RESTRICTED DISCLOSURE NOTICE ON PAGE 2

P.O. BOX 3689 BRISTOL, TENNESSEE 37625-3689 USA 

TELEPHONE: 423-538-5151 TOLL FREE: 800-251-7094

TELEFAX: 423-538-8469 E-MAIL: sales@aero-access.com

techsupport@aero-access.com 

INSTRUCTIONS 

for

CONTINUED AIRWORTHINESS 

for

CROSSTUBES 

STC: SR00646AT (LOW SKID GEAR) 

P/N 212-320-103 / 212-320-104 

P/N 412-320-104 / 412-320-154

STC: SR01052AT (HIGH SKID GEAR) 

P/N 212-321-103 (S/N 1250 and Sub) 

P/N 412-321-104 / 412-321-304 (S/N 1274 and Sub) 

FOR 

BELL HELICOPTER TEXTRON MODEL 205A, 205A-1, 205B, 

212, 412, 412EP, 412CF HELICOPTERS 

AGUSTA S.P.A. MODEL AB412, AB412EP HELICOPTERS 

STC: SR01924AT (LOW OR HIGH SKID GEAR) 

P/N 212-321-103 (S/N 1250 and Sub) / 212-321-104

FOR 

RESTRICTED CATEGORY UH-1B, UH-1H, SW204, SW205 

GARLICK HELICOPTERS, US HELICOPTERS, INC., 

WESTERN INTERNATIONAL AVIATION, INC., SOUTHWEST FLORIDA 

AVIATION HELICOPTERS 

Report Number AA-01136 

Revision K 

February 15, 2012 
BHT 205A, 205A-1, 205B INSTRUCTIONS for CONTINUED AIRWORTHINESS AA-01136

212, 412, 412EP, 412CF, CROSSTUBES Revision K

AGUSTA AB412, AB412EP,

UH-1B, UH-1H, SW204, SW205 

AERONAUTICAL ACCESSORIES

February 15, 2012 Page 2 of 78

RESTRICTED DISCLOSURE NOTICE

THE DRAWINGS, SPECIFICATIONS, DESCRIPTIONS, AND OTHER 

TECHNICAL DATA ATTACHED HERETO ARE PROPRIETARY AND 

CONFIDENTIAL TO BELL HELICOPTER TEXTRON, INC (BHTI) AND 

CONSTITUTE TRADE SECRETS FOR PURPOSES OF THE TRADE 

SECRET AND FREEDOM OF INFORMATION ACTS. NO DISCLOSURE 

TO OTHERS, EITHER IN THE UNITED STATES OR ABROAD, OR 

REPRODUCTION OF ANY PART OF THE INFORMATION SUPPLIED IS 

TO BE MADE, AND NO MANUFACTURE, SALE OR USE OF ANY 

INVENTION OR DISCOVERY DISCLOSED HEREIN SHALL BE MADE, 

EXCEPT BY WRITTEN AUTHORIZATION OF BHTI. THIS NOTICE 

WILL NOT OPERATE TO NULLIFY OR LIMIT RIGHTS GRANTED BY 

CONTRACT. THE DATA SUBJECT TO THIS RESTRICTION JS 

CONTAINED IN ALL SHEETS AND IS DISCLOSED TO PERSONNEL 

OF BHTI, FOR THE PURPOSE(S) OF INTERNAL USE AND 

DISTRIBUTION ONLY.

© (2012) BHTI

UNPUBLISHED – ALL RIGHTS RESERVED
BHT 205A, 205A-1, 205B INSTRUCTIONS for CONTINUED AIRWORTHINESS AA-01136

212, 412, 412EP, 412CF, CROSSTUBES Revision K

AGUSTA AB412, AB412EP,

UH-1B, UH-1H, SW204, SW205 

AERONAUTICAL ACCESSORIES

February 15, 2012 Page 3 of 78

LOG OF REVISIONS

Date Revision Description Pages

09/04/01 NR Original Release All

02/21/02 A Deleted 3.1, 3.2, 3.3 5 – 7 

Added 3.1, 3.1.1, 3.1.2, 3.2, 3.2.1, 3.2.2 6 – 9 

Revised Crosstube weights in Table 6 19

04/22/02 B Deleted Figures 3 and 4 16

Added 412CF Model Effectivity, 205B & 412CF to report header, 

crosstube damage NOTE to 3.0, torque value to Table 2, 5.7 and 5.8, 

Figures 4 and 5

All, All, 

6,10,14,19,

20

Revised 3.1.2 (#2, a) and 3.2.2 (#2, a), Table 1, Section 3.4 Repair, 

Figure 2 and Table 5, 212-320-104 weight in Table 6, 412 Low & 412 

High Skid Crosstube Parts Lists in 12.0, Appendix A

7,8,9,10,

16,17,23,24

,25,28

Changed Figure 5 to Figure 3 and added “205/212 ONLY” effectivity 

to Aft Crosstube Assembly, changed washer quantity in 212-320-203 

Hardware Kit, changed part reference on Hardware Kit Table for 412-

320-230 & 412-321-200

18, 25, 26

07/30/02 C Revised 3.1.2 (2, b), 3.2.2 (2, b), Table 2, 5.3 (3, Note), 5.4, 5.8 

(Note), Figure 3, 12.0 Parts List, Appendix A

7,8,10,12 

13,14,19, 

25–27,31

Changed MIL Spec reference from MIL-C-5541 to MIL-DTL-81706, 

and MIL-S-8802 to AMS-S-8802

10, 12, 13, 

14

08/29/06 D Reformatted, reorganized document All

Added UH-1H, SW205 model effectivity All

Revised Section 1.0, Introduction 7

Revised Section 2.0, Description 7

Revised Table 1, Damage and Repair Limits: added metric 

equivalents

11

Revised Table 2, Torque Values: added metric equivalents 12

Added Section 5.9, Removal – Plate Assembly 17

Added Section 5.10, Installation – Plate Assembly 17

Deleted Section 8.0, Recommended Overhaul Periods; renumbered 

subsequent sections

-

Section 8.0, Airworthiness Limitations: Incorporated information from 

(deleted) Recommended Overhaul Periods section

18

Revised Section 9.0, Weight and Balance: added metric equivalents 19

Revised Section 11.0, Parts Breakdown: 

reformatted, revised Tables 4 thru 11

20 – 25 

Reorganized Figures 1 thru 7 36 – 32 

06/24/09 E Reformatted, reorganized document. Incorporated engineering 

updates. Complete revision

All

BHT 205A, 205A-1, 205B INSTRUCTIONS for CONTINUED AIRWORTHINESS AA-01136

212, 412, 412EP, 412CF, CROSSTUBES Revision K

AGUSTA AB412, AB412EP,

UH-1B, UH-1H, SW204, SW205 

AERONAUTICAL ACCESSORIES

February 15, 2012 Page 5 of 78

LIST OF EFFECTIVE PAGES

All pages contained herein are at latest revision shown in Log of Revisions.

LIST OF EFFECTIVE PAGES 1 – 78
BHT 205A, 205A-1, 205B INSTRUCTIONS for CONTINUED AIRWORTHINESS AA-01136

212, 412, 412EP, 412CF, CROSSTUBES Revision K

AGUSTA AB412, AB412EP,

UH-1B, UH-1H, SW204, SW205 

TABLE OF CONTENTS

Identification Title Page

AERONAUTICAL ACCESSORIES

February 15, 2012 Page 6 of 78

1.0 INTRODUCTION................................................................................................ 11

1.1 DISTRIBUTION .................................................................................................. 11

1.2 REVISION .......................................................................................................... 11

2.0 DESCRIPTION................................................................................................... 11

3.0 MAINTENANCE INSTRUCTIONS...................................................................... 12

3.1 CROSSTUBE INSPECTION – ALL.................................................................... 13

3.1.1 DAILY INSPECTION (SERIES 1 INSPECTION) // 25 HOUR / 30 DAY 

INSPECTION (SERIES 2 INSPECTION)................................................. 14

3.1.2 100 HOUR / 12 CALENDAR MONTH INSPECTION (SERIES 1 

INSPECTION) // 300 HOUR INSPECTION (SERIES 2 INSPECTION)... 14

3.2 CROSSTUBE INSPECTION, 212-321-103 HIGH FORWARD CROSSTUBE 

ONLY................................................................................................................. 15

3.2.1 AT 7500 TAKEOFF/LANDINGS AND FOLLOWING EVERY 

SUBSEQUENT 200 TAKEOFF/LANDINGS THEREAFTER VISUAL 

INSPECTION........................................................................................... 15

3.2.2 AT 10,000 TAKEOFF/LANDINGS AND FOLLOWING EVERY 

SUBSEQUENT 12 MONTHS OR 2500 TAKEOFF/LANDINGS, 

WHICHEVER COMES FIRST, THEREAFTER DIMENSIONAL 

INSPECTION........................................................................................... 16

3.2.3 AT 12,500 TAKEOFF/LANDINGS AND EVERY SUBSEQUENT 5000 

TAKEOFF/LANDINGS THEREAFTER INSPECTION AND OVERHAUL 17

3.3 CROSSTUBE INSPECTION, 412-321-104 AND 412-321-304 HIGH AFT 

CROSSTUBES ONLY....................................................................................... 20

3.3.1 AT 2500 TAKEOFF/LANDINGS AND FOLLOWING EVERY 

SUBSEQUENT 450 TAKEOFF/LANDINGS THEREAFTER VISUAL 

INSPECTION........................................................................................... 20

3.3.2 AT 2500 TAKEOFF/LANDINGS AND EVERY 12 MONTHS / 2500 

TAKEOFF/LANDINGS, WHICHEVER COMES FIRST, THEREAFTER 

DIMENSIONAL INSPECTION ................................................................. 21

3.3.3 AT 7500 TAKEOFF/LANDINGS AND EVERY SUBSEQUENT 5000 

TAKEOFF/LANDINGS THEREAFTER INSPECTION AND OVERHAUL 22

3.4 HARD LANDING CROSSTUBE DEFLECTION INSPECTION........................... 25

3.5 REPAIR .............................................................................................................. 26

3.6 CLEANING REQUIREMENTS ........................................................................... 27

3.7 ADJUSTMENTS................................................................................................. 27
BHT 205A, 205A-1, 205B INSTRUCTIONS for CONTINUED AIRWORTHINESS AA-01136

212, 412, 412EP, 412CF, CROSSTUBES Revision K

AGUSTA AB412, AB412EP,

UH-1B, UH-1H, SW204, SW205 

TABLE OF CONTENTS

Identification Title Page

AERONAUTICAL ACCESSORIES

February 15, 2012 Page 7 of 78

4.0 TROUBLESHOOTING INFORMATION ............................................................. 28

5.0 REMOVAL AND REPLACEMENT INFORMATION............................................ 29

5.1 REMOVAL – CROSSTUBES ............................................................................. 29

5.2 INSTALLATION – CROSSTUBES ..................................................................... 29

5.3 REMOVAL – CROSSTUBE SUPPORTS........................................................... 30

5.4 INSTALLATION – CROSSTUBE SUPPORTS ................................................... 30

5.5 REMOVAL – BEAM ASSEMBLY........................................................................ 31

5.6 INSTALLATION – BEAM ASSEMBLY................................................................ 31

5.7 REMOVAL – CLAMP ASSEMBLY ..................................................................... 31

5.8 INSTALLATION – CLAMP ASSEMBLY ............................................................. 32

5.9 REMOVAL – PLATE ASSEMBLY ...................................................................... 32

5.10 INSTALLATION – PLATE ASSEMBLY .............................................................. 32

6.0 STRUCTURAL FASTENER DATA..................................................................... 33

7.0 SPECIAL TOOLS NEEDED ............................................................................... 33

8.0 TOWING AIRCRAFT.......................................................................................... 33

9.0 WEIGHT AND BALANCE................................................................................... 33

9.1 LOW SKID GEAR CROSSTUBE........................................................................ 33

9.2 HIGH SKID GEAR CROSSTUBE....................................................................... 33

10.0 AIRWORTHINESS LIMITATIONS...................................................................... 34

10.1 RETIREMENT LIFE............................................................................................ 34

11.0 PARTS BREAKDOWN....................................................................................... 35

11.1 LOW SKID GEAR PARTS BREAKDOWN.......................................................... 36

11.1.1 212-320 SERIES LOW GEAR CROSSTUBES........................................ 36

11.1.2 412-320 SERIES LOW GEAR CROSSTUBES........................................ 38

11.2 HIGH SKID GEAR PARTS BREAKDOWN......................................................... 40

11.2.1 212-321 SERIES HIGH GEAR CROSSTUBES....................................... 40

11.2.2 412-321 SERIES HIGH GEAR CROSSTUBES....................................... 42

12.0 REFERENCE CROSSTUBE FIGURES ............................................................. 44
BHT 205A, 205A-1, 205B INSTRUCTIONS for CONTINUED AIRWORTHINESS AA-01136

212, 412, 412EP, 412CF, CROSSTUBES Revision K

AGUSTA AB412, AB412EP,

UH-1B, UH-1H, SW204, SW205 

TABLE OF CONTENTS

Identification Title Page

AERONAUTICAL ACCESSORIES

February 15, 2012 Page 8 of 78

APPENDIX A: DAILY (SERIES 1) // 25 HOUR / 30 DAY (SERIES 2) INSPECTION 

RECORD............................................................................................................ 55

APPENDIX B: 100 HOUR / 12 MONTH (SERIES 1) 300 HOUR (SERIES 2) 

INSPECTION RECORD ..................................................................................... 57

APPENDIX C: AT 7500 TAKEOFF/LANDINGS // EVERY SUBSEQUENT 200 

TAKEOFF/LANDINGS 212-321-103 HIGH FORWARD CROSSTUBE ONLY 

INSPECTION RECORD ..................................................................................... 59

APPENDIX D: AT 10,000 TAKEOFF/LANDINGS // EVERY SUBSEQUENT 12 

MONTH / 2500 TAKEOFF/LANDINGS DIMENSIONAL INSPECTION 212-321-

103 HIGH FORWARD CROSSTUBE ONLY INSPECTION RECORD............... 62

APPENDIX E: AT 12,500 TAKEOFF/LANDINGS // EVERY SUBSEQUENT 5,000 

TAKEOFF/LANDINGS 212-321-103 HIGH FORWARD CROSSTUBE ONLY 

INSPECTION/OVERHAUL RECORD ................................................................ 64

APPENDIX F: AT 2500 TAKEOFF/LANDINGS // EVERY SUBSEQUENT 450 

TAKEOFF/LANDINGS 412-321-104 / 412-321-304 HIGH AFT CROSSTUBE 

ONLY INSPECTION RECORD .......................................................................... 68

APPENDIX G: AT 2,500 TAKEOFF/LANDINGS // EVERY SUBSEQUENT 12 MONTH 

/ 2,500 TAKEOFF/LANDINGS DIMENSIONAL INSPECTION 412-321-104 / 412-

321-304 HIGH AFT CROSSTUBE ONLY INSPECTION RECORD ................... 71

APPENDIX H: AT 7,500 TAKEOFF/LANDINGS // EVERY SUBSEQUENT 5,000 

TAKEOFF/LANDINGS 412-321-104 / 412-321-304 HIGH AFT CROSSTUBE 

ONLY INSPECTION/OVERHAUL RECORD...................................................... 73

APPENDIX I: HISTORICAL SERVICE RECORD........................................................ 77
BHT 205A, 205A-1, 205B INSTRUCTIONS for CONTINUED AIRWORTHINESS AA-01136

