# ALERT SERVICE BULLETIN

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25200 W. Rye Canyon Road • Santa Clarita, California 91355-1265 • 661/294-6000 • FAX 661/259-9622 FLIGHT CONTROLS – DUAL SERVOACT UATOR ASSEMBLY, PART NUMBER 141600



### 1.

U 

### Planning Information

A. Effectivity
This Alert Service Bulletin applies to all Dual Servoactuator Assemblies 141600-101 (Bell Helicopter 222-382-001-107) used on Bell model 430, 230, and 222 aircraft. This Alert Service Bulletin provides notice of an inspection requirement for the presence of corrosion and for the potential of non-conforming hardware.

B. Concurrent Requirements None

C. Reason

It has been discovered that there is potential for Output Piston Rod Assemblies to exist with unacceptable levels of corrosion. This corrosion can lead to stress corrosion cracking resulting in the failure of the Output Piston Rod Assembly. During the corrosion investigation it has been found that Output Piston Rod Assemblies exist with non-conforming grind reliefs. This Alert Service Bulletin will instruct for the inspection requirements for the potential presence of both of these conditions. The presence of either corrosion or a non-conforming grind relief have the potential to lead to stress corrosion cracking resulting in loss of control of the
aircraft.

D. Description

This Alert Service Bulletin instructs in the procedure to disassemble the Servoactuator to the extent required to inspect the Output Piston Rod Assembly for the potential existence of corrosion and the non-conforming grind relief. This Alert Service Bulletin will then instruct on how to rework as required and reassemble the unit for operation. If the Piston Rod Assembly or Servoactuator needs to be
returned to Woodward HRT for maintenance it should be sent to the address below:

Attn: SB141600-67-02 Woodward HRT 25200 West Rye Canyon Road, Santa Clarita, CA 91355-1265;

E. Compliance

Due to potential loss of control of the aircraft, compliance with this Alert Service Bulletin shall be accomplished upon receipt.

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25200 W. Rye Canyon Road • Santa Clarita, California 91355-1265 • 661/294-6000 • FAX 661/259-9622 F. Approval

This Alert Service Bulletin contains no modification information that revises the approved configuration and therefore does not require governmental or other regulatory agency approval.

G. Manpower

Once the Servoactuator is removed from the aircraft the disassembly, inspection, and reassembly of one Servoactuator can be performed in less than 4 hours.

H. Weight and Balance

None

I. Electrical Load Data

Not Changed

J. Software Accomplishment Summary

Not Applicable

K. References

1. Existing Data:

Component Maintenance Manual 67-31-08

2. Data supplied with this Alert Service Bulletin:

None

L. Other Publications Affected

U Publication

U U Chapter-Section-Subject

U Component Maintenance Manual 67-31-08

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25200 W. Rye Canyon Road • Santa Clarita, California 91355-1265 • 661/294-6000 • FAX 661/259-9622 

### 2.

U 

### Material Information

A. Material - Price and Availability

Nut (570) 141517-001

Cotter Pin (565) MS24665-302

The above material may be required for the completion of this Alert Service Bulletin.

B. Special Tooling - Price and Availability

87001499-TQFX DET 1 Torque Fixture

87003495 Assembly Bullet

The above special tooling is required for the completion of this Alert Service Bulletin. The tool drawings are available in figures 10 and 11 for local manufacture by the operator. They are also availabl e by contacting Terry Eyrolet at

H U Terry.Eyrolet@woodward.com

U H or (661) 702-5437.



### 3.

U 

### Accomplishment Instructions

Note : All Item numbers indicated below shown in parentheses refer to CMM 67-31-08 Illustrated Parts List. The appropriate section from CMM 67-31-08 IPL is included in figure 14-1, 14-2, and 14-3 for reference.

Caution: No intermingling of components between Servoactuators is permissible. All components must go back into the same Servoactuator.

A. Part I. Disassembly Required to Gain Access to Piston Rod Assembly (575).

Caution : Note lockwire position during disassembly to aid in the replacement of lockwire during assembly.

Caution : Procedure requires removal and reassembly of piston which can introduce FOD into the hydraulic system. FOD has the potential to cause loss of control of the aircraft.

