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
PYLON HARDPOINT KIT
407-854-001 (L/H) / 407-854-002 (R/H)
407-854-003 (L/H Kit & R/H Kit w/407-855-001 WIRING KIT)
STC SR09540RC
FOR
BELL HELICOPTER TEXTRON MODEL 407 HELICOPTERS
Report Number AA-10120
Revision A
September 12, 2012
RESTRICTED DISCLOSURE NOTICE ON PAGE 2
BHT 407
INSTRUCTIONS FOR CONTINUED AIRWORTHINESS
PYLON HARDPOINT KIT
AA-10120
Revision A
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 IS
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UNPUBLISHED - ALL RIGHTS RESERVED
AERONAUTICAL ACCESSORIES
September 12, 2012
Page 2 of 38
BHT 407
INSTRUCTIONS FOR CONTINUED AIRWORTHINESS
PYLON HARDPOINT KIT
AA-10120
Revision A
LOG OF REVISIONS
Date
Revision
Description
09/12/12
A
(cont’d)
Table 4
(cont’d)
Affected Approved / Accepted /
Pages
Date
Date
23 -24
- Added P/Ns (and ALT P/Ns) to part list:
NAS1097AD5-5, NAS1739M5-3, NAS9301B-6-03
(ALT: CR3213-4-2), NAS9301B-4-02 (ALT:
CR3213-6-3), NAS9307M-4-2 (ALT: CR3523-4-2),
NAS9307M-5-6 (ALT: CR3523-5-6), NAS9307M-6-4
(ALT: CR3523-6-4), NAS9307M-6-5 (ALT:
CR3523-6-5), NAS9307M-6-6 (ALT: CR3523-6-6),
NAS9308M-4-2 (ALT: CR3522-4-2), NAS9308M-4-3
(ALT: CR3552-5-6), NAS9308M-4-4 (ALT:
CR3522-4-4), NAS9311M-5-6 (ALT: CR3522-4-3),
407-853-143, 206-032-120-105, 206-032-120-106,
MS21075L3N, 120-225C3R08, NAS6204-3,
NAS6204-5, 80-007-08-4, 110-220-T6-150,
100-159-6-5, 100-158-5-3, 30-296-5W (Collar),
30-295-6W (Collar), HRH-36/OX-3/16-3.0, AA-10119,
AA-10120, AA-10121, and DWG 407-854
Table 5
25 – 26
- Corrected P/N’s (from “M27488-22-2,” “M27488-20-2,”
and “M27488-16-2” to “MS27488-22-2,” “MS27488-20-2,”
and “MS27488-16-2” respectively)
- Added amount (15cc) to 099-859-002
- Adjusted quantities of:
36152, 5211001903S, ATUM-16/4-0, M23053/5-104-0,
M81714/60-20-01, M85049/93-08, M85049/93-10, and
M85049/95-25A-A
- Deleted P/Ns from part list:
319A064XO22, 319A064XO25, 319A064XO09,
319A064XO24, MIL-PRF-8516, MS25036-102, and
NAS1801-06-6
- Added P/Ns to part list:
319H064XO25, 319F064XO24, 319H064XO09,
319F064XO22, 36160, 36154, 320619, 7270-1-25,
ATUM-32/8-0, M39029/32-259, M85049/93-14, 870
B-2, and NAS1801-06-8
Updated Figure 3 (sheets 1 thru 5) and Figure 4 (sheets 1
thru 5) per drawings 407-854 and 407-855, respectively
27 – 36
AERONAUTICAL ACCESSORIES
September 12, 2012
Page 4 of 38
BHT 407
INSTRUCTIONS FOR CONTINUED AIRWORTHINESS
PYLON HARDPOINT KIT
AA-10120
Revision A
TABLE OF CONTENTS
Identification
1.0
Title
Page
INTRODUCTION .................................................................................................... 9
1.1
DISTRIBUTION .................................................................................................. 9
1.2
REVISION .......................................................................................................... 9
2.0
DESCRIPTION ....................................................................................................... 9
2.1
SYSTEM OVERVIEW ........................................................................................ 9
3.0
TROUBLESHOOTING.......................................................................................... 11
4.0
MAINTENANCE INSTRUCTIONS ........................................................................ 11
4.1
ANNUAL INSPECTION .................................................................................... 11
4.2
CONDITIONAL INSPECTIONS........................................................................ 11
4.3
REPAIR ............................................................................................................ 12
5.0
PYLON HARDPOINT KIT REMOVAL / INSTALLATION INFORMATION ............ 13
5.1
REMOVAL / INSTALLATION – MECHANICAL ................................................ 13
5.1.1 PYLON FITTING REMOVAL.......................................................................... 13