212, 412, 412EP, 412CF, CROSSTUBES Revision K

AGUSTA AB412, AB412EP,

UH-1B, UH-1H, SW204, SW205 

LIST OF TABLES

Table Title Page

AERONAUTICAL ACCESSORIES

February 15, 2012 Page 9 of 78

TABLE 1. DAMAGE AND REPAIR LIMITS.................................................................. 26

TABLE 2. TORQUE VALUES ...................................................................................... 27

TABLE 3. TROUBLESHOOTING................................................................................. 28

TABLE 4. PARTS BREAKDOWN, LOW SKID GEAR CROSSTUBES, 212-320-103 

FORWARD / 212-320-104 AFT(1) CROSSTUBE ASSEMBLY............................ 36

TABLE 5. PARTS BREAKDOWN, 212-320-203 / 212-320-207 HARDWARE KIT....... 36

TABLE 6. PARTS BREAKDOWN, CROSSTUBE ASSEMBLIES 605-013-101 

FORWARD // 605-015-101(1) AFT...................................................................... 37

TABLE 7. PARTS BREAKDOWN, LOW SKID GEAR AFT CROSSTUBES 

412-320-104(1) / 412-320-154(1) AFT CROSSTUBE ASSEMBLIES ................... 38

TABLE 8. PARTS BREAKDOWN, 412-320-203 HARDWARE KIT.............................. 38

TABLE 9. PARTS BREAKDOWN, 605-015-201 AFT CROSSTUBE ASSEMBLY....... 39

TABLE 10. PARTS BREAKDOWN, HIGH SKID GEAR CROSSTUBES, 212-321-103 

FORWARD CROSSTUBE ASSEMBLY 212-321-104(1) / 212-321-304(1) AFT 

CROSSTUBE ASSEMBLY................................................................................. 40

TABLE 11. PARTS BREAKDOWN, 212-321-203 / 212-321-207 HARDWARE KIT..... 40

TABLE 12. PARTS BREAKDOWN, CROSSTUBE ASSEMBLIES 605-003-101 

FORWARD // 605-005-101(1) AFT CROSSTUBE ASSEMBLY........................... 41

TABLE 13. PARTS BREAKDOWN, HIGH SKID GEAR AFT CROSSTUBES, 

412-321-106(1) / 412-321-306(1) AFT CROSSTUBE ASSEMBLY....................... 42

TABLE 14. PARTS BREAKDOWN, HIGH SKID GEAR AFT CROSSTUBES, 

412-321-104(1) / 412-321-304(1) AFT CROSSTUBE ASSEMBLY....................... 42

TABLE 15. PARTS BREAKDOWN, 412-321-200 HARDWARE KIT............................ 43

TABLE 16. PARTS BREAKDOWN, 605-005-201 AFT CROSSTUBE ASSEMBLY..... 43
BHT 205A, 205A-1, 205B INSTRUCTIONS for CONTINUED AIRWORTHINESS AA-01136

212, 412, 412EP, 412CF, CROSSTUBES Revision K

AGUSTA AB412, AB412EP,

UH-1B, UH-1H, SW204, SW205 

LIST OF FIGURES

Figure Title Page

AERONAUTICAL ACCESSORIES

February 15, 2012 Page 10 of 78

FIGURE 1. CLEAR COAT AND INSPECTION AREA, 212-321-103 HIGH FORWARD 

CROSSTUBE (S/N AA-1250 AND SUBSEQUENT)........................................... 44

FIGURE 2. CLEAR COAT AND INSPECTION AREA, 412-321-104 AND 412-321-304 

HIGH AFT CROSSTUBE (S/N AA-1274 AND SUBSEQUENT) ......................... 45

FIGURE 3 (SHEET 1 OF 2). CROSSTUBE DAMAGE LIMITS AND REPAIR ZONES 46

FIGURE 3 (SHEET 2 OF 2). CROSSTUBE DAMAGE LIMITS AND REPAIR ZONES 47

FIGURE 4. CROSSTUBE DEFLECTION LIMITS ........................................................ 48

FIGURE 5. PAINT REMOVAL AREA, 212-321-103 HIGH FORWARD CROSSTUBE 49

FIGURE 6. PAINT REMOVAL AREA, 412-321-104 / 412-321-304 HIGH AFT 

CROSSTUBE ..................................................................................................... 49

FIGURE 7. 212-321-103 HIGH FORWARD CROSSTUBE ASSEMBLY...................... 50

FIGURE 8. 212-321-104 / 212-321-304 HIGH AFT CROSSTUBE ASSEMBLY.......... 51

FIGURE 9. 412-321-104 / 212-321-304 HIGH AFT CROSSTUBE ASSEMBLY.......... 52

FIGURE 10. 412-320 /412-321 SERIES AFT CROSSTUBE ASSEMBLIES................ 53

FIGURE 11. CROSSTUBE TO SKID TUBE ATTACHMENT ....................................... 54
BHT 205A, 205A-1, 205B INSTRUCTIONS for CONTINUED AIRWORTHINESS AA-01136

212, 412, 412EP, 412CF, CROSSTUBES Revision K

AGUSTA AB412, AB412EP,

UH-1B, UH-1H, SW204, SW205 

AERONAUTICAL ACCESSORIES

February 15, 2012 Page 11 of 78

1.0 INTRODUCTION

These instructions contain the information necessary for inspection and 

maintenance of AERONAUTICAL ACCESSORIES REPLACEMENT 

CROSSTUBES installed on Bell Helicopter Textron model 205A, 205A-1, 205B, 

212, 412, 412EP, 412CF; and Agusta model AB412, AB412EP helicopters in 

accordance with STC SR00646AT (Low Skid Gear) or SR01052AT (High Skid 

Gear); and on Restricted Category model UH-1B, UH-1H, SW204, and SW205 

helicopters in accordance with STC SR01924AT High or Low Skid Gear.

1.1 DISTRIBUTION

These instructions are provided with each Crosstube. Any airworthiness or flight 

safety revisions will be immediately made available to all affected Crosstube 

owners.

1.2 REVISION

A Log of Revision section Js included in these instructions and will be utilized to 

document all changes. Change recommendations should be submitted to: 

Aeronautical Accessories Bell Helicopter Piney Flats 

Technical Support 

P.O. Box 3689 

Bristol, TN 37625-3689 

Email: techsupport@aero-access.com

2.0 DESCRIPTION

Aeronautical Accessories Crosstubes are complete assemblies which include 

Crosstube Supports. As direct replacements for OEM crosstubes, Aeronautical 

Accessories Crosstubes are interchangeable with Bell Helicopter and Agusta

S.p.A. crosstubes for use with other OEM landing gear components.

The Crosstubes are designed to provide an interface between the Landing Gear 

Skids and the helicopter and to absorb landing loads.

The Forward and Aft Crosstubes for model 205 and 212 helicopters are fitted 

with two supports, which contact mating Support Fittings in the helicopter 

structure. 

The Aft Crosstube for model 412 variant helicopters utilizes a Beam Assembly, 

which contacts mating Support Fittings in the helicopter structure. The function 

of the Beam Assembly on the Aft Crosstube is to reduce the possibility of ground 

resonance.
BHT 205A, 205A-1, 205B INSTRUCTIONS for CONTINUED AIRWORTHINESS AA-01136

212, 412, 412EP, 412CF, CROSSTUBES Revision K

AGUSTA AB412, AB412EP,

UH-1B, UH-1H, SW204, SW205 

AERONAUTICAL ACCESSORIES

February 15, 2012 Page 12 of 78

3.0 MAINTENANCE INSTRUCTIONS

Maintenance Instructions for Aeronautical Accessories Crosstubes consist of two 

differing series of inspections. Aeronautical Accessories Series 1 and Series 2

Scheduled Inspections coincide with the Bell Helicopter Part A and Part B 

Scheduled Inspections for the convenience of the operator. Either inspection 

series may be employed. However, once a specific inspection series has been 

established, the helicopter shall remain on that specific inspection series except 

for the following.

NOTE

Scheduled inspection interval tolerances shall be 10% or up

to a maximum of 100 hours operating time / 30 calendar 

days, whichever is less.

1. If the Crosstubes are being reviewed on Series 1 Inspection and are desired 

to be changed to Series 2 Inspection, a complete 100 Hour / 12 Calendar 

Months Inspection shall be implemented before changing the helicopter to 

Series 2 beginning with the 25 Hour / 30 Day Inspection.

2. If the Crosstubes are being reviewed on Series 2 Inspection and it is desired 

to change to Series 1 Inspection, a complete 300 Hour Inspection shall be 

implemented before changing the helicopter to Series 1 beginning with the 

Daily Inspection.

NOTE

All Crosstube damage is unacceptable and shall be repaired. 

Refer to Table 1 for damage and repair limits and Section 3 

for repair criteria.

NOTE

If Crosstube repair is required, refer to Section 5 for removal 

of Crosstubes from helicopter.

NOTE

The indications of corrosion are 1) corrosion deposits (a 

white or gray powder on aluminum), 2) pits in the aluminum 

surface, 3) blisters, bulging, or flaking of protective coatings.

CAUTION

Helicopter towing operations must be conducted in 

accordance with the applicable aircraft model’s 

Maintenance Manual. Manufacturer towing 

requirements are applicable to any aircraft being towed 

with weight on gear which includes towing aircraft with 

ground handling wheels installed or aircraft resting on 

moveable platforms. Failure to follow manufacturer 

towing instructions may result in crosstube damage 

and/or failure.
BHT 205A, 205A-1, 205B INSTRUCTIONS for CONTINUED AIRWORTHINESS AA-01136

212, 412, 412EP, 412CF, CROSSTUBES Revision K

AGUSTA AB412, AB412EP,

UH-1B, UH-1H, SW204, SW205 

AERONAUTICAL ACCESSORIES

February 15, 2012 Page 13 of 78

3.1 CROSSTUBE INSPECTION – ALL 

Crosstubes shall be inspected utilizing Series 1 Inspection or Series 2 Inspection 

and applicable additional inspections as summarized below.

NOTE

Crosstube visual inspection Js conducted with aircraft at rest 

on skid landing gear; minimum gross weight at inspection Js 

9,000 pounds.

NOTE

P/N 412-321-104 High Aft Crosstubes, serial number 

AA-1274 and subsequent, and P/N 212-321-103 High 

Forward Crosstubes, serial number AA-1250 and 

subsequent, are manufactured with two primed and 

clear-coated inspection areas.

CROSSTUBE INSPECTIONS

ALL CROSSTUBES

Section Inspection

3.1.1 Daily Inspection (Series 1) // 25 Hour / 30 Day Inspection (Series 2)

3.1.2 100 Hour / 12 Calendar Month (Series 1) // 300 Hour (Series 2)

3.4 Hard Landing Crosstube Deflection Inspection

212-321-103 HIGH FORWARD CROSSTUBES ONLY

3.2.1 At 7500 Takeoff/Landings and Following Every Subsequent 200 

Takeoff/Landings Thereafter Visual Inspection

3.2.2 At 10,000 Takeoff/Landings and Following Every Subsequent 12 Month Or 

2500 Takeoff / Landings, Whichever Comes First, Thereafter Dimensional 

Inspection

3.2.3 At 12,500 Takeoff/Landings and Following Every Subsequent 5000 

Takeoff/Landings Thereafter Inspection and Overhaul

412-321-104 / 412-321-304 HIGH AFT CROSSTUBES ONLY

3.3.1 At 2500 Takeoff/Landings and Following Every Subsequent 450 

Takeoff/Landings Thereafter Visual Inspection

3.3.2 At 2500 Takeoff/Landings and Following Every Subsequent 12 Month Or 

2500 Takeoff/Landings, Whichever Comes First, Thereafter Dimensional 

Inspection

3.3.3 At 7500 Takeoff/Landings and Following Every Subsequent 5000 

Takeoff/Landings Thereafter Inspection and Overhaul
BHT 205A, 205A-1, 205B INSTRUCTIONS for CONTINUED AIRWORTHINESS AA-01136

212, 412, 412EP, 412CF, CROSSTUBES Revision K

AGUSTA AB412, AB412EP,

UH-1B, UH-1H, SW204, SW205 

AERONAUTICAL ACCESSORIES

February 15, 2012 Page 14 of 78

3.1.1 DAILY INSPECTION (SERIES 1 INSPECTION) //

25 HOUR / 30 DAY INSPECTION (SERIES 2 INSPECTION)

1. Inspect the Crosstubes for condition.

2. Inspect Crosstube Supports for condition and security of attachment 

(evidence of debonding and/or movement).

NOTE

If any evidence of debonding and/or movement of the Upper 

and Lower Supports are found, complete the Support 

removal and rebonding procedures, Section 5.

3. Visually inspect Crosstube inspection windows, as applicable, for evidence of 

cracking.

4. Utilize the Inspection Record provided in Appendix A to document inspection.

3.1.2 100 HOUR / 12 CALENDAR MONTH INSPECTION (SERIES 1 INSPECTION) //

300 HOUR INSPECTION (SERIES 2 INSPECTION)

1. Perform Daily Inspection (Series 1 Inspection) // 25 hour / 30 Day Inspection 

(Series 2 Inspection).

2. Inspect forward and aft caps holding Crosstubes to helicopter for security, 

and the rubber pads for looseness and/or deterioration.

3. Visually inspect Crosstubes for damage as follows:

NOTE

Particular care should be taken to inspect in the areas of the 

Supports at the aircraft attach points.

a. Inspect the Crosstube for scratches, nicks, dents, and corrosion and note the 

depth of the damage. (Refer to the zones and limits shown in Figure 3.) The 

minimal longitudinal distance between repairs is 3.0 inches. Crosstubes 

exceeding the damage limits shown in Table 1 must be replaced.

NOTE

The limits of the damage are also restricted axially and 

radially as shown in Figure 3.

b. Visually inspect the Supports for nicks, dents, and corrosion. Support 

damage and repair limits: .020 in. depth for a maximum area of 1.0 square 

inch. No more than two repairs per support are allowed. Replace Support if 

damaged beyond limits.

4. Check the torque [80 – 100 in-lbs (9.0 – 11.3 Nm)] on the U-bolts that attach 

the Supports. Re-torque if necessary.

5. Utilize the Inspection Record provided in Appendix B to document inspection.
BHT 205A, 205A-1, 205B INSTRUCTIONS for CONTINUED AIRWORTHINESS AA-01136

212, 412, 412EP, 412CF, CROSSTUBES Revision K

AGUSTA AB412, AB412EP,

UH-1B, UH-1H, SW204, SW205 

AERONAUTICAL ACCESSORIES

February 15, 2012 Page 15 of 78

3.2 CROSSTUBE INSPECTION, 

212-321-103 HIGH FORWARD CROSSTUBE ONLY

3.2.1 AT 7500 TAKEOFF/LANDINGS AND FOLLOWING EVERY SUBSEQUENT 

200 TAKEOFF/LANDINGS THEREAFTER VISUAL INSPECTION

(See Figure 1.)

1. Use MIL-PRF-87937 cleaning compound prepared in accordance with the

manufacturer’s recommendations to clean all residue and dirt from the cross 

tube surfaces shown in Figure 1.

2. Using at least 10X magnification and a strong light source, visually inspect 

the clear coated crosstube areas for indications of cracking.

3. If cracking is suspected, remove clear coat and primer per steps 4 thru 6 

below and inspect per step 7.

WARNING

IF CRACKING IS DISCOVERED, THE CROSSTUBE IS NO 

LONGER AIRWORTHY AND MUST BE IMMEDIATELY 

REPLACED. REMOVE AND REPLACE CROSSTUBE 

PER SECTION 5 OF THIS REPORT.

4. Apply MIL-R-81294, Type I or II chemical paint remover with a brush and 

allow it to set from 15 to 45 minutes to soften paint. 

5. Using a stiff fiber brush and clean water, rinse paint from crosstube. If 

required, use abrasive pad (Scotch-Brite, Type A) and MIL-R-81294, Type I 

or II chemical paint remover to aid in lifting paint. Brush crosstube with 

abrasive pad in the longitudinal direction, using care so as not to abrade 

crosstube metal surface. 

WARNING

DO NOT SAND CROSSTUBE IN A CIRCUMFERENTIAL 

DIRECTION.

6. Rinse part clean with clean water and dry thoroughly. 

NOTE

Reapplication of chemical paint remover may be required to 

ensure that paint and primer is completely removed so that 

the metal surface of the cross tube is clearly visible. If 

required, repeat steps 4 thru 6.

7. Using at least 10X magnification and a strong light source, visually inspect 

the stripped areas for indications of cracking. If cracking is suspected, 

fluorescent penetrant inspect crosstube per ASTM E1417, Type I, Method B, 

C, or D, Level 2 in accordance with Bell Helicopter Standard Practices 

Manual (BHT-ALL-SPM). 
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WARNING

IF CRACKING IS DISCOVERED, THE CROSSTUBE IS NO 

LONGER AIRWORTHY AND MUST BE IMMEDIATELY 

REPLACED. REMOVE AND REPLACE CROSSTUBE 

PER SECTION 5 OF THIS REPORT. 

