED AND INDICATES THE HELICOPTER
COMPONENTS OR THE AREAS OF THE HELICOPTER STRUCTURES THAT ARE CONSIDERED
CRITICAL. IT IS NOT ACCEPTABLE TO PERFORM REPAIRS (CHAPTER 3 AND CHAPTER 4) IN
THE FOLLOWING LOCATIONS WITHOUT PRIOR WRITTEN APPROVAL FROM PRODUCT
SUPPORT ENGINEERING OR AS SPECIFIED BY THE MODEL-SPECIFIC SRM.
NOTE
The following list is not exhaustive and may change as seen appropriate by Bell Helicopter Textron. If
you have questions concerning the repair area, contact Product Support Engineering for assistance.
The term structure means all metallic and composite parts.
The following restrictions are sorted by helicopter model.
All models:

1-10

Nodal beam or pylon attachment and their support structures

Engine mount fittings and their backup structures

Tailboom to fuselage attachment structure, up to and including one frame forward and aft of attachment
bulkheads (on medium helicopters, this extends aft to BSTA 101.38). The term structure shall mean all
metallic and composite parts.

All aerodynamic surfaces such as vertical fins, horizontal stabilizers, and auxiliary fins

All tail rotor gearbox attachment structures

Control support fittings, their backup structures, and control tubes

Landing gear backup structure

Landing gear crosstubes

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All clevises

All lugs

All drivetrain components (hanger bearing supports, gearbox, etc.)

Whenever fit and/or function and/or alignment of the next assembly is affected

Whenever interchangeability of a part is affected

All areas with cold expanded fastener holes

All areas covered by an Airworthiness Directive (AD)

All parts listed as critical parts in the model-specific Maintenance Manual

Light helicopters (206 series (inclusive of U.S. army designation TH-57 and TH-67), 407, etc.):

Vertical tunnel (center post) structure

Roof beam assembly, including intercostals, internal bulkheads, and attachment fittings

Aft fuselage carbon skins (aft of station 204 on Model 407)

Aft lower fairing (boat tail on Model 407 only)

Monocoque tailboom structure

Intermediate helicopters (222 series, 230, 427, 430, etc.):

Vertical tunnel (center post) structure

Roof beam assembly, including intercostals, internal bulkheads, and attachment fittings

Wing attachment fittings and their backup structure

Vertical fin attachment fitting

Floor beams

Radome

Carbon fiber "T" stiffeners and their bond lines to the side body and floor on Model 427

Monocoque tailboom structure on Model 427

Medium helicopters (204, 205, 210, 212, 214 series, 412 series, etc.):

Vertical fin forward and aft spars and their attachment splices to the tailboom bulkhead

Vertical tie of the forward pylon angle to main beam located at the floor (WL 22.00)

Floor main beams

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Main lift beam (below transmission) and its attachment structure

Radome

429 helicopters:

1-12

Forward lift frame aft composite cover

Roof beam assembly, including intercostals

All lift frame joints to roof and keel beams and all lift frame splices

Aft fuselage skins aft of station 326

Canted beams between STA 278.606 and STA 326.00

Horizontal stabilizer spar tube

Vertical fin and its attachment fittings

Skid tubes

Carbon fiber "T" stiffeners and their bond lines to the side body and floor

Tailboom structure

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