1. Remove Input Linkage Assembly: 1.1. Remove lockwire and Remove Bolt (365), Washer (370), Bolt (355), and Washer (360). 1.2. Remove lockwire and Remove Bolt (320) and Locking Washer (325) 1.3. Clean the face of Lever (CMM IPL Figure 2 Item Number 10, ref figure14.1) and Arm Assembly (380), with Acetone.

Caution : Take care of the positioning and handling of the Servoactuator during the disassembly and assembly process to prevent the inadvertent wiping off of marking. This

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25200 W. Rye Canyon Road • Santa Clarita, California 91355-1265 • 661/294-6000 • FAX 661/259-9622 mark locates the hydraulic null in relation to the mechanical stops and is critical in order to preserve required bypass stroke.

1.4. Mark a line across the spline of the lever and the face of the adjoining part in multiple locations as shown in figure 1 with a felt tip pen and/or grease pencil.

Caution : The removal of the Input Arm Assembly, Arm Assembly, and Link Assembly is critical in that any damage to the components can compromise the safe operation of the
Servoactuator. Remove with care.

1.5. Carefully remove Input Arm Assembly (330), Arm Assembly (380), and Link Assembly (405) from Input Structur e Assembly (510) and Lever (CMM IPL Figure 2 Item Number 10, ref figure14.1).

2. Remove Output Structure Assembly (515) 2.1. Remove lockwire and remove Screw (445) qty 4 and Washer (450) qty 4 2.2. Remove lockwire and remove Bolt (500) qty 4 and Flat Washer (505) qty 4 2.3. Cut lockwire that is looped through holes in Output Structure Assembly (515) indicated in figure 2. This Lockwire attaches to Bearing Retainer (630) inside the Output Structure Assembly (515). 2.4. Using minimal force remove Output Structure Assembly (515). Removal may not be achievable by hand; if so the use of a wood or plastic punch in combination with a mallet to assist in the removal of the output structure is allowable. Reference figure 3 for using a punch and mallet for removal. 3. Remove Piston Rod Assembly (575) 3.1. Remove Cotter Pin (565).

Caution : Due to the large amount of torque retaining Nut (570), two technicians are
recommended for removal.

Note: Nut (570) should go back into the same Servoactuator that it came out of.

3.2. Referencing Figure 4, place Servoactuator in soft jawed vice or equivalent to protect the exterior finish of the component and avoid degrading the structural integrity of the Servoactuator. Attach tool 87001499-TQFX to end of Piston Rod Assembly (575) and remove Nut (570). 3.3. Clean all visible portions of the Piston Rod Assembly (575), Bearing Retainer (630), and Bearing Assembly (685) using Acetone and a nylon

bristle brush.

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25200 W. Rye Canyon Road • Santa Clarita, California 91355-1265 • 661/294-6000 • FAX 661/259-9622 3.4. Install 87003495 Assembly Bullet onto threads of the Piston Rod Assembly (575) to aid in removal reference figure 12. 3.5. Reference Figure 5 and carefully remove Piston Rod Assembly (575). Hydraulic fluid will flow from piston bore upon removal. Avoid damage to the contacting seals as damage seals will require the Servoactuator to be returned to a service center for repair.

B. Part II. Cleaning and Inspection of Piston Rod Assembly (575) and Nut(570).

Note: If any doubt exists in the inspection or rework of hardware contact Woodward HRT Engineer Joseph Kempton by Email at

H U Joe.Kempton@woodward.com

U H or by phone at (661) 702-5735 for additional assistance (24 hour assistance is available at (661) 255-1818). For engineering review please supply digital Photos of parts on white background.