8. Following crosstube inspection, coat the stripped crosstube area with 

MIL-PRF-85582 primer (.0006 – .0009 thick) by spraying in accordance with 

manufacturer’s instructions. Allow primer to cure per manufacturer 

instructions. 

NOTE

The MIL-PRF-85582 primer (PRC-DeSoto EWDE 072A/B)

[packaged as a 1-gallon, 1-qt (Parts A&B) kit (P/N 

EWDE072)] and the MIL-PRF-85285, Type I clear coat paint 

(Deft 03X085) [packaged as a 3-qt kit (P/N MIL-PRF-85285)] 

may be procured from a Bell Helicopter Supply Center. The 

primer and paint may also be procured [packaged in 1-qt, 

primer and paint, kits (P/N 1272K)] from Aerospace 

Products, Inc., 6413 Midway Road, Halton City, TX 76117 

(817-332-1669). 

9. Following primer cure, paint the area with MIL-PRF-85285 polyurethane clear 

coat paint by spraying in accordance with manufacturer’s instructions. Allow 

paint to cure per manufacturer instructions. 

Utilize the Inspection Record provided in Appendix C to document inspection.

3.2.2 AT 10,000 TAKEOFF/LANDINGS AND FOLLOWING EVERY SUBSEQUENT 

12 MONTHS OR 2500 TAKEOFF/LANDINGS, WHICHEVER COMES FIRST, 

THEREAFTER DIMENSIONAL INSPECTION

1. Perform Hard Landing Crosstube Deflection Inspection per Section 3.4.

2. Utilize the Inspection Record provided in Appendix D to document inspection.
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3.2.3 AT 12,500 TAKEOFF/LANDINGS AND EVERY SUBSEQUENT 

5000 TAKEOFF/LANDINGS THEREAFTER INSPECTION AND OVERHAUL

(See Figures 1 and 5.)

NOTE

Neither the assignment of a time period overhaul of a 

component nor failure to assign a time period for overhaul of 

a component constitutes a warranty of any kind. The only 

warranty applicable to the component is that warranty 

included in the Purchase Agreement for the component.

Time between overhauls and inspection periods is based 

upon experience, testing, and engineering judgment and is 

subject to change at the sole discretion of Aeronautical 

Accessories or an appropriate government agency.

WARNING

ALL PARTS REMOVED, DUE TO REACHING THEIR 

LIMITS OR AS A RESULT OF AN ACCIDENT/INCIDENT 

AND DEEMED UNAIRWORTHY, SHALL BE 

PERMANENTLY MARKED AS SCRAP OR PHYSICALLY 

DESTROYED TO THE EXTENT THAT THERE IS NO 

CHANCE OF REPAIR OR INSTALLATION ON ANY 

HELICOPTER OR COMPONENT.

1. Remove fairings from Forward Crosstube Assembly, if installed.

2. Hoist or jack the helicopter until no weight is on the skid tubes.

3. Remove forward straps and associated hardware from forward fuselage 

fittings.

4. Remove aft straps and associated hardware from aft fuselage fittings.

5. Raise helicopter until it is clear of skid landing gear, and remove landing 

gear.

6. Remove crosstube supports from Forward Crosstube Assembly in 

accordance with Section 5.

WARNING

DO NOT SAND CROSSTUBE IN A CIRCUMFERENTIAL 

DIRECTION.
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7. Remove aged sealant from Crosstube by scraping with a sharp piece of 

plastic. Use of a heat gun to soften the sealant may facilitate removal. 

Finish by lightly sanding with 400 grit abrasive cloth or paper in the 

longitudinal direction of the crosstube.

8. Prepare crosstube by chemically removing crosstube paint and primer to top 

of saddles.

a. Apply MIL-R-81294, Type I or II chemical paint remover with a brush and 

allow it to set from 15 to 45 minutes to soften paint. 

b. Using a stiff fiber brush and clean water, rinse paint from crosstube. If 

required, use abrasive pad (Scotch-Brite, Type A) and MIL-R-81294, Type I 

or II chemical paint remover to aid in lifting paint. Brush crosstube with 

abrasive pad in the longitudinal direction, using care so as not to abrade 

crosstube metal surface.

WARNING

DO NOT SAND CROSSTUBE IN A CIRCUMFERENTIAL 

DIRECTION.

c. Rinse part clean with clean water and dry thoroughly. Reapplication of 

chemical paint remover may be required to ensure that paint and primer is 

completely removed so that the (bare) metal surface of the cross tube is 

clearly visible

9. When crosstube is not to be processed immediately after cleaning, apply 

corrosion preventive oil, to all parts to protect against corrosion. Wrap parts 

in barrier material and secure with tape. 

10. Inspect the stripped areas of the Crosstubes using fluorescent penetrant 

method per ASTM E1417, Type I, Method B, C, or D, Level 2, in accordance 

with Bell Helicopter Standard Practices Manual (BHT-ALL-SPM). Refer to 

BHT-ALL-SPM for fluorescent penetrant inspection procedures. 

WARNING

IF CRACKING IS DISCOVERED, THE CROSSTUBE IS NO 

LONGER AIRWORTHY AND MUST BE IMMEDIATELY 

REPLACED. REMOVE AND REPLACE CROSSTUBE 

PER SECTION 5 OF THIS REPORT. 

11. Repair damage within repairable limits in accordance with Section 3.
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12. Refinish crosstube by applying MIL-PRF-85582 primer and MIL-PRF-85285 

paint (or equivalent) per manufacturer instructions to the stripped areas. The 

areas to be inspected per Section 3 should be masked to omit 

MIL-PRF-85285 paint as shown in Figure 1. Paint inspection areas with 

MIL-PRF-85285 Type I Gloss Clear coat per manufacturer instructions and 

Figure 1.

13. Reinstall Forward Crosstube straps and fittings per Section 5.

14. Reinstall landing gear/Crosstubes to aircraft per Section 5.

15. Reinstall fairings, as applicable, and return aircraft to service.

16. Utilize the Inspection Record provided in Appendix E to document inspection.
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3.3 CROSSTUBE INSPECTION, 

412-321-104 AND 412-321-304 HIGH AFT CROSSTUBES ONLY

3.3.1 AT 2500 TAKEOFF/LANDINGS AND FOLLOWING EVERY SUBSEQUENT 

450 TAKEOFF/LANDINGS THEREAFTER VISUAL INSPECTION

(See Figure 2.)

1. Use MIL-PRF-87937 cleaning compound prepared in accordance with the

manufacturer’s recommendations to clean all residue and dirt from the cross 

tube surfaces shown in Figure 2.

2. Using at least 10X magnification and a strong light source, visually inspect 

the clear coated crosstube areas for indications of cracking.

3. If cracking is suspected, remove clear coat and primer per steps 4 thru 6 

below and inspect per step 7.

WARNING

IF CRACKING IS DISCOVERED, THE CROSSTUBE IS NO 

LONGER AIRWORTHY AND MUST BE IMMEDIATELY 

REPLACED. REMOVE AND REPLACE CROSSTUBE 

PER SECTION 5 OF THIS REPORT.

4. Apply MIL-R-81294, Type I or II chemical paint remover with a brush and 

allow it to set from 15 to 45 minutes to soften paint. 

5. Using a stiff fiber brush and clean water, rinse paint from crosstube. If 

required, use abrasive pad (Scotch-Brite, Type A) and MIL-R-81294, Type I 

or II chemical paint remover to aid in lifting paint. Brush crosstube with 

abrasive pad in the longitudinal direction, using care so as not to abrade 

crosstube metal surface. 

WARNING

DO NOT SAND CROSSTUBE IN A CIRCUMFERENTIAL 

DIRECTION.

6. Rinse part clean with clean water and dry thoroughly. 

NOTE

Reapplication of chemical paint remover may be required to 

ensure that paint and primer is completely removed so that 

the metal surface of the cross tube is clearly visible. If 

required, repeat steps 4 thru 6.

7. Using at least 10X magnification and a strong light source, visually inspect 

the stripped areas for indications of cracking. If cracking is suspected, 

fluorescent penetrant inspect crosstube per ASTM E1417, Type I, Method B, 

C, or D, Level 2 in accordance with Bell Helicopter Standard Practices 

Manual (BHT-ALL-SPM). 
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WARNING

IF CRACKING IS DISCOVERED, THE CROSSTUBE IS NO 

LONGER AIRWORTHY AND MUST BE IMMEDIATELY 

REPLACED. REPLACE CROSSTUBE PER SECTION 5

OF THIS REPORT. 

8. Following crosstube inspection, coat the stripped crosstube area with 

MIL-PRF-85582 primer (.0006 – .0009 thick) by spraying in accordance with 

manufacturer’s instructions. Allow primer to cure per manufacturer 

instructions. 

NOTE

The MIL-PRF-85582 primer (PRC-DeSoto EWDE 072A/B)

[packaged as a 1-gallon, 1-qt (Parts A&B) kit (P/N 

EWDE072)] and the MIL-PRF-85285, Type I clear coat paint 

(Deft 03X085) [packaged as a 3-qt kit (P/N MIL-PRF-85285)] 

may be procured from a Bell Helicopter Supply Center. The 

primer and paint may also be procured [packaged in 1-qt, 

primer and paint, kits (P/N 1272K)] from Aerospace 

Products, Inc., 6413 Midway Road, Halton City, TX 76117 

(817-332-1669). 

9. Following primer cure, paint the area with MIL-PRF-85285 polyurethane clear 

coat paint by spraying in accordance with manufacturer’s instructions. Allow 

paint to cure per manufacturer instructions. 

10. Utilize the Inspection Record provided in Appendix F to document inspection.

3.3.2 AT 2500 TAKEOFF/LANDINGS AND EVERY 12 MONTHS / 2500 

TAKEOFF/LANDINGS, WHICHEVER COMES FIRST, THEREAFTER 

DIMENSIONAL INSPECTION

1. Perform Hard Landing Crosstube Deflection Inspection per Section 3.

2. Utilize the Inspection Record provided in Appendix G to document 

inspection.
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3.3.3 AT 7500 TAKEOFF/LANDINGS AND EVERY SUBSEQUENT 

5000 TAKEOFF/LANDINGS THEREAFTER INSPECTION AND OVERHAUL

(See Figures 2 and 6.)

NOTE

Neither the assignment of a time period overhaul of a 

component nor failure to assign a time period for overhaul of 

a component constitutes a warranty of any kind. The only 

warranty applicable to the component is that warranty 

included in the Purchase Agreement for the component.

Time between overhauls and inspection periods is based 

upon experience, testing, and engineering judgment and is 

subject to change at the sole discretion of Aeronautical 

Accessories or an appropriate government agency.

WARNING

ALL PARTS REMOVED DUE TO REACHING THEIR 

LIMITS OR AS A RESULT OF AN ACCIDENT/INCIDENT 

AND DEEMED UNAIRWORTHY SHALL BE 

PERMANENTLY MARKED AS SCRAP OR PHYSICALLY 

DESTROYED TO THE EXTENT THAT THERE IS NO 

CHANCE OF REPAIR OR INSTALLATION ON ANY 

HELICOPTER OR COMPONENT.

1. Remove fairings from Aft Crosstube Assembly, if installed.

2. Hoist or jack the helicopter until no weight is on the skid tubes.

3. Remove forward straps and associated hardware from forward fuselage 

fittings.

4. Remove aft straps and associated hardware from aft fuselage fittings.

5. Raise helicopter until it is clear of skid landing gear, and remove landing 

gear.

6. Remove Aft Crosstube Assembly, Aft Crosstube Beam Assembly, and both 

Aft Crosstube Clamp Assemblies in accordance with Section 5.

NOTE

The Upper Center Support on the Aft Crosstube is bonded 

with structural adhesive and is not designed for removal.

WARNING

DO NOT SAND CROSSTUBE IN A CIRCUMFERENTIAL 

DIRECTION.

7. Remove aged sealant from Crosstube by scraping with a sharp piece of 

plastic. Use of a heat gun to soften the sealant may facilitate removal. 

Finish by lightly sanding with 400 grit abrasive cloth or paper in the 

longitudinal direction of the crosstube.
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8. Prepare crosstube by chemically removing crosstube paint and primer to top 

of saddles.

CAUTION 

Protect Upper Center Support area on aft high crosstube

to prevent contamination by paint strippers and 

penetrant inspection chemicals.

a. Apply MIL-R-81294, Type I or II chemical paint remover with a brush and 

allow it to set from 15 to 45 minutes to soften paint. 

b. Using a stiff fiber brush and clean water, rinse paint from crosstube. If 

required, use abrasive pad (Scotch-Brite, Type A) and MIL-R-81294, Type I 

or II chemical paint remover to aid in lifting paint. Brush crosstube with 

abrasive pad in the longitudinal direction, using care so as not to abrade 

crosstube metal surface.

WARNING

DO NOT SAND CROSSTUBE IN A CIRCUMFERENTIAL 

DIRECTION.

c. Rinse part clean with clean water and dry thoroughly. Reapplication of 

chemical paint remover may be required to ensure that paint and primer is 

completely removed so that the (bare) metal surface of the cross tube is 

clearly visible

9. When crosstube is not to be processed immediately after cleaning, apply 

corrosion preventive oil, to all parts to protect against corrosion. Wrap parts 

in barrier material and secure with tape. 

10. Inspect the stripped areas of the Crosstube using fluorescent penetrant 

method per ASTM E1417, Type I, Method B, C, or D, Level 2, in accordance 

with Bell Helicopter Standard Practices Manual (BHT-ALL-SPM). Refer to 

BHT-ALL-SPM for fluorescent penetrant inspection procedures. 

WARNING

IF CRACKING IS DISCOVERED, THE CROSSTUBE IS NO 

LONGER AIRWORTHY AND MUST BE IMMEDIATELY 

REPLACED. REMOVE AND REPLACE CROSSTUBE 

PER SECTION 5 OF THIS REPORT. 

11. Repair damage within repairable limits in accordance with Section 3.

12. Refinish crosstube by applying MIL-PRF-85582 primer and MIL-PRF-85285 

paint (or equivalent) per manufacturer instructions to the stripped areas. The 

areas to be inspected per Section 3 should be masked to omit 

MIL-PRF-85285 paint as shown in Figure 2. Paint inspection areas with 

MIL-PRF-85285 Type I Gloss Clear coat per manufacturer instructions and 

Figure 2.
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13. Reinstall Aft Crosstube Clamp Assemblies and Aft Crosstube Beam 

Assembly in accordance with Section 5.

14. Reinstall landing gear/Crosstubes to aircraft per Section 5.

15. Reinstall fairings, as applicable, and return aircraft to service.

16. Utilize the Inspection Record provided in Appendix H to document inspection.
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3.4 HARD LANDING CROSSTUBE DEFLECTION INSPECTION

Crosstube hard landing inspection shall be conducted after a known or 

suspected hard landing. Inspect Crosstubes for deflection as follows:

1. Hoist or jack the helicopter until no weight is on the skid tubes.

2. Measure the lateral distance between the two forward Crosstube attachment 

straps. Measure the lateral distance between the two aft Crosstube 

attachment straps. Divide these dimensions by two to determine the 

helicopter centerline, BL 0.00.

3. Measure the Crosstube horizontal deflection from the centerline of the 

helicopter, BL 0.00, to the outside of the skid tubes.

4. The Crosstube horizontal deflection as measured in step 3 above must be 

within the limits as shown in Figure 4. Crosstubes that measure outside of 

the limits must be replaced.
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3.5 REPAIR

Repair all damage (scratches, nicks, dents) and corrosion as follows. Refer to 

Table 1 for damage/repair limits:

TABLE 1. DAMAGE AND REPAIR LIMITS

Component

Maximum Allowable Damage And Repair Limits *

(Damage and corrosion may be repaired as noted in Section 3.5

Repair, if it does not exceed these limits.)

