DATE 

### ALERT SERVICE BULLETIN REVISION NOTICE

AN APPROPRIATE ENTRY SHOULD BE MADE IN TH E AIRCRAFT LOGBOOK UPON ACCOMPLISHMENT IF OWNERSHIP OF AIRCRAFT HAS CHANGED PLEASE FORWARD TO NEW OWNER Dec 08, 2008

TO: All Owners/Operators of Bell 205A & 205A-1 Helicopters

SUBJECT: REVISION “A” TO ALERT SE RVICE BULLETIN 205-07-94: (STARTER/GENERATOR PO WER CABLE UPGRADE)

Revision “A” to this bulletin is to incorpor ate minor changes into the text for better comprehension, also to make a correction to the kit part list by adding a missing nut and two missing washers . Please note that the intent of the bulle tin did not change. Consequently, no action is r equired on aircraft already m odified per the original release of this bulletin.NO.

DATE

PAGE DATE

REV 

### ALERT SERVICE BULLETIN

AN APPROPRIATE ENTRY SHOULD BE MADE IN TH E AIRCRAFT LOGBOOK UPON ACCOMPLISHMENT IF OWNERSHIP OF AIRCRAFT HAS CHANGED PLEASE FORWARD TO NEW OWNER 205-07-94
Dec 08, 08 June 01, 2007

A 1 of 7

MODEL AFFECTED: 205A & 205A-1

SUBJECT: STARTER/GENERATOR POWER CABLE, UPGRADE.

HELICOPTERS AFFECTED: Model 205A & 205A-1 helicopters serial number 30001 through 30332.

COMPLIANCE: 1 year from release date of this bulletin.

DESCRIPTION:

Bell Helicopter has been made aware of a possibility of fire hazard caused by the starter/generator power cabl e shorting out at connector P81 (J81) pins. This ASB addresses this issue by replacing the affected cable assemblies.

APPROVAL:

The engineering design aspects of th is bulletin are FAA/DER approved.

MANPOWER:

Approximately 10.0 man-hours ar e required to complete this bulletin. Man-hours are based on hands-on time, and may vary wit h personnel and facilities available.

WARRANTY:

Owners / Operators of Bell 205 A-205A1 Helicopters who comply with the instructions in this Bulletin will be el igible to receive a 100% credit for the r eplacement parts Kit CT205-07-94-1 outlined under the r equired material section.ASB 205-07-94 Page 2 of 7

To receive this credit:

• Purchase the required kit CT2 05-07-94-1 from a BHT supply

source.

• Comply with the instructions c ontained in this Bulletin no later than the applicable hours or date listed in the “compliance section” of this ASB.

• Submit an MMIR to the Be ll Warranty Department for the replacement parts.

-NOTECustomers who fail to comply with the instructions in this Bulletin after one year from dat e of release of this Bulletin are not eligible for the special warranty credit provisions listed above. No labor cost will be covered under this bulletin.

MATERIAL:

Required Material: The following material is required for the ac complishment of this bulletin and may be obtained through your Bell Helico pter Textron Supply Center.

Part Number Nomenclature Quantity

CT205-07-94-1 Starter/gen erator cable kit 1

Note: The Starter/generator cable kit consists of the following parts:

205-075-265-103 Cable Assembly 1 205-075-265-105S Cable Assembly 1 MS27212-5-2 Terminal Board 1 MS18029-5S2 Cover 1 MS3373-A3 Insulating strip 1 MS3373-C3 Insulating strip 1 31-034-1-150 Tape 1 80-011-P7F0-0 Plug 3 80-011-S7D08-0 Sleeve 3 MS21042L6 Nut 1 AN960D616L Washer 2 AASB 205-07-94 Page 3 of 7

Consumable Material: The following material is required to acco mplish this bulletin, but may not require ordering, depending on t he operator’s consumable material stock levels. This material may be obtained through your Bell He licopter Textron Supply Center.

Part Number Nomenclature Quantity Reference

299-947-100, type II, cla ss 2 Adhesive A/R C-317 MIL-S-81733 type 2 Sealant A/R C-251

SPECIAL TOOLS:

Part Number Nomenclature Quantity

MS 25441 (or equivalent) Crimper 1 MS 23002-1 (or equivalent) Die 1

ELECTRICAL LOAD DATA:

Not affected

REFERENCES:

BHT-205-IPB Illustra ted Parts Breakdown BHT-205-MM Maintenance Manual BHT-MED-SRM-1 Structural Repair Manual BHT-ELECT-SPM Electrical Standard Practice Manual

PUBLICATIONS AFFECTED:

BHT-205-IPB Illustra ted Parts Breakdown BHT-205-MM Maintenance Manual

ACCOMPLISHMENT INSTRUCTIONS:

1) Prepare helicopter for maintenance.