1. Clean the entire Piston Rod Assembly and Nut (570) using Acetone and a nylon bristle brush removing all contaminates to allow for inspection. 2. Inspection: Inspect the configuration of the grind relief of the piston. 2.1. Inspection Requirement: Reference figure 6 for acceptable and unacceptable grind relief configurations. If the Unacceptable grind relief exists the Piston Rod Assembly (575) should be returned to Woodward HRT for replacement. 3. Using a 10x or greater magnifying gl ass visually inspect Nut (570). 3.1. Inspection Requirements: Any corrosion or damage in the threads is cause for rejection of the Nut (570) and the Nut must be replaced . If no corrosion or damage is found in the threads the Nut (570) it is acceptable for re-use. For Nuts that need to be replaced the nut should be returned to Woodward
HRT with the serial number Servoactuator it was removed from for a replacement Nut. 4. Using a 10x or greater magnifying gla ss visually inspect Piston Rod Assembly (575) in the areas identified in figure 7 as defined in the inspection requirements

below. 4.1. Inspection Requirements: Any corrosion, damage, or visible lack of cadmium plate in the areas of figure 7 identified as “Critical Areas” are cause for rejection of the Piston Rod Assembly and it must be returned to

Woodward HRT for repair or replacement depending upon condition. For the visible identification of cadmium plating inspect for a gold or grey color depending upon age of unit. 4.2. Inspection Requirements: If any corrosion, damage, or a visible lack of cadmium plate is evident on the piston in areas that are not considered ”Critical Areas” move to step 4.3 for rework instructions and requirements.

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25200 W. Rye Canyon Road • Santa Clarita, California 91355-1265 • 661/294-6000 • FAX 661/259-9622 If no corrosion, damage, or the visible lack of cadmium plate appears on the piston it is acceptable and no rework is required. Go to section “C. Part III. Assembly of Dual Servoactuator Assembly” for reassembly. Pistons meeting this criteria have a limited service life of 2400 hours or 2 years. 4.3. Rework: For Piston Rod Assemblies failing inspection requirements of step 4.2 above it is permissible to remove the surface corrosion that does not penetrate into the base material by lightly buffing with scotch-brite (3M Scotch-Brite, Clean and Finish Roll – white). Any pitting into the base material is not acceptable and the Piston Rod Assembly must be returned to Woodward HRT. After rework clean part using Acetone and a nylon bristle brush to remove any residual residue. 4.3.1. Inspection: If any corrosion is found that is red or orange in color it should be removed in step 4.3 and the part should undergo Magnetic Particle Inspection in accordance with ASTM E 1444 acceptance criteria, no cracks or indications allowed. 4.3.1.1. Inspection Requirement: If Piston Rod Assembly fails magnetic particle inspection the Piston Rod Assembly (575)
should be returned to Woodward HRT for maintenance. 4.4. Inspection Requirements: Inspect for areas of bare base metal that are not coated with Cadmium plate. The total surface area of the Piston Rod Assembly that is not cadmium plated shall be less than 1.0 inches 2

. Additionally any single bare area cannot exceed 0.25 inches in width. 4.4.1. If Piston Rod Assembly passes this inspection the Zinc Chromate Primer applied during assembly is adequate protection for the Piston Rod Assembly resulting in a limited service life of 1200 hours or 1 year service life upon date of compliance with Alert Service Bulletin. A service life of 2400 hours or 2 years is possible if the additional rework in steps 4.5 is performed. If the rework identified in 4.5. is not possible proceed to section “C. Part III. Assembly of Dual Servoactuator Assembly” for reassembly. 4.4.2. If Piston Rod Fails the inspection stated in 4.4 the rework procedure in 4.5 is required for the Piston Rod Assembly to be returned
to service. If the rework identified in 4.5. is not possible Piston Rod Assembly must be returned to Woodward HRT for rework. 4.5. Rework: Apply Brush Cadmium Plating to all bare and reworked areas in accordance with Mil-std-865 using Sifco Cad LHE (SPS5070) 0.0002 to 0.0005 inches thick, no bake required after plating. Piston Rod Assemblies that have Brush Cadmium applied sha ll have a limited life of 2400 hours or 2 year service life whichever comes first.