Scratches/Nicks/Dents And Corrosion Cracks/Holes

Crosstube Refer to Figure 3, sheets 1 and 2 None

Forward Support

To a depth of .020” (.508mm) for a maximum 

area of 1.0 square inch (25.4mm2). No more 

than two repairs per support allowed.

None

Aft Support

To a depth of .020” (.508mm) for a maximum 

area of 1.0 square inch (25.4mm2). No more 

than two repairs per support allowed.

None

Clamp Assembly To a depth of .005” (.127mm) None

Notes

The following apply to Crosstube damage and repair:

a. All Crosstube damage is unacceptable and shall be repaired. 

b. Damage limits apply to the surface areas of the Crosstube as indicated by 

Figure 3. Circumferential grooves or grind marks are not acceptable. 

c. All corrosion shall be cleaned up to twice the visible corrosion depth and 

shall not exceed the damage limits allowed (refer to Figure 3). 

d. The orientation of scratches and corrosion damage is limited by the 

dimensions in Figure 3.

e. The minimal longitudinal distance between repairs is 3.0 inches.

CAUTION

Abrasive blending-out strokes must be parallel to the 

Crosstube, not circumferential.

1. Polish the affected area in a longitudinal direction using Scotch-Brite or No. 

400 to 600 abrasive paper or cloth. Ensure the limits presented in Table 1 

and Figure 3 are not exceeded.

2. Clean repaired area with isopropyl alcohol, brush Alodine bare aluminum 

areas per MIL-DTL-81706 or equivalent, and reprime with Epoxy Polyamide 

primer per MIL-PRF-23377 or equivalent.

3. Paint repaired area to match existing finish. 
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3.6 CLEANING REQUIREMENTS

Any dirt, sand, or debris should be cleaned from the Replacement Crosstubes

using a mild, nonabrasive soap. Wipe surfaces dry with a nonabrasive cloth or 

paper before cleaning agent evaporates.

3.7 ADJUSTMENTS

Adjustment of the Replacement Crosstubes is not required. Apply the following 

torque to all noted fasteners during component or fastener replacement (torque 

all fasteners in accordance with Table 2):

1. Torque the fasteners attaching the T-Bolt and Clamps 

(10 Fastener Size).

2. Torque the fasteners attaching the U-Bolt and Supports 

(1/4 Fastener Size).

3. Torque the fasteners attaching the Saddles to the Crosstubes 

(1/4 or 3/8 Fastener Size).

TABLE 2. TORQUE VALUES

Fastener Size Torque (In-lbs) Torque (Nm)

10 30 – 40 3.4 – 4.5

1/4 80 – 100 9.0 – 11.3

1/4 (AN4-XXX) 30 – 40 3.4 – 4.5

1/4 (NAS6604-XX) 50 – 70 5.6 – 7.9

3/8 (AN6-XXX) 95 – 100 10.7 – 11.3

3/8 (NAS6606-XX) 160 – 190 18.1 – 21.5
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4.0 TROUBLESHOOTING INFORMATION

TABLE 3. TROUBLESHOOTING

Problem Probable Cause Remedy

Landing Gear -

Replacement 

Crosstube is 

loose or has 

excessive 

vibration.

Attachment components or 

fasteners loose, damaged, 

or missing.

Check security of crosstube attachment 

components. Check torque on all fasteners 

according to Table 2.

Replacement Crosstube is 

damaged allowing 

movement.

Check Crosstube for cracks or other 

damage in accordance with Table 1. 

Repair / replace as needed.

Aircraft does 

not sit level

Forward or Aft Crosstube is 

spread.

Perform Crosstube Hard Landing 

Inspection per Section 3.4. Replace 

Components as required.
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5.0 REMOVAL AND REPLACEMENT INFORMATION

5.1 REMOVAL – CROSSTUBES

1. Remove fairings, if installed, per manufacturer instructions.

2. Hoist or jack the helicopter until no weight is on the skid tubes.

3. Remove forward straps and associated hardware from forward fuselage 

fittings.

4. Remove aft straps and associated hardware from aft fuselage fittings.

5. Raise helicopter until it is clear of skid landing gear, and remove landing 

gear.

6. Remove the skid tubes and the associated hardware from the Crosstubes.

7. If necessary, remove the Beam Assembly (refer to Section 5.5) and attaching 

hardware from 412 Aft Crosstubes.

5.2 INSTALLATION – CROSSTUBES

NOTE

If skid tubes were removed from Crosstubes, complete steps 

1 thru 6. If skid tubes were not removed from Crosstubes,

proceed to step 7.

1. Reinstall Crosstubes into skid tube saddles with existing hardware. Apply 

sealant (AMS-S-8802) under each screw head. Do not torque fasteners at 

this time. 

2. Reinstall the Beam Assembly (refer to Section 5.6) on 412 Aft Crosstubes if 

previously removed. 

3. Install the landing gear on aircraft while keeping the skids off the ground.

4. Torque all screws attaching the Crosstubes to the saddles per Table 2.

5. Lower the helicopter to the ground.

6. Apply a fillet of sealant (AMS-S-8802) around top edge of the saddle.

7. Attach the skid gear to the helicopter with the existing cap assemblies and 

the attaching hardware. Torque all bolts 100 – 140 in-lbs (11.3 – 15.8 Nm).
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5.3 REMOVAL – CROSSTUBE SUPPORTS

NOTE

The 604-026-001 Upper Aft Support on the model 412 Aft 

Crosstubes is bonded with structural adhesive and is not 

designed for removal. Contact Aeronautical Accessories 

Bell Helicopter Piney Flats Technical Support for assistance 

if replacement is required.

1. Remove the Support U-bolts from the Crosstube Assembly.

2. Remove the Supports from the Crosstube Assembly. Use of a heat gun to 

soften the sealant may facilitate removal.

3. Using a plastic scraper, remove the old sealant from Crosstube and 

Supports. Clean with a clean cloth and alcohol.

NOTE

Inspect the inner surface coating material for deterioration 

(pealing, cracking, or wear). 604-025-001 / 604-025-003 / 

604-025-011 / 604-025-013 and 604-026-003 Supports have 

black Nylon coating and 205-050-132-001 / 

205-050-132-003 and 205-050-133-001 / 205-050-133-003 / 

412-050-007-101 Supports have EC2216 adhesive coating. 

Replace Supports if Nylon coating has separated or has 

worn through. For EC2216 coated Supports, two coats of 

EC2216 adhesive may be applied for restoration of the 

protective barrier. Allow 24 hours for the adhesive to cure.

5.4 INSTALLATION – CROSSTUBE SUPPORTS 

NOTE

The 604-026-001 Upper Aft Support on the model 412 Aft 

Crosstubes is not designed for field replacement. Contact 

Aeronautical Accessories Bell Helicopter Piney Flats 

Technical Support for assistance if replacement is required. 

NOTE

Do not reinstall any Aeronautical Accessories Support if 

uncoated. Aeronautical Accessories coated Supports must 

be used for reinstallation. Replace coated Supports if 

damaged or worn. (This note is not applicable to alternate 

BHT uncoated Supports.)

1. Scuff the faying surface of the Crosstube and the Supports with 180 grit 

abrasive paper. Do no remove paint from the Crosstube or Nylon/EC2216 

coating from the Supports.
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2. Clean the sanding residue from the Crosstube and Supports using alcohol 

and a clean cloth.

3. Apply one layer (approx. 1/16 inch thick) of sealant (AMS-S-8802) to inside 

surface of the Supports prior to assembly. 

4. Reassemble the Upper and Lower Supports and the U-Bolts on the 

Crosstube, Refer to Figures 7 thru 10.

5. Remove excess sealant or adhesive and wipe clean after assembly.

6. Torque the U-bolt nuts to 80 – 100 in-lbs (9.0 to 11.3 Nm) within 30 minutes 

after application of sealant or adhesive. 

a. Verify torque after cure is complete (72 hours at room temperature). 

Re-torque as required. 

b. Apply fillet of 099-050-222 Sealant to edges of the Support and 

Crosstube. (Sealant to have no voids.)

CAUTION

Flight/landing operations prior to full cure (72 hours at 

room temperature) could result in Crosstube Support 

movement.

5.5 REMOVAL – BEAM ASSEMBLY

1. Remove the Cotter Pin, the Nut, the Washers, and the Bolt from the Beam 

Assembly and the Aft Center Support.

2. Remove the Beam Assembly.

5.6 INSTALLATION – BEAM ASSEMBLY

1. Use the Bolt, the Washers, and the Nut and install the Beam Assembly on 

the Aft Center Support.

2. Safety the Nut with a new Cotter Pin. 

5.7 REMOVAL – CLAMP ASSEMBLY

1. Remove the Nuts from the Clamp Assembly.

2. Remove the Clamp Assembly from the Crosstube Assembly. Use of a heat 

gun to soften the sealant may facilitate removal.

3. Using a plastic scraper, remove the old sealant from Crosstube and Clamp 

Assembly. Clean with a clean cloth and alcohol.

NOTE

Inspect the Nylon coating on the faying surface of the Clamp 

for condition. Replace if coating has separated or has worn 

through.
BHT 205A, 205A-1, 205B INSTRUCTIONS for CONTINUED AIRWORTHINESS AA-01136

212, 412, 412EP, 412CF, CROSSTUBES Revision K

AGUSTA AB412, AB412EP,

UH-1B, UH-1H, SW204, SW205 

AERONAUTICAL ACCESSORIES

February 15, 2012 Page 32 of 78

5.8 INSTALLATION – CLAMP ASSEMBLY

NOTE

Do not reinstall any Clamp if uncoated. Coated Clamps 

must be used for reinstallation. Replace if damaged or worn. 

1. Scuff the faying surface of the Crosstube and the Clamps with 180 grit 

abrasive paper. Do no remove paint from the Crosstube or Nylon Coating 

from the Clamps.

2. Clean the sanding residue from the Crosstube and Clamps using alcohol and 

a clean cloth.

3. Apply a layer (approx. 1/16 inch thick) of sealant (AMS-S-8802) to inside 

surface of the Clamp prior to assembly.

4. Reassemble the Clamp Assembly on the Crosstube (refer to Figures 9 and 10).

5. Remove excess sealant and wipe clean after assembly.

NOTE

Use of a wire/string may be required to keep the Clamp 

Assemblies from sliding down the Crosstube when torque is 

being applied.

6. Torque the Nuts to 30 – 40 in-lbs (3.4 – 4.5 Nm) within 30 minutes after 

application of sealant. Check torque after 15 minutes. Re-torque as required. 

a. Apply fillet of 099-050-222 Sealant to edges of the Clamp. 

(Sealant to have no voids.)

5.9 REMOVAL – PLATE ASSEMBLY

1. Remove the Crosstubes from the helicopter per Section 5.1.

2. Using #30 drill bit (.127 – .133), drill out the rivets securing the Plate 

Assembly to the Crosstube.

3. Remove the Plate Assembly.

5.10 INSTALLATION – PLATE ASSEMBLY

1. Slide the Plate Assembly into the Crosstube until the Saddle bolt holes align 

with the Plate Assembly bolt holes.

2. Temporarily secure the Plate Assembly in place with crosstube/saddle bolts 

of the appropriate diameter using washers as spacers if required.

3. Match drill Crosstube rivet holes to the Plate Assembly using a #30 drill bit 

(.127 – .133).

4. Remove crosstube/saddle bolts and slide Plate Assembly out from 

Crosstube. Deburr and apply one coat of Epoxy Polyamide Primer per 

MIL-PRF-23377 or equivalent to Plate Assembly rivet holes.
BHT 205A, 205A-1, 205B INSTRUCTIONS for CONTINUED AIRWORTHINESS AA-01136

212, 412, 412EP, 412CF, CROSSTUBES Revision K

AGUSTA AB412, AB412EP,

UH-1B, UH-1H, SW204, SW205 

AERONAUTICAL ACCESSORIES

February 15, 2012 Page 33 of 78

5. Slide the Plate Assembly into the Crosstube until the Saddle bolt and rivet 

holes align with the Plate Assembly bolt and rivet holes.

6. Wet Install rivets with Sealant per AMS-S-8802.

6.0 STRUCTURAL FASTENER DATA

For hardware identification and torque refer to Tables 2 and 4 thru 12, and 

Figures 1 thru 11.

7.0 SPECIAL TOOLS NEEDED

Torque Wrench

8.0 TOWING AIRCRAFT

Helicopter towing operations must be conducted in accordance with applicable 

model Bell Helicopter Maintenance Manual. Manufacturer towing requirements 

are applicable to any aircraft being towed with weight on gear. This includes 

towing aircraft with ground handling wheels installed and aircraft resting on 

moveable platforms.

CAUTION

Failure to follow manufacturer towing instructions may 

result in crosstube damage and/or failure. 

9.0 WEIGHT AND BALANCE

9.1 LOW SKID GEAR CROSSTUBE

Part Number Weight 

(lbs)

Weight 

(kg)

FS 

(in)

FS 

(mm)

BL 

(in)

BL 

(mm)

212-320-103 – Forward 25.19 11.43 71.65 1820 0.00 0.00

212-320-104 – Aft 36.31 16.47 163.00 4140 0.00 0.00

412-320-104 – Aft 42.51 19.28 163.00 4140 0.00 0.00

412-320-154 – Aft

(Including Beam Assembly)

53.52 24.28 163.00 4140 0.00 0.00

9.2 HIGH SKID GEAR CROSSTUBE

Part Number Weight 

(lbs)

Weight 

(kg)

FS 

(in)

FS 

(mm)

BL

(in)

BL 

(mm)

212-321-103 – Forward 32.08 14.55 71.65 1820 0.00 0.00

212-321-104 / 212-321-304 – Aft 44.67 20.26 163.00 4140 0.00 0.00

412-321-104 / 412-321-304 – Aft 49.33 22.38 163.00 4140 0.00 0.00

412-321-106 / 412-321-306 – Aft 

(Including Beam Assembly)

60.34 27.37 163.00 4140 0.00 0.00
BHT 205A, 205A-1, 205B INSTRUCTIONS for CONTINUED AIRWORTHINESS AA-01136

212, 412, 412EP, 412CF, CROSSTUBES Revision K

AGUSTA AB412, AB412EP,

UH-1B, UH-1H, SW204, SW205 

AERONAUTICAL ACCESSORIES

February 15, 2012 Page 34 of 78

10.0 AIRWORTHINESS LIMITATIONS

10.1 RETIREMENT LIFE

A retirement life has been established for High Aft Crosstubes P/Ns 412-321-304 

and 412-321-104 (Serial number 1274 and subsequent) and 212-321-304 (Serial 

number 1250 and subsequent). An Historical Record is provided (Appendix I) for 

recording of takeoff/landing operations for the listed life-limited Crosstubes.

PART NUMBER (1) COMPONENT LIFE LIMIT (RIN) (2)

212-321-304 (3) Aft Crosstube, High Skid Gear 24,000 Takeoff/Landings

412-321-104 (4) Aft Crosstube, High Skid Gear 20,000 Takeoff/Landings

412-321-304 (4) Aft Crosstube, High Skid Gear 20,000 Takeoff/Landings

NOTES:

(1) The airworthiness limitation for part number listed applies to all successive dash numbers 

for that component unless otherwise specified.

(2) RIN (Retirement Index Number) is the retirement life based on fatigue damage from 

normal helicopter lifts and takeoffs. New components will begin with an accumulated RIN of 

zero that will be increased as takeoffs and landings are performed. Operators must record 

the number of takeoffs/landings and increase the accumulated RIN by 1 for each 

takeoff/landing. When the maximum RIN is reached, the component will be removed from 

service.

(3) Applicable to BHT model 205 and 212 helicopters.

(4) Applicable to BHT model 412 helicopters.

The Airworthiness Limitations Section Js FAA approved and specifies 

maintenance required under §§ 43.16 and 91.403 of the Federal Aviation 

Regulations unless an alternative program has been FAA approved.