2) Remove and discard cable assembly 205-075-902-017 using following steps:

a) Gain access to connector P81 located on the left hand side engine deck. A AASB 205-07-94 Page 4 of 7

b) Disconnect connector P81 from J81 and disconnect wires at starter/generator terminals E, B, and C. Retain hardware for re-installation.

3) Remove and discard cable assembly 205-075-911-007 using following steps:

-NOTENote cable routing and clam ping when removing cables, and use similar routing and clampi ng when installing the new cables.

a) Gain access to connector J81 loca ted underneath the left hand side engine deck.

b) Remove connector J81 from lowe r engine deck panel. Retain attaching hardware for re-installation.

4) Remove wires as per Table 1. Re tain hardware for re-installation.

5) Install plugs and sleeves as follow:

a) Locate qty 3 holes in accordance with Figure 1.

b) Drill qty 3 holes 0.296 to 0.289 inch through panel assembly as shown on figure 1.

c) Install qty 3 sleeves P/N 80-011-S7D08-0 far side and plug P/N 80-011-P7F0-0 using adhesive C-317 as detailed in Structural Repair Manual (SRM).

d) Allow adhesive to cure.

6) Install terminal board P/ N MS27212-5-2, TB 150, on inboard side of main beam at STA 205.10 using qty 3 screws MS35206-233, qty 3 wash ers AN960PD6L, and qty 3 nuts NAS679A06.

7) Install identification tape P/N 31- 034-1-150 beside terminal board and apply sealant C-251 over tape.

8) Install cable assembly P/N 205-075-265-105 c onnector J81 on lower side of engine deck using retained hardware.

- NOTE Reference to Figure 2 for the following steps.

9) Prepare ground pad for elec trical bonding per BHT-EL ECT-SPM. Connect wire P73B1N to ground pad using retained hardware.ASB 205-07-94 Page 5 of 7

10) Connect wire P95B1 to K57 (starter re lay) terminal A2 using retained hardware.

11) Connect wire P72B1 and P7 2C1 to TB 150, terminal 1 using strip P/N MS3373-A3, strip P/N MS3373-C3, qty 2 washer P/ N AN960D616L and nut P/N MS21042L6.

12) Install cover assembly P/ N MS18029-5S-2 on TB 150.

13) Connect the other end of wire P72C1 to R1 (Generator Shunt) on the + side as follows:

a) Route wire P72C1 to R1 (Generator Shunt).

b) Cut wire P72C1 and install terminal lug P/N MS25036-130 using crimper p/n MS 25441 with die p/n MS23002-1.

c) Connect wire P72C1 to RI (generator Shunt) on + side using retained hardware.

14) Install cable assembly P/N 205-075-265-10 3 by connecting P81 to J81 and safety with lockwire.

15) Perform continuity check using multimeter as follow:

a) Check continuity between end of wire P73A1 and ground. Reading should be approximately 0 ohms.

b) Check continuity between end of wire P72A1 and R1, + side (generator shunt). Reading should be appr oximately 0 ohms.

c) Check continuity between end of wire P95A1 and K57 terminal A2 (starter relay). Reading should be approximately 0 ohms.

16) Connect wires to G6 (starter generator)

a) Connect wire P73A1 to G6 (starter generator) terminal E using retained hardware.

b) Connect wire P72A1 to G6, te rminal B using retained hardware.

c) Connect wire P95A1 to G6, te rminal C using retained hardware.

17) Make helicopter safe for flight.

18) Make an entry in helicopter historical re cord indicating compliance with this Alert Service Bulletin.ASB 205-07-94 Page 6 of 7

Wire number From connection Pin K5B0N GROUND PAD N/A K5D4N GROUND PAD N/A P37D4 GENERATOR SHUNT R1 + SIDE P37B0 GENERATOR SHUNT R1 + SIDE K6C4 STARTER RELAY AFT K57 A2 K6A4 STARTER RELAY AFT K57 A2

Table 1 Remove wires

80

- 011

- S7D08

- 0 3.00 IN (76.2 mm)

Figure 1 Structural Modification 1.50 IN (38.1 mm)ASB 205-07-94 Page 7 of 7Figure 2Wiring diagram