Nb WOODWARD_~ 4/:!ftT 

ALERT SERVICE BULLETIN 

FLIGHT CONTROLS- DUAL SERVOACTUATOR ASSEMBLY, PART NUMBER 141600 

1. 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 model430, 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~ 

E. Compliance 

Attn: SB141600-67-02 

Woodward HRT 

25200 West Rye Canyon Road, 

Santa Clarita. CA 91355-1265; 

Due to potential loss of control of the aircraft. compliance with this Alert Service 

Bulletin shall be accomplished upon receipt. 

August 18, 2010 

Rev 0 

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25200 W. Rye Canyon Road • Santa Clarita, California 91355-1265 • 6611294-6000 ·FAX 6611259-9622 
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ALERT SERVICE BULLETIN 

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 

Publication 

Component Maintenance Manual 

August 18, 2010 

Rev 0 

Chapter-Section-Subject 

67-31-08 

141600-67-02 

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

2. Material Information 

A. Material · Price and Availability 

Nut (570) 

Cotter Pin (565) 

141517-001 

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 available by contacting Terry Eyrolet at 

TerrvEyrolet@woodward .com or (661) 702-5437. 

3. Accomplishment Instructions 

Note: All Item numbers indicated below shown m 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 positiomng and handling of the Servoactuator dunng the 

disassembly and assembly process to prevent the inadvertent wtpmg off of marking. Th1s 

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25200 W. Rye Canyon Road • Santa Clarita, California 91355-1265 • 6611294-6000 • FAX 661/259-9622 
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ALERT SERVICE BULLETIN 

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 Structure Assembly (510) and Lever (CMM IPL 

Figure 21tem Number 10, reffigure14.1). 

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). 

Caut ion: 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 1t 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 • 6611294-6000 • FAX 6611259-9622 
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ALERT SERVICE BULLETIN 

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 ln the inspection or rework of hardware contact Woodward HRT 

Engineer Joseph Kempton by Email at Joe.Kempton@woodward com 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 prston. 

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 1 Ox or greater magnlfying glass 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 1 Ox or greater magnifying glass 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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ALERT SERVICE BULLETIN 

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 Ill. 

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 inches2

• 

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 Ill. 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 shall have a limited life of 2400 hours or 

2 year service life whichever comes first. 

August 18, 2010 

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

ALERT SERVICE BULLETIN 

C Part Ill. 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 Rod 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 disband. 

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 Chromate 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 
N!::, WOODWARD~ i:JBT 

ALERT SERVICE BULLETIN 

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 

21tem Number 10, reffigure14.1). 

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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ALERT SERVICE BULLETIN 

Markings on 

spl ine and input 

lever 

August18, 2010 

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Figure 1 

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ALERT SERVICE BULLETIN 

August 18, 2010 

Rev 0 

Figure 2 

l ockwire 

needs to be 

removed 

141600-67-02 

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August 18, 2010 

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Figure 3 

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ALERT SERVICE BULLETIN 

August 18, 2010 

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( 

Figure 4 

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August 18, 2010 

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Figure 5 

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August 18, 2010 

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Figure 6 

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August 18, 2010 

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Figure 7 

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ALERT SERVICE BULLETIN 

August 18, 2010 

Rev 0 

Figure 8 

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141600-67-02 

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

August 18, 2010 

Rev 0 

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141600-67-02 

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25200 W. Rye Canyon Road· Santa Clarita, California 91355-1265 • 661/294-6000 • FAX 661/259-9622 
WOODWARD~ 4!:JBT 

ALERT SERVICE BULLETIN 

August 18, 2010 

Rev 0 

' ' 

2X R .375 

.300 

I (, ( 1\ 

I 

. 

\ 

tlx R .025 

.035 

.256 

.251 i 

14.00 .405 16.00 .345 

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DETAIL A 

MATERIAL: CRES OR STEEL WITH 

HARDNESS 4 5-50 RC 

.188 1.50 

.200 - 1.00 

87001499-TQFX Det 1 

Figure 10 

141600-67-02 

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25200 W. Rye Canyon Road • Santa Clarita, California 91355-1265 • 661/294-6000 • FAX 661/259-9622 
WOODWARD_~ (I:!BT 

ALERT SERVICE BULLETIN 

C oumo 

I".'ETER H~LL I, T [• (( ~ T 

f .c fill . 

DElETE II 

B)fl'l H: t.'J',, 

I S .. NETniC ;IE/. f~"~P '?EFEI\EI'.CE 01\L Y 

August 18, 2010 

RevO 

1.500 

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Figure 11 

141600-67-02 

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August 18, 2010 

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Figure 12 

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ALERT SERVICE BULLETIN 

.060 Max 

Cotter Pin to be installed and 

staked as shown. Trim 

Cotter Pin within these limits 

and approximately as shown. 

August 18, 2010 

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Figure 13 

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ALERT SERVICE BULLETIN 

* F1gure 10 1$ (REF) because 1t 1s from IPL Figure 2 Image From CMM 67-31-08 IPL Figure 1 

August 18, 2010 

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Figure 14-1 

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ALERT SERVICE BULLETIN 

I 

580 

Image From CMM 67-31-08 IPL Figure 1 

August 18, 2010 

Rev 0 

Figure 14-2 

565 

635 

570 

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ALERT SERVICE BULLETIN 

/ . soo 1 ~ 

505 

51 0 

I 

Image From CMM 67-31-08 IPL Figure 1 

August 18, 2010 

Rev 0 

Figure 14-3 

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