AIRWORTHINESS LIMITATIONS REVISION HISTORY FAA APPROVAL DATE

Report revision NR thru D N/A –

Report revision E Lance T. Gant 04/14/10

Report revision F: No Change N/A –

Report revision G: No Change N/A –

Report revision H: No Change N/A –

Report revision I: No Change N/A –

Report revision J: No Change N/A –

Report revision K: No Change N/A –
BHT 205A, 205A-1, 205B INSTRUCTIONS for CONTINUED AIRWORTHINESS AA-01136

212, 412, 412EP, 412CF, CROSSTUBES Revision K

AGUSTA AB412, AB412EP,

UH-1B, UH-1H, SW204, SW205 

AERONAUTICAL ACCESSORIES

February 15, 2012 Page 35 of 78

11.0 PARTS BREAKDOWN

Tables 4 thru 16 contain Parts Breakdown data for Aeronautical Accessories 

Replacement Crosstubes for model 205A, 205A-1, 205B, 212, 412, 412EP, 

412CF, AB412, AB412EP, UH-1B, UH-1H, SW204, and SW205 helicopters.

The column Availability Code (AV Code) specifies the procurement status for 

each part. The codes to identify if a part is procurable, procedure details to get 

an assembly or local manufacture code are as follows:

AV 

Code Details

0 Nonprocurable part

1 Procurable part

2 Procure as detail parts only

3 Procurable as Next Higher Assembly

4 Local manufacture. Contact Product Support Engineering (PSE)

5 Part replacement requires a fixture or special equipment. Contact PSE

6 Non-stock procurable part
BHT 205A, 205A-1, 205B INSTRUCTIONS for CONTINUED AIRWORTHINESS AA-01136

212, 412, 412EP, 412CF, CROSSTUBES Revision K

AGUSTA AB412, AB412EP,

UH-1B, UH-1H, SW204, SW205 

AERONAUTICAL ACCESSORIES

February 15, 2012 Page 36 of 78

11.1 LOW SKID GEAR PARTS BREAKDOWN

11.1.1 212-320 SERIES LOW GEAR CROSSTUBES

TABLE 4. PARTS BREAKDOWN, LOW SKID GEAR CROSSTUBES,

212-320-103 FORWARD / 212-320-104 AFT(1) CROSSTUBE ASSEMBLY

Qty

-103

Qty

-104 Part Number Description

AV 

Code

1 212-320-203 Hardware Kit 1

1 212-320-207 Hardware Kit 1

1 1 099-091-001 Decal (Alt: 099-091-011) 1

1 605-013-101 Forward Crosstube Assembly 3

1 605-015-101 Aft Crosstube Assembly 3

Notes:

1. 212-320-104 Assembly not for use on 412 models 

TABLE 5. PARTS BREAKDOWN, 212-320-203 / 212-320-207 HARDWARE KIT

Qty

-203

Qty

-207 Part Number Description

AV 

Code

4 NAS1149D0416J Washer 1

8 12 NAS1149D0616J Washer 1

4 NAS6604-11 Bolt 1

8 12 NAS6606-9 Bolt 1

12 NAS6606-11 Bolt 1
BHT 205A, 205A-1, 205B INSTRUCTIONS for CONTINUED AIRWORTHINESS AA-01136

212, 412, 412EP, 412CF, CROSSTUBES Revision K

AGUSTA AB412, AB412EP,

UH-1B, UH-1H, SW204, SW205 

AERONAUTICAL ACCESSORIES

February 15, 2012 Page 37 of 78

TABLE 6. PARTS BREAKDOWN, CROSSTUBE ASSEMBLIES

605-013-101 FORWARD // 605-015-101

(1) AFT

Qty

-013-101

Qty

-015-101 Part Number Description

AV 

Code

1 604-003-001 Forward Crosstube 3

1 604-005-001 Aft Crosstube 3

4 604-023-101 Plate Assembly 1

4 4 604-023-103 Plate Assembly 1

4 604-023-105 Plate Assembly 1

2 604-025-001(2) Upper Forward Support (Alt: 205-050-132-001(3)) 1

2 604-025-003(2)

Lower Forward Support (Alt: 205-050-133-001(3)) 1

4 604-025-005 U-Bolt 1

2 604-025-011(2) Upper Aft Support (Alt: 205-050-132-003(3)) 1

2 604-025-013(2)

Lower Aft Support (Alt: 205-050-133-003(3)) 1

4 604-025-015 U-Bolt 1

1 1 099-050-222 Sealant (Alt: 099-050-223) 1

1 4067 Plug 1

20 CR3212-4-8 Rivet 1

20 CR3212-5-8 Rivet 1

8 8 MS21043-4 Nut 1

8 8 NAS1149C0463R Washer (Alt: AN960C416) 1

Notes:

1. Assembly not for use on 412 models

2. Aeronautical Accessories Coated Support 

3. BHT Uncoated Support 
BHT 205A, 205A-1, 205B INSTRUCTIONS for CONTINUED AIRWORTHINESS AA-01136

212, 412, 412EP, 412CF, CROSSTUBES Revision K

AGUSTA AB412, AB412EP,

UH-1B, UH-1H, SW204, SW205 

AERONAUTICAL ACCESSORIES

February 15, 2012 Page 38 of 78

11.1.2 412-320 SERIES LOW GEAR CROSSTUBES

TABLE 7. PARTS BREAKDOWN, LOW SKID GEAR AFT CROSSTUBES

412-320-104(1) / 412-320-154(1) AFT CROSSTUBE ASSEMBLIES

Qty

-104

Qty

-154 Part Number Description

AV 

Code

1 412-320-203 Hardware Kit 1

1 099-091-001 Decal (Alt: 099-091-011) 1

1 605-015-201 Aft Crosstube Assembly 3

1 412-320-104 Aft Crosstube Assembly 1

1 604-030-001 Beam Assembly (Alt: 412-050-003-109 / -111 / -113) 1

1 412-050-008-101(2) Bolt (Alt: 604-028-001) 1

1 MS14145L8(2) Nut 1

1 MS24665-287(2) Cotter Pin 1

1 NAS1149D1063K(2) Washer 1

Notes:

1. Assembly for use on BHT 412, 412EP, 412CF, Agusta AB412, AB412EP models only

2. Used to attach Beam Assembly to Crosstube

TABLE 8. PARTS BREAKDOWN, 412-320-203 HARDWARE KIT

Qty Part Number Description

AV 

Code

12 NAS1149D0616J Washer 1

12 NAS6606-11 Bolt 1
BHT 205A, 205A-1, 205B INSTRUCTIONS for CONTINUED AIRWORTHINESS AA-01136

212, 412, 412EP, 412CF, CROSSTUBES Revision K

AGUSTA AB412, AB412EP,

UH-1B, UH-1H, SW204, SW205 

AERONAUTICAL ACCESSORIES

February 15, 2012 Page 39 of 78

TABLE 9. PARTS BREAKDOWN, 605-015-201 AFT CROSSTUBE ASSEMBLY

Qty Part Number Description

AV 

Code

1 604-005-003 Aft Crosstube 3

4 604-023-103 Plate Assembly 1

4 604-023-105 Plate Assembly 1

1 604-026-001 Upper Aft Support (Alt: 412-050-006-101A) 1

1 604-026-003 Lower Aft Support (Alt: 412-050-007-101) 1

2 604-026-015 Aft U-Bolt (Alt: 214-052-008-101) 1

2 604-027-001 Clamp Assembly (Alt: 604-027-002) 1

2 604-027-103 Abrasion Strip 1

1 099-050-121 Adhesive 1

1 099-050-222 Sealant (Alt: 099-050-223) 1

20 CR3212-5-9 Rivet 1

1 EC 9324B Adhesive Primer 1

1 LARSON L100 Adhesive 1

8 MS21043-4 Nut 1

8 NAS1149C0463R Washer (Alt: AN960C416) 1
BHT 205A, 205A-1, 205B INSTRUCTIONS for CONTINUED AIRWORTHINESS AA-01136

212, 412, 412EP, 412CF, CROSSTUBES Revision K

AGUSTA AB412, AB412EP,

UH-1B, UH-1H, SW204, SW205 

AERONAUTICAL ACCESSORIES

February 15, 2012 Page 40 of 78

11.2 HIGH SKID GEAR PARTS BREAKDOWN

11.2.1 212-321 SERIES HIGH GEAR CROSSTUBES

TABLE 10. PARTS BREAKDOWN, HIGH SKID GEAR CROSSTUBES, 

212-321-103 FORWARD CROSSTUBE ASSEMBLY

212-321-104(1) / 212-321-304(1) AFT CROSSTUBE ASSEMBLY

Qty

-103

Qty

-104

Qty

-304 Part Number Description

AV 

Code

1 212-321-203 Hardware Kit 1

1 1 212-321-207 Hardware Kit 1

1 1 1 099-091-001 Decal 1

1 605-003-101 Forward Crosstube Assembly 3

1 1 605-005-101 Aft Crosstube Assembly 3

Notes:

1. Assembly not for use on 412 models

TABLE 11. PARTS BREAKDOWN, 212-321-203 / 212-321-207 HARDWARE KIT

Qty

-203

Qty

-207 Part Number Description

AV 

Code

12 NAS6606-11 Bolt 1

8 12 NAS6606-9 Bolt 1

12 12 NAS1149D0616J Washer 1
BHT 205A, 205A-1, 205B INSTRUCTIONS for CONTINUED AIRWORTHINESS AA-01136

212, 412, 412EP, 412CF, CROSSTUBES Revision K

AGUSTA AB412, AB412EP,

UH-1B, UH-1H, SW204, SW205 

AERONAUTICAL ACCESSORIES

February 15, 2012 Page 41 of 78

TABLE 12. PARTS BREAKDOWN, CROSSTUBE ASSEMBLIES

605-003-101 FORWARD // 605-005-101

(1) AFT CROSSTUBE ASSEMBLY

Qty

-003-101

Qty

-005-101 Part Number Description

AV 

Code

2 605-005-121 Decal 1

1 604-003-011 Forward Crosstube 3

1 604-005-011 Aft Crosstube 3

4 4 604-023-103 Plate Assembly 1

4 4 604-023-105 Plate Assembly 1

2 604-025-001(2) Upper Forward Support (Alt: 205-050-132-001(3)) 1

2 604-025-003(2)

Lower Forward Support (Alt: 205-050-133-001(3)) 1

4 604-025-005 U-Bolt 1

2 604-025-011(2) Upper Aft Support (Alt: 205-050-132-003(3)) 1

2 604-025-013(2)

Lower Aft Support (Alt: 205-050-133-003(3)) 1

4 604-025-015 U-Bolt 1

1 1 099-050-222 Sealant (Alt: 099-050-223) 1

1 4067 Plug 1

20 CR3212-4-9 Rivet 1

20 CR3212-5-9 Rivet 1

8 8 NAS1149C0463R Washer 1

8 8 MS21043-4 Nut 1

Notes:

1. Assembly not for use on 412 models

2. Aeronautical Accessories Coated Support 

3. BHT Uncoated Support 
BHT 205A, 205A-1, 205B INSTRUCTIONS for CONTINUED AIRWORTHINESS AA-01136

212, 412, 412EP, 412CF, CROSSTUBES Revision K

AGUSTA AB412, AB412EP,

UH-1B, UH-1H, SW204, SW205 

AERONAUTICAL ACCESSORIES

February 15, 2012 Page 42 of 78

11.2.2 412-321 SERIES HIGH GEAR CROSSTUBES

TABLE 13. PARTS BREAKDOWN, HIGH SKID GEAR AFT CROSSTUBES,

412-321-106(1) / 412-321-306(1) AFT CROSSTUBE ASSEMBLY

Qty

-106

Qty

-306 Part Number Description AV Code

1 412-321-104 Aft Crosstube Assembly 1

1 412-321-304 Aft Crosstube Assembly 1

1 1 604-028-001(2) Bolt (Alt: 412-050-008-101) 1

1 1 604-030-001 Beam Assembly (Alt: 412-050-003-109 / -111 / -113) 1

1 1 MS14145L8(2) Nut 1

1 1 MS24665-287(2) Cotter Pin 1

1 1 NAS1149D1063K(2) Washer 1

Notes:

1. Assembly for use on BHT 412, 412EP, 412CF, Agusta AB412, AB412EP models only

2. Used to attach Beam Assembly to Crosstube

TABLE 14. PARTS BREAKDOWN, HIGH SKID GEAR AFT CROSSTUBES,

412-321-104(1) / 412-321-304(1) AFT CROSSTUBE ASSEMBLY

Qty

-104

Qty

-304 Part Number Description AV Code

1 1 412-321-200 Hardware Kit 1

1 1 099-091-001 Decal (Alt: 099-091-011) 1

1 1 605-005-201 Aft Crosstube Assembly 3

Notes:

1. Assembly for use on BHT 412, 412EP, 412CF, Agusta AB412, AB412EP models only
BHT 205A, 205A-1, 205B INSTRUCTIONS for CONTINUED AIRWORTHINESS AA-01136

212, 412, 412EP, 412CF, CROSSTUBES Revision K

AGUSTA AB412, AB412EP,

UH-1B, UH-1H, SW204, SW205 

AERONAUTICAL ACCESSORIES

February 15, 2012 Page 43 of 78

TABLE 15. PARTS BREAKDOWN, 412-321-200 HARDWARE KIT

Qty Part Number Description

AV 

Code

12 NAS1149D0616J Washer 1

12 NAS6606-11 Bolt 1

TABLE 16. PARTS BREAKDOWN, 605-005-201 AFT CROSSTUBE ASSEMBLY

Qty Part Number Description

AV 

Code

2 605-005-121 Decal 1

1 604-005-013 Aft Crosstube 3

4 604-023-103 Plate Assembly 1

4 604-023-105 Plate Assembly 1

1 604-026-001 Upper Aft Support (Alt: 412-050-006-101A) 1

1 604-026-003 Lower Aft Support (Alt: 412-050-007-101) 1

2 604-026-015 Aft U-Bolt (Alt: 214-052-008-101) 1

2 604-027-002 Clamp Assembly 1

2 604-027-103 Abrasion Strip 1

1 099-050-222 Sealant (Alt: 099-050-223) 1

20 CR3212-5-9 Rivet 1

1 EC 3924B Adhesive Primer 1

1 Larson L100 Adhesive 1

4 MS21043-4 Nut 1

4 NAS1149C0463R Washer (Alt: AN960C416) 1
BHT 205A, 205A-1, 205B INSTRUCTIONS for CONTINUED AIRWORTHINESS AA-01136

212, 412, 412EP, 412CF, CROSSTUBES Revision K

AGUSTA AB412, AB412EP,

UH-1B, UH-1H, SW204, SW205 

AERONAUTICAL ACCESSORIES

February 15, 2012 Page 44 of 78

12.0 REFERENCE CROSSTUBE FIGURES 

NOTE

Reference Crosstube figures are NOT TO SCALE.