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25200 W. Rye Canyon Road • Santa Clarita, California 91355-1265 • 661/294-6000 • FAX 661/259-9622 C. Part III. Assembly of Dual Servoactuator Assembly 1. Install Piston Rod Assembly (575) 1.1. Clean the Piston Rod Assembly (575) with Acetone to ensure a clean part prior to reassembly. Verify Piston R od Assembly is dry prior to proceeding. 1.2. Masking as required, paint areas of Piston Rod Assembly (575) with a single coat of Zinc Chromate Primer TT-P-1757 in areas shown in figure 8. Spray application method for Chromate Primer shall be required to allow for a consistent thin coat of primer. Verify primer has dried hard prior to proceeding. 1.3. Using high adhesion tape (3M #250 tape) apply a one inch wide strip of tape to the Piston Rod Assembly in an area that was painted. Press the tape down using firm hand pressure. Remove tape with an abrupt motion and examine for adhesion. No paint shall disbond. 1.3.1. If paint fails the adhesion tape test, strip paint using MEK or lacquer thinner. Thoroughly clean and dry the surface prior to repainting the surface per step 1.2 and retesting the paint adhesion per step 1.3. 1.4. Install 87003495 Assembly Bullet onto threads of the Piston Rod Assembly (575) to aid in installation.

Caution : During installation of Piston Rod Assembly care should be taken to prevent any scraping off of the recently applied Zinc Chroma te Primer internally in the Servoactuator.

1.5. For ease of installation orient the actuator vertically so that the installation of the piston will be in a downward direction. Carefully install Piston Rod Assembly (575) into Servoactuator and remove 87003495 Assembly Bullet.

Warning: The torque of Nut (570) is critical to the safe operation of the Servoactuator and must be performed as described. Failure to do so could cause an unsafe condition resulting in loss of control of the aircraft. Nut (570) should go back into the same
Servoactuator that it came out of.

Caution: Nut (570) must have a minimum free running torque of 6 inch-pounds. If free running torque is less than 6 inch-pounds nut must be replaced.

1.6. Secure Piston Rod Assembly (575) with Nut (570) using Tool 87001499- TQFX and torque Nut (570) to 450 to 500 inch-pounds above running torque with castellations in nut (570) aligned with bore in Piston Rod Assembly (575). 1.7. Install new Cotter Pin (565). Referencing figure 13, stake and trim Cotter

Pin.

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25200 W. Rye Canyon Road • Santa Clarita, California 91355-1265 • 661/294-6000 • FAX 661/259-9622 1.8. Seal Nut (570) and Cotter Pin (565) with Proseal 890 or equivalent as shown in figure 9 2. Install Output Structure Assembly (515) 2.1. Lockwire Bearing Retainer (630) with a long pigtail to allow for terminating end of wire to match figure 2. 2.2. Install Output Structure Assembly (515) and secure with Bolt (500) qty 4, and Washer (505) qty 4. Torque bolts (500) to 60 to 80 inch-pounds in a cross hatch pattern and re-lockwire to match the prior configuration. 2.3. Complete lockwire of Bearing Retainer (630) to Output Structure Assembly (515) to match figure 2.2.4. Install Screw (445) qty 4 and Washer (450) qty 4 and torque to 8-12 inchpounds on a cross hatch pattern and re-lockwire to match the prior configuration. 3. Install Input Linkage Assembly: 3.1. Ensuring the lines added to the spline of the lever and face of the adjoining part align to verify that the assembly in the same position. Carefully install the Input Arm Assembly (330), Arm Assembly (380), and Link Assembly (405) onto the Input Structure Assembly (510) and Lever (CMM IPL Figure 2 Item Number 10, ref figure14.1). 3.2. Install Locking Washer (325) and Bolt (320) and torque Bolt to 30 to 50 inch-pounds. Re-lockwire Bolt (320) to match the prior configuration. 3.3. Install washer (370) and Bolt (365) and Torque to 50 to 70 inch-pounds. 3.4. Install washer (360) and Bolt (355) and Torque to 20 to 25 inch-pounds and re-lockwire bolt (355) to bolt (365) to the prior configuration.
4. Identification 4.1. Upon completion of the above identify the Servoactuator with the letter “B” following the serial Number on the name plate using a scribe or vibrating stylus.

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# Figure 1

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# Figure 2

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# Figure 3

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# Figure 4

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# Figure 5

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# Figure 6

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# Figure 7

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# Figure 8

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# Figure 9

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### 87001499-TQFX Det 1 

# Figure 10

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# Figure 11

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# Figure 12

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# Figure 13

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# Figure 14-1

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# Figure 14-2

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# Figure 14-3