FIGURE 1. CLEAR COAT AND INSPECTION AREA,

212-321-103 HIGH FORWARD CROSSTUBE (S/N AA-1250 AND SUBSEQUENT)
BHT 205A, 205A-1, 205B INSTRUCTIONS for CONTINUED AIRWORTHINESS AA-01136

212, 412, 412EP, 412CF, CROSSTUBES Revision K

AGUSTA AB412, AB412EP,

UH-1B, UH-1H, SW204, SW205 

AERONAUTICAL ACCESSORIES

February 15, 2012 Page 45 of 78

FIGURE 2. CLEAR COAT AND INSPECTION AREA,

412-321-104 AND 412-321-304 HIGH AFT CROSSTUBE (S/N AA-1274 AND SUBSEQUENT)
BHT 205A, 205A-1, 205B INSTRUCTIONS for CONTINUED AIRWORTHINESS AA-01136

212, 412, 412EP, 412CF, CROSSTUBES Revision K

AGUSTA AB412, AB412EP,

UH-1B, UH-1H, SW204, SW205 

AERONAUTICAL ACCESSORIES

February 15, 2012 Page 46 of 78

FIGURE 3 (SHEET 1 OF 2). CROSSTUBE DAMAGE LIMITS AND REPAIR ZONES
BHT 205A, 205A-1, 205B INSTRUCTIONS for CONTINUED AIRWORTHINESS AA-01136

212, 412, 412EP, 412CF, CROSSTUBES Revision K

AGUSTA AB412, AB412EP,

UH-1B, UH-1H, SW204, SW205 

AERONAUTICAL ACCESSORIES

February 15, 2012 Page 47 of 78

Model 205 / 212 Crosstube Damage Limits

Zone

Forward Crosstube Aft Crosstube

in. mm in. mm

A1 .005 .127 .005 .127

A2 .015 .381 .015 .381

A3 .005 .127 .005 .127

A4 .015 .381 .015 .381

B1 .015 .381 .015 .381

B2 .015 .381 .015 .381

B3 .015 .381 .015 .381

B4 .015 .381 .015 .381

C1 .010 .254 .012 .305

C2 .010 .254 .012 .305

C3 .010 .254 .012 .305

C4 .010 .254 .012 .305

D .030 .762 .038 .965

Model 412 Crosstube Damage Limits

Zone

Forward Crosstube Aft Crosstube

in. mm in. mm

A1 .005 .127 .005 .127

A2 .015 .381 .015 .381

A3 .005 .127 .005 .127

A4 .015 .381 .015 .381

B1 .005 .127 .005 .127

B2 .015 .381 .015 .381

B3 .005 .127 .005 .127

B4 .015 .381 .015 .381

C1 .010 .254 .012 .305

C2 .010 .254 .012 .305

C3 .005 .127 .005 .127

C4 .010 .254 .012 .305

D .030 .762 .038 .965

FIGURE 3 (SHEET 2 OF 2). CROSSTUBE DAMAGE LIMITS AND REPAIR ZONES 
BHT 205A, 205A-1, 205B INSTRUCTIONS for CONTINUED AIRWORTHINESS AA-01136

212, 412, 412EP, 412CF, CROSSTUBES Revision K

AGUSTA AB412, AB412EP,

UH-1B, UH-1H, SW204, SW205 

AERONAUTICAL ACCESSORIES

February 15, 2012 Page 48 of 78

Crosstube, Low Skid Gear

Part Number Model Effectivity “A” “B”

in. mm in. mm

212-320-103 (Forward) 205 / 212 / 412 52.00 1321 54.00 1372

212-320-104 (Aft) 205 / 212 52.00 1321 54.00 1372

412-320-154 / 412-320-104 (Low) 412 52.00 1321 54.00 1372

Crosstube, High Skid Gear

Part Number Model Effectivity “A” “B”

in. mm in. mm

212-321-103 (Forward) 205A / 205A-1 / 205B / 212 / 412 /

412EP / 412CF / AB412 /

AB412EP / UH-1B / UH-1H /

SW204 / SW205 

57.00 1448 59.00 1499

212-321-104 / 212-321-304 (Aft) 205 / 212 57.00 1448 59.00 1499

412-321-104 / 412-321-304 (Aft) 412 57.00 1448 59.00 1499

FIGURE 4. CROSSTUBE DEFLECTION LIMITS
BHT 205A, 205A-1, 205B INSTRUCTIONS for CONTINUED AIRWORTHINESS AA-01136

212, 412, 412EP, 412CF, CROSSTUBES Revision K

AGUSTA AB412, AB412EP,

UH-1B, UH-1H, SW204, SW205 

AERONAUTICAL ACCESSORIES

February 15, 2012 Page 49 of 78

FIGURE 5. PAINT REMOVAL AREA, 212-321-103 HIGH FORWARD CROSSTUBE 

FIGURE 6. PAINT REMOVAL AREA, 412-321-104 / 412-321-304 HIGH AFT CROSSTUBE
BHT 205A, 205A-1, 205B INSTRUCTIONS for CONTINUED AIRWORTHINESS AA-01136

212, 412, 412EP, 412CF, CROSSTUBES Revision K

AGUSTA AB412, AB412EP,

UH-1B, UH-1H, SW204, SW205

AERONAUTICAL ACCESSORIES

February 15, 2012 Page 50 of 78

SYMMETRY

CL

13.970

13.940



47.5 2.5

CL

ARC LENGTH

2.00

47.5

45°

45°

 

VIEW B - B VIEW D - D





CLEARCOAT/INSPECTION AREA

LEFT SIDE AND RIGHT SIDE OF TUBE

APPLY LAYER (APPROX. 1/16" THK) OF

SEALANT TO INSIDE SURFACE OF SUPPORT

PRIOR TO ASSEMBLY WITH CROSSTUBE.

SEALANT TO HAVE NO VOIDS AROUND EDGE.

APPLY LAYER (APPROX. 1/16" THK) OF

SEALANT TO INSIDE SURFACE OF SUPPORT

PRIOR TO ASSEMBLY WITH CROSSTUBE.

SEALANT TO HAVE NO VOIDS AROUND EDGE.

APPLY FILLET OF SEALANT TO EDGE

OF U-BOLTS/SUPPORT/CROSSTUBE.

SEALANT TO HAVE NO VOIDS AROUND EDGE.

CL

13.940-13.970

604-025-001 UPPER FORWARD SUPPORT

604-025-003 LOWER FORWARD SUPPORT

604-025-005 U-BOLT

(2 PLACES)

605-005-121 DECAL

212-321-103 FORWARD CROSSTUBE ASSEMBLY

SECTION C - C

SYMMETRY





VIEW A

MS21043-4 NUT

NAS1149C0463R WASHER

TORQUE 80 - 100 IN-LBS WITHIN 30 MINUTES OF APPLYING SEALANT.

RECHECK TORQUE AFTER SEALANT HAS CURED (72 HOURS)

(4 PLACES)

FIGURE 7. 212-321-103 HIGH FORWARD CROSSTUBE ASSEMBLY
BHT 205A, 205A-1, 205B INSTRUCTIONS for CONTINUED AIRWORTHINESS AA-01136

212, 412, 412EP, 412CF, CROSSTUBES Revision K

AGUSTA AB412, AB412EP,

UH-1B, UH-1H, SW204, SW205

AERONAUTICAL ACCESSORIES

February 15, 2012 Page 51 of 78

FIGURE 8. 212-321-104 / 212-321-304 HIGH AFT CROSSTUBE ASSEMBLY

SYMMETRY

CL

13.970

13.940



APPLY LAYER (APPROX. 1/16" THK) OF

SEALANT TO INSIDE SURFACE OF SUPPORT

PRIOR TO ASSEMBLY WITH CROSSTUBE.

SEALANT TO HAVE NO VOIDS AROUND EDGE.

APPLY LAYER (APPROX. 1/16" THK) OF

SEALANT TO INSIDE SURFACE OF SUPPORT

PRIOR TO ASSEMBLY WITH CROSSTUBE.

SEALANT TO HAVE NO VOIDS AROUND EDGE.

APPLY FILLET OF SEALANT TO EDGE

OF U-BOLTS/SUPPORT/CROSSTUBE.

SEALANT TO HAVE NO VOIDS AROUND EDGE.

CL

MS21043-4 NUT

NAS1149C0463R WASHER

TORQUE 80 - 100 IN-LBS WITHIN 30 MINUTES OF APPLYING SEALANT.

RECHECK TORQUE AFTER SEALANT HAS CURED (72 HOURS)

(4 PLACES)

13.940-13.970

604-025-011 UPPER AFT SUPPORT

604-025-013 LOWER AFT SUPPORT

604-025-015 U-BOLT

(2 PLACES)

212-321-104 / 212-321-304 AFT CROSSTUBE ASSEMBLY

SECTION C - C

SYMMETRY





VIEW A
BHT 205A, 205A-1, 205B INSTRUCTIONS for CONTINUED AIRWORTHINESS AA-01136

212, 412, 412EP, 412CF, CROSSTUBES Revision K

AGUSTA AB412, AB412EP,

UH-1B, UH-1H, SW204, SW205

AERONAUTICAL ACCESSORIES

February 15, 2012 Page 52 of 78

FIGURE 9. 412-321-104 / 212-321-304 HIGH AFT CROSSTUBE ASSEMBLY

SYMMETRY

CL



CL

ARC LENGTH

2.00 45°

45°

 

VIEW C - C

VIEW D - D





CLEARCOAT/INSPECTION AREA

LEFT SIDE AND RIGHT SIDE OF TUBE

605-005-121 DECAL

412-321-104 / 412-321-304

AFT CROSSTUBE ASSEMBLY

12.0

12.0



18.0 15.810

55°-65°

120° REF

604-027-002 CLAMP ASSY

604-027-103 ABRASION STRIP REF.

15.81

APPLY LAYER (APPROX. 1/16" THK) OF SEALANT TO INSIDE SURFACE OF CLAMP

PRIOR TO ASSEMBLY WITH CROSSTUBE. REMOVE EXCESS AND WIPE CLEAN.

APPLY FILLET SEALANT AROUND OUTSIDE EDGE.

TORQUE CLAMP 30 - 40 IN-LBS WITHIN 30 MINUTES OF APPLYING SEALANT.

RECHECK CLAMP TORQUE AFTER 15 MINUTES.

604-027-103 ABRASION STRIP

VIEW A





SECTION E - E

SYMMETRY

CL

604-026-003

604-026-003 LOWER AFT SUPPORT

604-026-001 UPPER AFT SUPPORT 604-026-015 AFT U-BOLT

(2 PLACES)

 VIEW B



SECTION F - F

MS21043-4 NUT

NAS1149C0463R WASHER

TORQUE 80 - 100 IN-LBS WITHIN 30 MINUTES OF APPLYING SEALANT

RECHECK TORQUE AFTER SEALANT HAS CURED (72 HOURS)

(4 PLACES)
BHT 205A, 205A-1, 205B INSTRUCTIONS for CONTINUED AIRWORTHINESS AA-01136

212, 412, 412EP, 412CF, CROSSTUBES Revision K

AGUSTA AB412, AB412EP,

UH-1B, UH-1H, SW204, SW205

AERONAUTICAL ACCESSORIES

February 15, 2012 Page 53 of 78

FIGURE 10. 412-320 /412-321 SERIES AFT CROSSTUBE ASSEMBLIES

SYMMETRY

CL

604-030-001 BEAM ASSEMBLY

LOW GEAR

412-050-008-101 BOLT

NAS1149D1063K WASHER

MS14145L8 NUT

MS24665-287 COTTER PIN

INSTALLED WITH THREADS FACING FORWARD

HIGH GEAR

604-028-001 BOLT

NAS1149D1063K WASHER

MS14145L8 NUT

MS24665-287 COTTER PIN

INSTALLED WITH THREADS FACING FORWARD

412-320-104

AFT CROSSTUBE ASSEMBLY (LOW GEAR)

412-321-104 / 412-321-304

AFT CROSSTUBE ASSEMBLY (HIGH GEAR)

412-320-154 AFT CROSSTUBE ASSEMBLY (LOW SKID GEAR)

412-321-106 / 412-321-306 AFT CROSSTUBE ASSEMBLY (HIGH SKID GEAR)



412-320-104

AFT CROSSTUBE ASSEMBLY (LOW GEAR)

412-321-104 / 412-321-304

AFT CROSSTUBE ASSEMBLY (HIGH GEAR)

412-320-104 AFT CROSSTUBE ASSEMBLY (LOW SKID GEAR)

412-321-104 / 412-321-304 AFT CROSSTUBE ASSEMBLY (HIGH SKID GEAR)

099-091-001 DECAL

APPLIED ON LOWER SURFACE

 

SYMMETRY

CL

605-015-201 AFT CROSSTUBE ASSEMBLY (LOW GEAR)

605-005-201 AFT CROSSTUBE ASSEMBLY (HIGH GEAR)

604-026-001 UPPER AFT SUPPORT

604-026-003 LOWER AFT SUPPORT

604-027-001 CLAMP ASSEMBLY (LOW GEAR)

604-027-002 CLAMP ASSEMBLY (HIGH GEAR)

604-027-001 CLAMP ASSEMBLY (LOW GEAR)

604-027-002 CLAMP ASSEMBLY (HIGH GEAR)
BHT 205A, 205A-1, 205B INSTRUCTIONS for CONTINUED AIRWORTHINESS AA-01136

212, 412, 412EP, 412CF, CROSSTUBES Revision K

AGUSTA AB412, AB412EP,

UH-1B, UH-1H, SW204, SW205

AERONAUTICAL ACCESSORIES

February 15, 2012 Page 54 of 78

FIGURE 11. CROSSTUBE TO SKID TUBE ATTACHMENT

212-320-103 FORWARD CROSSTUBE ASSEMBLY (LOW)

212-321-103 FORWARD CROSSTUBE ASSEMBLY (HIGH)

412-320-104 AFT CROSSTUBE ASSEMBLY (LOW) /

412-320-154 AFT CROSSTUBE ASSEMBLY (LOW) (SHOWN)

412-321-106 AFT CROSSTUBE ASSEMBLY (HIGH)



 



SECTION A - A

LOW GEAR

(4) NAS6606-11 BOLT (INSTALL TIP WET)

(4) NAS1149D0616J WASHER

TORQUE BOLTS 160 - 190 IN-LBS

LOW GEAR

(2) NAS6604-11 BOLT (INSTALL TIP WET)

(2) NAS1149D0416J WASHER

TORQUE BOLTS 50 - 70 IN-LBS

HIGH GEAR

(2) NAS6606-11 BOLT (INSTALL TIP WET)

(2) NAS1149D0416J WASHER

TORQUE BOLTS 160 - 190 IN-LBS

LOW OR HIGH GEAR

(4) NAS6606-11 BOLT (INSTALL TIP WET)

(4) NAS1149D0616J WASHER

TORQUE BOLTS 160 - 190 IN-LBS

LOW SKID GEAR ASSEMBLY

(AA P/N 412-320-500 / 412-320-502)

HIGH SKID GEAR ASSEMBLY

(AA P/N 412-321-500 / 412-321-502)

SECTION B - B

099-050-221 SEALANT

099-050-221 SEALANT

LOW OR HIGH GEAR

(2) NAS6606-11 BOLT

(2) NAS1149D0616J WASHER

INSTALL WET WITH SEALANT (AMS-S-8802)

TORQUE BOLTS 160 - 190 IN-LBS

HIGH GEAR

(4) NAS6606-9 BOLT (INSTALL TIP WET)

(4) NAS1149D0616J WASHER

TORQUE BOLTS 160 - 190 IN-LBS
BHT 205A, 205A-1, 205B INSTRUCTIONS for CONTINUED AIRWORTHINESS AA-01136

212, 412, 412EP, 412CF, CROSSTUBES Revision K

AGUSTA AB412, AB412EP,

UH-1B, UH-1H, SW204, SW205 

Daily (Series 1) // 25 Hour / 30 Day (Series 2) Inspection Record

AERONAUTICAL ACCESSORIES

February 15, 2012 Page 55 of 78

APPENDIX A: 

DAILY (SERIES 1) //

25 HOUR / 30 DAY (SERIES 2) INSPECTION RECORD
BHT 205A, 205A-1, 205B INSTRUCTIONS for CONTINUED AIRWORTHINESS AA-01136

212, 412, 412EP, 412CF, CROSSTUBES Revision K

AGUSTA AB412, AB412EP,

UH-1B, UH-1H, SW204, SW205 

Daily (Series 1) // 25 Hour / 30 Day (Series 2) Inspection Record

AERONAUTICAL ACCESSORIES

February 15, 2012 Page 56 of 78

Work Order Number: _________________________

Registration Number: _________________________

Serial Number: _________________________

Total Time: _________________________

Date: _________________________

Inspect in accordance with Section 3. The inspection shall consist of the following items:

1. Inspect the Crosstubes for condition.

2. Inspect Crosstube Supports for condition and security of attachment 

(evidence of debonding and/or movement).

NOTE

If any evidence of debonding and/or movement 

of the Upper and Lower Supports are found, 

complete the Support removal and rebonding 

procedures, Section 5.

3. Visually inspect Crosstube inspection windows, as applicable, for evidence 

of cracking.

Signature ________________________ A & P No. _________________________

Signature ________________________ Inspector _________________________
BHT 205A, 205A-1, 205B INSTRUCTIONS for CONTINUED AIRWORTHINESS AA-01136

212, 412, 412EP, 412CF, CROSSTUBES Revision K

AGUSTA AB412, AB412EP,

UH-1B, UH-1H, SW204, SW205 

100 Hour / 12 Month (Series 1) // 300 Hour (Series 2) Inspection Record

AERONAUTICAL ACCESSORIES

February 15, 2012 Page 57 of 78

APPENDIX B: 

100 HOUR / 12 MONTH (SERIES 1)

300 HOUR (SERIES 2) INSPECTION RECORD
BHT 205A, 205A-1, 205B INSTRUCTIONS for CONTINUED AIRWORTHINESS AA-01136

212, 412, 412EP, 412CF, CROSSTUBES Revision K

AGUSTA AB412, AB412EP,

UH-1B, UH-1H, SW204, SW205 

100 Hour / 12 Month (Series 1) // 300 Hour (Series 2) Inspection Record

AERONAUTICAL ACCESSORIES

February 15, 2012 Page 58 of 78

Work Order Number: _________________________

Registration Number: _________________________

Serial Number: _________________________

Total Time: _________________________

Date: _________________________

Inspect in accordance with Section 3. The inspection shall consist of the following items:

1. Perform Daily Inspection (Series 1 Inspection) / 25 hour / 30 Day Inspection 

(Series 2 Inspection).

2. Inspect forward and aft caps holding Crosstubes to helicopter for security, 

and the rubber pads for looseness and/or deterioration.

3. Visually inspect Crosstubes for damage as follows:

NOTE

Particular care should be taken to inspect in 

the areas of the Supports at the aircraft attach 

points.

a. Inspect the Crosstube for scratches, nicks, dents, and corrosion and note 

the depth of the damage. (Refer to the zones and limits shown in Figure 3.) 

The minimal longitudinal distance between repairs is 3.0 inches. Crosstubes 

exceeding the damage limits shown in Table 1 must be replaced.

NOTE

The limits of the damage are also restricted 

axially and radially as shown in Figure 3.

b. Visually inspect the Supports for nicks, dents, and corrosion. Support 

damage and repair limits: .020 in. depth for a maximum area of 1.0 square 

inch. No more than two repairs per support are allowed. Replace Support if 

damaged beyond limits

5. Check the torque on the U-bolts that attach the Supports 

(80 – 100 in-lbs / 9.0 – 11.3 Nm). Retorque if necessary.

Signature ________________________ A & P No. _________________________

Signature ________________________ Inspector _________________________
BHT 205A, 205A-1, 205B INSTRUCTIONS for CONTINUED AIRWORTHINESS AA-01136

212, 412, 412EP, 412CF, CROSSTUBES Revision K

AGUSTA AB412, AB412EP,

UH-1B, UH-1H, SW204, SW205 

At 7500 Takeoff/Landings // Every Subsequent 200 Takeoff/Landings

212-321-103 High Forward Crosstube ONLY Inspection Record

AERONAUTICAL ACCESSORIES

February 15, 2012 Page 59 of 78

APPENDIX C: 

AT 7500 TAKEOFF/LANDINGS // EVERY SUBSEQUENT 200 TAKEOFF/LANDINGS

212-321-103 HIGH FORWARD CROSSTUBE ONLY INSPECTION RECORD
BHT 205A, 205A-1, 205B INSTRUCTIONS for CONTINUED AIRWORTHINESS AA-01136

212, 412, 412EP, 412CF, CROSSTUBES Revision K

AGUSTA AB412, AB412EP,

UH-1B, UH-1H, SW204, SW205 

At 7500 Takeoff/Landings // Every Subsequent 200 Takeoff/Landings

212-321-103 High Forward Crosstube ONLY Inspection Record

AERONAUTICAL ACCESSORIES

February 15, 2012 Page 60 of 78

Work Order Number: _________________________

Registration Number: _________________________

Serial Number: _________________________

Total Time: _________________________

Date: _________________________

Inspect in accordance with Section 3. The inspection shall consist of the following items:

1. Use MIL-PRF-87937 cleaning compound prepared in accordance with the 

manufacturer’s recommendations to clean all residue and dirt from the cross 

tube surfaces shown in Figure 1.

2. Using at least 10X magnification and a strong light source, visually inspect 

the clear coated crosstube areas for indications of cracking.

3. If cracking is suspected, remove clear coat and primer per steps 4 thru 6 

below and inspect per step 7.

WARNING

IF CRACKING IS DISCOVERED, THE 

CROSSTUBE IS NO LONGER AIRWORTHY 

AND MUST BE IMMEDIATELY REPLACED. 

REMOVE AND REPLACE CROSSTUBE PER 

SECTION 5 OF THIS REPORT.

4. Apply MIL-R-81294, Type I or II chemical paint remover with a brush and 

allow it to set from 15 to 45 minutes to soften paint.

5. Using a stiff fiber brush and clean water, rinse paint from crosstube. If 

required, use abrasive pad (Scotch-Brite, Type A) and MIL-R-81294, Type I 

or II chemical paint remover to aid in lifting paint. Brush crosstube with 

abrasive pad in the longitudinal direction, using care so as not to abrade 

crosstube metal surface.

WARNING

DO NOT SAND CROSSTUBE IN A 

CIRCUMFERENTIAL DIRECTION.

6. Rinse part clean with clean water and dry thoroughly.

NOTE

Reapplication of chemical paint remover may 

be required to ensure that paint and primer is 

completely removed so that the metal surface 

of the cross tube is clearly visible. If required, 

repeat steps 4 thru 6.
BHT 205A, 205A-1, 205B INSTRUCTIONS for CONTINUED AIRWORTHINESS AA-01136

212, 412, 412EP, 412CF, CROSSTUBES Revision K

AGUSTA AB412, AB412EP,

UH-1B, UH-1H, SW204, SW205 

At 7500 Takeoff/Landings // Every Subsequent 200 Takeoff/Landings

212-321-103 High Forward Crosstube ONLY Inspection Record

AERONAUTICAL ACCESSORIES

February 15, 2012 Page 61 of 78

7. Using at least 10X magnification and a strong light source, visually inspect 

the stripped areas for indications of cracking. If cracking is suspected, 

fluorescent penetrant inspect crosstube per ASTM E1417, Type I, Method B, 

C, or D, Level 2 in accordance with Bell Helicopter Standard Practices 

Manual (BHT-ALL-SPM).

WARNING

IF CRACKING IS DISCOVERED, THE 

CROSSTUBE IS NO LONGER AIRWORTHY 

AND MUST BE IMMEDIATELY REPLACED. 

REMOVE AND REPLACE CROSSTUBE PER 

SECTION 5 OF THIS REPORT.

8. Following crosstube inspection, coat the stripped crosstube area with 

MIL-PRF-85582 primer (.0006 – .0009 thick) by spraying in accordance with 

manufacturer’s instructions. Allow primer to cure per manufacturer 

instructions.

NOTE

The MIL-PRF-85582 primer (PRC-DeSoto

EWDE 072A/B) [packaged as a 1-gallon, 1-qt 

(Parts A&B) kit (P/N EWDE072)] and the 

MIL-PRF-85285, Type I clear coat paint (Deft 

03X085) [packaged as a 3-qt kit (P/N 

MIL-PRF-85285)] may be procured from a Bell 

Helicopter Supply Center. The primer and 

paint may also be procured [packaged in 1-qt, 

primer and paint, kits (P/N 1272K)] from 

Aerospace Products, Inc., 6413 Midway Road, 

Halton City, TX 76117 (817-332-1669).

9. Following primer cure, paint the area with MIL-PRF-85285 polyurethane 

clear coat paint by spraying in accordance with manufacturer’s instructions. 

Allow paint to cure per manufacturer instructions.

Signature ________________________ A & P No. _________________________

Signature ________________________ Inspector _________________________
BHT 205A, 205A-1, 205B INSTRUCTIONS for CONTINUED AIRWORTHINESS AA-01136

212, 412, 412EP, 412CF, CROSSTUBES Revision K

AGUSTA AB412, AB412EP,

UH-1B, UH-1H, SW204, SW205 

At 10,000 Takeoff/Landings // Every Subsequent 12 Month / 

2500 Takeoff/Landings Dimensional Inspection

212-321-103 High Forward Crosstube ONLY Inspection Record

AERONAUTICAL ACCESSORIES

February 15, 2012 Page 62 of 78

APPENDIX D: 

AT 10,000 TAKEOFF/LANDINGS // EVERY SUBSEQUENT 12 MONTH / 

2500 TAKEOFF/LANDINGS DIMENSIONAL INSPECTION

212-321-103 HIGH FORWARD CROSSTUBE ONLY INSPECTION RECORD
BHT 205A, 205A-1, 205B INSTRUCTIONS for CONTINUED AIRWORTHINESS AA-01136

212, 412, 412EP, 412CF, CROSSTUBES Revision K

AGUSTA AB412, AB412EP,

UH-1B, UH-1H, SW204, SW205 

At 10,000 Takeoff/Landings // Every Subsequent 12 Month / 

2500 Takeoff/Landings Dimensional Inspection

212-321-103 High Forward Crosstube ONLY Inspection Record

AERONAUTICAL ACCESSORIES

February 15, 2012 Page 63 of 78

Work Order Number: _________________________

Registration Number: _________________________

Serial Number: _________________________

Total Time: _________________________

Date: _________________________

Inspect in accordance with Section 3. The inspection shall consist of the following items:

1. Hoist or jack the helicopter until no weight is on the skid tubes.

2. Measure the lateral distance between the two forward Crosstube attachment 

straps. Measure the lateral distance between the two aft Crosstube 

attachment straps. Divide these dimensions by two to determine the 

helicopter centerline, BL 0.00.

3. Measure the Crosstube horizontal deflection from the centerline of the 

helicopter, BL 0.00, to the outside of the skid tubes.

4. The Crosstube horizontal deflection as measured in step 3 above must be 

within the limits as shown in Figure 4. Crosstubes that measure outside of 

the limits must be replaced.

Signature ________________________ A & P No. _________________________

Signature ________________________ Inspector _________________________
BHT 205A, 205A-1, 205B INSTRUCTIONS for CONTINUED AIRWORTHINESS AA-01136

212, 412, 412EP, 412CF, CROSSTUBES Revision K

AGUSTA AB412, AB412EP,

UH-1B, UH-1H, SW204, SW205 

At 12,500 Takeoff/Landings // Every Subsequent 5,000 Takeoff/Landings

212-321-103 High Forward Crosstube ONLY Inspection/Overhaul Record

AERONAUTICAL ACCESSORIES

February 15, 2012 Page 64 of 78

APPENDIX E: 

AT 12,500 TAKEOFF/LANDINGS // EVERY SUBSEQUENT 5,000 TAKEOFF/LANDINGS

212-321-103 HIGH FORWARD CROSSTUBE ONLY INSPECTION/OVERHAUL RECORD
BHT 205A, 205A-1, 205B INSTRUCTIONS for CONTINUED AIRWORTHINESS AA-01136

212, 412, 412EP, 412CF, CROSSTUBES Revision K

AGUSTA AB412, AB412EP,

UH-1B, UH-1H, SW204, SW205 

At 12,500 Takeoff/Landings // Every Subsequent 5,000 Takeoff/Landings

212-321-103 High Forward Crosstube ONLY Inspection/Overhaul Record

AERONAUTICAL ACCESSORIES

February 15, 2012 Page 65 of 78

Work Order Number: _________________________

Registration Number: _________________________

Serial Number: _________________________

Total Time: _________________________

Date: _________________________

NOTE

Neither the assignment of a time period overhaul of a 

component nor failure to assign a time period for overhaul of 

a component constitutes a warranty of any kind. The only 

warranty applicable to the component is that warranty 

included in the Purchase Agreement for the component.

Time between overhauls and inspection periods is based upon experience, 

testing, and engineering judgment and is subject to change at the sole discretion 

of Aeronautical Accessories or an appropriate government agency.

WARNING

ALL PARTS REMOVED, DUE TO REACHING THEIR 

LIMITS OR AS A RESULT OF AN ACCIDENT/INCIDENT 

AND DEEMED UNAIRWORTHY, SHALL BE 

PERMANENTLY MARKED AS SCRAP OR PHYSICALLY 

DESTROYED TO THE EXTENT THAT THERE IS NO 

CHANCE OF REPAIR OR INSTALLATION ON ANY 

HELICOPTER OR COMPONENT.

Inspect in accordance with Section 3. The inspection shall consist of the following items:

1. Remove fairings from Forward Crosstube Assembly, if installed.

2. Hoist or jack the helicopter until no weight is on the skid tubes.

3. Remove forward straps and associated hardware from forward fuselage 

fittings.

4. Remove aft straps and associated hardware from aft fuselage fittings.

5. Raise helicopter until it is clear of skid landing gear, and remove landing 

gear

6. Remove crosstube supports from Forward Crosstube Assembly in 

accordance with Section 5.
BHT 205A, 205A-1, 205B INSTRUCTIONS for CONTINUED AIRWORTHINESS AA-01136

212, 412, 412EP, 412CF, CROSSTUBES Revision K

AGUSTA AB412, AB412EP,

UH-1B, UH-1H, SW204, SW205 

At 12,500 Takeoff/Landings // Every Subsequent 5,000 Takeoff/Landings

212-321-103 High Forward Crosstube ONLY Inspection/Overhaul Record

AERONAUTICAL ACCESSORIES

February 15, 2012 Page 66 of 78

WARNING

DO NOT SAND CROSSTUBE IN A 

CIRCUMFERENTIAL DIRECTION.

7. Remove aged sealant from Crosstube by scraping with a sharp piece of 

plastic. Use of a heat gun to soften the sealant may facilitate removal. 

Finish by lightly sanding with 400 grit abrasive cloth or paper in the 

longitudinal direction of the crosstube.

8. Prepare crosstube by chemically removing crosstube paint and primer to top 

of saddles.

a. Apply MIL-R-81294, Type I or II chemical paint remover with a brush 

and allow it to set from 15 to 45 minutes to soften paint.

b. Using a stiff fiber brush and clean water, rinse paint from crosstube. If 

required, use abrasive pad (Scotch-Brite, Type A) and MIL-R-81294, 

Type I or II chemical paint remover to aid in lifting paint. Brush crosstube 

with abrasive pad in the longitudinal direction, using care so as not to 

abrade crosstube metal surface.

WARNING

DO NOT SAND CROSSTUBE IN A 

CIRCUMFERENTIAL DIRECTION.

c. Rinse part clean with clean water and dry thoroughly. Reapplication of 

chemical paint remover may be required to ensure that paint and primer 

is completely removed so that the (bare) metal surface of the cross tube 

is clearly visible

9. When crosstube is not to be processed immediately after cleaning, apply 

corrosion preventive oil, to all parts to protect against corrosion. Wrap parts 

in barrier material and secure with tape.

10. Inspect the stripped areas of the Crosstubes using fluorescent penetrant 

method per ASTM E1417, Type I, Method B, C, or D, Level 2, in accordance 

with Bell Helicopter Standard Practices Manual (BHT-ALL-SPM). Refer to 

BHT-ALL-SPM for fluorescent penetrant inspection procedures.

WARNING

IF CRACKING IS DISCOVERED, THE 

CROSSTUBE IS NO LONGER AIRWORTHY 

AND MUST BE IMMEDIATELY REPLACED. 

REMOVE AND REPLACE CROSSTUBE PER 

SECTION 5 OF THIS REPORT.

11. Repair damage within repairable limits in accordance with Section 3.
BHT 205A, 205A-1, 205B INSTRUCTIONS for CONTINUED AIRWORTHINESS AA-01136

212, 412, 412EP, 412CF, CROSSTUBES Revision K

AGUSTA AB412, AB412EP,

UH-1B, UH-1H, SW204, SW205 

At 12,500 Takeoff/Landings // Every Subsequent 5,000 Takeoff/Landings

212-321-103 High Forward Crosstube ONLY Inspection/Overhaul Record

AERONAUTICAL ACCESSORIES

February 15, 2012 Page 67 of 78

12. Refinish crosstube by applying MIL-PRF-85582 primer and MIL-PRF-85285 

paint (or equivalent) per manufacturer instructions to the stripped areas. 

The areas to be inspected per Section 3 should be masked to omit 

MIL-PRF-85285 paint as shown in Figure 2. Paint inspection areas with 

MIL-PRF-85285 Type I Gloss Clear coat per manufacturer instructions and 

Figure 2.

13. Reinstall Forward Crosstube straps and fittings per Section 5.

14. Reinstall landing gear/Crosstubes to aircraft per Section 5.

15. Reinstall fairings, as applicable, and return aircraft to service.

Signature ________________________ A & P No. _________________________

Signature ________________________ Inspector _________________________
BHT 205A, 205A-1, 205B INSTRUCTIONS for CONTINUED AIRWORTHINESS AA-01136

212, 412, 412EP, 412CF, CROSSTUBES Revision K

AGUSTA AB412, AB412EP,

UH-1B, UH-1H, SW204, SW205 

At 2500 Takeoff/Landings // Every Subsequent 450 Takeoff/Landings

412-321-104 / 412-321-304 High Aft Crosstube ONLY Inspection Record

AERONAUTICAL ACCESSORIES

February 15, 2012 Page 68 of 78

APPENDIX F: 

AT 2500 TAKEOFF/LANDINGS // EVERY SUBSEQUENT 450 TAKEOFF/LANDINGS

412-321-104 / 412-321-304 HIGH AFT CROSSTUBE ONLY INSPECTION RECORD
BHT 205A, 205A-1, 205B INSTRUCTIONS for CONTINUED AIRWORTHINESS AA-01136

212, 412, 412EP, 412CF, CROSSTUBES Revision K

AGUSTA AB412, AB412EP,

UH-1B, UH-1H, SW204, SW205 

At 2500 Takeoff/Landings // Every Subsequent 450 Takeoff/Landings

412-321-104 / 412-321-304 High Aft Crosstube ONLY Inspection Record

AERONAUTICAL ACCESSORIES

February 15, 2012 Page 69 of 78

Work Order Number: _________________________

Registration Number: _________________________

Serial Number: _________________________

Total Time: _________________________

Date: _________________________

Inspect in accordance with Section 3. The inspection shall consist of the following items:

1. Use MIL-PRF-87937 cleaning compound prepared in accordance with the 

manufacturer’s recommendations to clean all residue and dirt from the cross 

tube surfaces shown in Figure 2.

2. Using at least 10X magnification and a strong light source, visually inspect 

the clear coated crosstube areas for indications of cracking.

3. If cracking is suspected, remove clear coat and primer per steps 4 thru 6 

below and inspect per step 7.

WARNING

IF CRACKING IS DISCOVERED, THE 

CROSSTUBE IS NO LONGER AIRWORTHY 

AND MUST BE IMMEDIATELY REPLACED. 

REMOVE AND REPLACE CROSSTUBE PER 

SECTION 5 OF THIS REPORT.

4. Apply MIL-R-81294, Type I or II chemical paint remover with a brush and 

allow it to set from 15 to 45 minutes to soften paint.

5. Using a stiff fiber brush and clean water, rinse paint from crosstube. If 

required, use abrasive pad (Scotch-Brite, Type A) and MIL-R-81294, Type I 

or II chemical paint remover to aid in lifting paint. Brush crosstube with 

abrasive pad in the longitudinal direction, using care so as not to abrade 

crosstube metal surface.

WARNING

DO NOT SAND CROSSTUBE IN A 

CIRCUMFERENTIAL DIRECTION.

6. Rinse part clean with clean water and dry thoroughly.

NOTE

Reapplication of chemical paint remover may 

be required to ensure that paint and primer is 

completely removed so that the metal surface 

of the cross tube is clearly visible. If required, 

repeat steps 4 thru 6.
BHT 205A, 205A-1, 205B INSTRUCTIONS for CONTINUED AIRWORTHINESS AA-01136

212, 412, 412EP, 412CF, CROSSTUBES Revision K

AGUSTA AB412, AB412EP,

UH-1B, UH-1H, SW204, SW205 

At 2500 Takeoff/Landings // Every Subsequent 450 Takeoff/Landings

412-321-104 / 412-321-304 High Aft Crosstube ONLY Inspection Record

AERONAUTICAL ACCESSORIES

February 15, 2012 Page 70 of 78

7. Using at least 10X magnification and a strong light source, visually inspect 

the stripped areas for indications of cracking. If cracking is suspected, 

fluorescent penetrant inspect crosstube per ASTM E1417, Type I, Method B, 

C, or D, Level 2 in accordance with Bell Helicopter Standard Practices 

Manual (BHT-ALL-SPM).

WARNING

IF CRACKING IS DISCOVERED, THE 

CROSSTUBE IS NO LONGER AIRWORTHY 

AND MUST BE IMMEDIATELY REPLACED. 

REMOVE AND REPLACE CROSSTUBE PER 

SECTION 5 OF THIS REPORT.

8. Following crosstube inspection, coat the stripped crosstube area with 

MIL-PRF-85582 primer (.0006 – .0009 thick) by spraying in accordance with 

manufacturer’s instructions. Allow primer to cure per manufacturer 

instructions.

NOTE

The MIL-PRF-85582 primer (PRC-DeSoto

EWDE 072A/B) [packaged as a 1-gallon, 1-qt 

(Parts A&B) kit (P/N EWDE072)] and the 

MIL-PRF-85285, Type I clear coat paint (Deft 

03X085) [packaged as a 3-qt kit (P/N 

MIL-PRF-85285)] may be procured from a Bell 

Helicopter Supply Center. The primer and 

paint may also be procured [packaged in 1-qt, 

primer and paint, kits (P/N 1272K)] from 

Aerospace Products, Inc., 6413 Midway Road, 

Halton City, TX 76117 (817-332-1669).

9. Following primer cure, paint the area with MIL-PRF-85285 polyurethane 

clear coat paint by spraying in accordance with manufacturer’s instructions. 

Allow paint to cure per manufacturer instructions.

Signature ________________________ A & P No. _________________________

Signature ________________________ Inspector _________________________
BHT 205A, 205A-1, 205B INSTRUCTIONS for CONTINUED AIRWORTHINESS AA-01136

212, 412, 412EP, 412CF, CROSSTUBES Revision K

AGUSTA AB412, AB412EP,

UH-1B, UH-1H, SW204, SW205 

At 2,500 Takeoff/Landings // Every Subsequent 12 Month / 

2,500 Takeoff/Landings Dimensional Inspection

412-321-104 / 412-321-304 High Aft Crosstube ONLY Inspection Record

AERONAUTICAL ACCESSORIES

February 15, 2012 Page 71 of 78

APPENDIX G: 

AT 2,500 TAKEOFF/LANDINGS // EVERY SUBSEQUENT 12 MONTH / 

2,500 TAKEOFF/LANDINGS DIMENSIONAL INSPECTION

412-321-104 / 412-321-304 HIGH AFT CROSSTUBE ONLY INSPECTION RECORD
BHT 205A, 205A-1, 205B INSTRUCTIONS for CONTINUED AIRWORTHINESS AA-01136

212, 412, 412EP, 412CF, CROSSTUBES Revision K

AGUSTA AB412, AB412EP,

UH-1B, UH-1H, SW204, SW205 

At 2,500 Takeoff/Landings // Every Subsequent 12 Month / 

2,500 Takeoff/Landings Dimensional Inspection

412-321-104 / 412-321-304 High Aft Crosstube ONLY Inspection Record

AERONAUTICAL ACCESSORIES

February 15, 2012 Page 72 of 78

Work Order Number: _________________________

Registration Number: _________________________

Serial Number: _________________________

Total Time: _________________________

Date: _________________________

Inspect in accordance with Section 3. The inspection shall consist of the following items:

1. Hoist or jack the helicopter until no weight is on the skid tubes.

2. Measure the lateral distance between the two forward Crosstube attachment 

straps. Measure the lateral distance between the two aft Crosstube 

attachment straps. Divide these dimensions by two to determine the 

helicopter centerline, BL 0.00.

3. Measure the Crosstube horizontal deflection from the centerline of the 

helicopter, BL 0.00, to the outside of the skid tubes.

4. The Crosstube horizontal deflection as measured in step 3 above must be 

within the limits as shown in Figure 4. Crosstubes that measure outside of 

the limits must be replaced.

Signature ________________________ A & P No. _________________________

Signature ________________________ Inspector _________________________
BHT 205A, 205A-1, 205B INSTRUCTIONS for CONTINUED AIRWORTHINESS AA-01136

212, 412, 412EP, 412CF, CROSSTUBES Revision K

AGUSTA AB412, AB412EP,

UH-1B, UH-1H, SW204, SW205 

At 7,500 Takeoff/Landings // Every Subsequent 5,000 Takeoff/Landings

412-321-104 / 412-321-304 High Aft Crosstube ONLY 

Inspection/Overhaul Record

AERONAUTICAL ACCESSORIES

February 15, 2012 Page 73 of 78

APPENDIX H: 

AT 7,500 TAKEOFF/LANDINGS // EVERY SUBSEQUENT 5,000 TAKEOFF/LANDINGS

412-321-104 / 412-321-304 HIGH AFT CROSSTUBE ONLY INSPECTION/OVERHAUL RECORD
BHT 205A, 205A-1, 205B INSTRUCTIONS for CONTINUED AIRWORTHINESS AA-01136

212, 412, 412EP, 412CF, CROSSTUBES Revision K

AGUSTA AB412, AB412EP,

UH-1B, UH-1H, SW204, SW205 

At 7,500 Takeoff/Landings // Every Subsequent 5,000 Takeoff/Landings

412-321-104 / 412-321-304 High Aft Crosstube ONLY 

Inspection/Overhaul Record

AERONAUTICAL ACCESSORIES

February 15, 2012 Page 74 of 78

Work Order Number: _________________________

Registration Number: _________________________

Serial Number: _________________________

Total Time: _________________________

Date: _________________________

NOTE

Neither the assignment of a time period overhaul of a 

component nor failure to assign a time period for overhaul of 

a component constitutes a warranty of any kind. The only 

warranty applicable to the component is that warranty 

included in the Purchase Agreement for the component.

Time between overhauls and inspection periods is based upon experience, 

testing, and engineering judgment and is subject to change at the sole discretion 

of Aeronautical Accessories or an appropriate government agency.

WARNING

ALL PARTS REMOVED, DUE TO REACHING THEIR 

LIMITS OR AS A RESULT OF AN ACCIDENT/INCIDENT 

AND DEEMED UNAIRWORTHY, SHALL BE 

PERMANENTLY MARKED AS SCRAP OR PHYSICALLY 

DESTROYED TO THE EXTENT THAT THERE IS NO 

CHANCE OF REPAIR OR INSTALLATION ON ANY 

HELICOPTER OR COMPONENT.

Inspect in accordance with Section 3. The inspection shall consist of the following items:

1. Remove fairings from Aft Crosstube Assembly, if installed.

2. Hoist or jack the helicopter until no weight is on the skid tubes.

3. Remove forward straps and associated hardware from forward fuselage 

fittings.

4. Remove aft straps and associated hardware from aft fuselage fittings.

5. Raise helicopter until it is clear of skid landing gear, and remove landing 

gear

6. Remove Aft Crosstube Assembly, Aft Crosstube Beam Assembly, and both 

Aft Crosstube Clamp Assemblies in accordance with Section 5.

NOTE

The Upper Center Support on the Aft 

Crosstube is bonded with structural adhesive 

and is not designed for removal.
BHT 205A, 205A-1, 205B INSTRUCTIONS for CONTINUED AIRWORTHINESS AA-01136

212, 412, 412EP, 412CF, CROSSTUBES Revision K

AGUSTA AB412, AB412EP,

UH-1B, UH-1H, SW204, SW205 

At 7,500 Takeoff/Landings // Every Subsequent 5,000 Takeoff/Landings

412-321-104 / 412-321-304 High Aft Crosstube ONLY 

Inspection/Overhaul Record

AERONAUTICAL ACCESSORIES

February 15, 2012 Page 75 of 78

WARNING

DO NOT SAND CROSSTUBE IN A 

CIRCUMFERENTIAL DIRECTION.

7. Remove aged sealant from Crosstube by scraping with a sharp piece of 

plastic. Use of a heat gun to soften the sealant may facilitate removal. 

Finish by lightly sanding with 400 grit abrasive cloth or paper in the 

longitudinal direction of the crosstube.

8. Prepare crosstube by chemically removing crosstube paint and primer to top 

of saddles.

CAUTION

Protect Upper Center Support area on aft 

high crosstube to prevent contamination by 

paint strippers and penetrant inspection 

chemicals.

a. Apply MIL-R-81294, Type I or II chemical paint remover with a brush 

and allow it to set from 15 to 45 minutes to soften paint.

b. Using a stiff fiber brush and clean water, rinse paint from crosstube. If 

required, use abrasive pad (Scotch-Brite, Type A) and MIL-R-81294, 

Type I or II chemical paint remover to aid in lifting paint. Brush 

crosstube with abrasive pad in the longitudinal direction, using care so 

as not to abrade crosstube metal surface.

WARNING

DO NOT SAND CROSSTUBE IN A 

CIRCUMFERENTIAL DIRECTION.

c. Rinse part clean with clean water and dry thoroughly. Reapplication of 

chemical paint remover may be required to ensure that paint and primer 

is completely removed so that the (bare) metal surface of the cross tube 

is clearly visible.

9. When crosstube is not to be processed immediately after cleaning, apply 

corrosion preventive oil, to all parts to protect against corrosion. Wrap parts 

in barrier material and secure with tape.

10. Inspect the stripped areas of the Crosstubes using fluorescent penetrant 

method per ASTM E1417, Type I, Method B, C, or D, Level 2, in accordance 

with Bell Helicopter Standard Practices Manual (BHT-ALL-SPM). Refer to 

BHT-ALL-SPM for fluorescent penetrant inspection procedures.
BHT 205A, 205A-1, 205B INSTRUCTIONS for CONTINUED AIRWORTHINESS AA-01136

212, 412, 412EP, 412CF, CROSSTUBES Revision K

AGUSTA AB412, AB412EP,

UH-1B, UH-1H, SW204, SW205 

At 7,500 Takeoff/Landings // Every Subsequent 5,000 Takeoff/Landings

412-321-104 / 412-321-304 High Aft Crosstube ONLY 

Inspection/Overhaul Record

AERONAUTICAL ACCESSORIES

February 15, 2012 Page 76 of 78

WARNING

IF CRACKING IS DISCOVERED, THE 

CROSSTUBE IS NO LONGER AIRWORTHY 

AND MUST BE IMMEDIATELY REPLACED. 

REMOVE AND REPLACE CROSSTUBE PER 

SECTION 5 OF THIS REPORT.

11. Repair damage within repairable limits in accordance with Section 3.

12. Refinish crosstube by applying MIL-PRF-85582 primer and MIL-PRF-85285 

paint (or equivalent) per manufacturer instructions to the stripped areas. 

The areas to be inspected per Section 3 should be masked to omit 

MIL-PRF-85285 paint as shown in Figure 2. Paint inspection areas with 

MIL-PRF-85285 Type I Gloss Clear coat per manufacturer instructions and 

Figure 2.

13. Reinstall Aft Crosstube Clamp Assemblies and Aft Crosstube Beam 

Assembly in accordance with Section 5.

14. Reinstall landing gear/Crosstubes to aircraft per Section 5.

15. Reinstall fairings, as applicable, and return aircraft to service.

Signature ________________________ A & P No. _________________________

Signature ________________________ Inspector _________________________
BHT 205A, 205A-1, 205B INSTRUCTIONS for CONTINUED AIRWORTHINESS AA-01136

212, 412, 412EP, 412CF, CROSSTUBES Revision K

AGUSTA AB412, AB412EP,

UH-1B, UH-1H, SW204, SW205 

HISTORICAL SERVICE RECORD

AERONAUTICAL ACCESSORIES

February 15, 2012 Page 77 of 78

APPENDIX I: 

HISTORICAL SERVICE RECORD
BHT 205A, 205A-1, 205B INSTRUCTIONS for CONTINUED AIRWORTHINESS AA-01136

212, 412, 412EP, 412CF, CROSSTUBES Revision K

AGUSTA AB412, AB412EP,

UH-1B, UH-1H, SW204, SW205 

HISTORICAL SERVICE RECORD

AERONAUTICAL ACCESSORIES

February 15, 2012 Page 78 of 78