5.1.2 PYLON FITTING INSTALLATION .................................................................. 14
5.1.3 COVER ASSEMBLY REMOVAL .................................................................... 14
5.1.4 COVER ASSEMBLY INSTALLATION ............................................................ 15
5.2
REMOVAL / INSTALLATION – ELECTRICAL ................................................. 15
5.2.1 FUSELAGE DISCONNECTS REMOVAL / INSTALLATION .......................... 15
5.2.1.1
L/H FUSELAGE DISCONNECTS REMOVAL.......................................... 15
5.2.1.2
L/H FUSELAGE DISCONNECTS INSTALLATION.................................. 16
5.2.1.3
R/H FUSELAGE DISCONNECT REMOVAL ........................................... 16
5.2.1.4
R/H FUSELAGE DISCONNECT INSTALLATION ................................... 17
5.2.2 INSTRUMENT PANEL MOUNTED PYLON HARDPOINT SWITCH REMOVAL17
5.2.3 INSTRUMENT PANEL MOUNTED PYLON HARDPOINT SWITCH
INSTALLATION .............................................................................................. 17
5.2.4 PILOT COLLECTIVE MOUNTED PYLON HARDPOINT SWITCH REMOVAL18
5.2.5 PILOT COLLECTIVE MOUNTED PYLON HARDPOINT SWITCH
INSTALLATION .............................................................................................. 18
5.2.6 PILOT OR COPILOT CYCLIC MOUNTED PYLON HARDPOINT SWITCH
REMOVAL...................................................................................................... 18
AERONAUTICAL ACCESSORIES
September 12, 2012
Page 5 of 38
BHT 407
INSTRUCTIONS FOR CONTINUED AIRWORTHINESS
PYLON HARDPOINT KIT
AA-10120
Revision A
TABLE OF CONTENTS
Identification
Title
Page
5.2.7 PILOT OR COPILOT CYCLIC MOUNTED PYLON HARDPOINT SWITCH
INSTALLATION .............................................................................................. 18
5.2.8 PYLON HARDPOINT CIRCUIT BREAKER REMOVAL ................................. 19
5.2.9 PYLON HARDPOINT CIRCUIT BREAKER INSTALLATION ......................... 19
5.2.10 TERMINAL BLOCKS REMOVAL / INSTALLATION ....................................... 19
5.2.10.1 TERMINAL BLOCK 24WT1, 24WT2, 24WT3 REMOVAL........................ 19
5.2.10.2 TERMINAL BLOCK 24WT1, 24WT1, 24WT3 INSTALLATION................ 19
5.2.10.3 TERMINAL BLOCK 24TB1 REMOVAL.................................................... 20
5.2.10.4 TERMINAL BLOCK 24TB1 INSTALLATION............................................ 20
6.0
PYLON HARDPOINT KIT RECOMMENDED OVERHAUL PERIODS ................. 21
7.0
PYLON HARDPOINT KIT AIRWORTHINESS LIMITATIONS .............................. 21
8.0
WEIGHT AND BALANCE ..................................................................................... 21
8.1
9.0
PYLON HARDPOINT KIT................................................................................. 21
PARTS BREAKDOWN ......................................................................................... 22
APPENDIX A – ANNUAL INSPECTION RECORD ....................................................... 37
AERONAUTICAL ACCESSORIES
September 12, 2012
Page 6 of 38
BHT 407
INSTRUCTIONS FOR CONTINUED AIRWORTHINESS
PYLON HARDPOINT KIT
AA-10120
Revision A
LIST OF TABLES
List of Tables
Title
Page
TABLE 1. TROUBLESHOOTING ..................................................................................... 11
TABLE 2. DAMAGE AND REPAIR LIMITS ...................................................................... 12
TABLE 3. PARTS BREAKDOWN, 407-854-003 PYLON HARDPOINT INSTALLATION
KIT (W/ WIRING KIT) ............................................................................................. 22
TABLE 4. PARTS BREAKDOWN, 407-854-001 (L/H) / 407-854-002 (R/H) PYLON
HARDPOINT INSTALLATION KIT ......................................................................... 23
TABLE 5. PARTS BREAKDOWN, 407-855-001 PYLON HARDPOINT WIRING KIT ..... 25
AERONAUTICAL ACCESSORIES
September 12, 2012
Page 7 of 38
BHT 407
INSTRUCTIONS FOR CONTINUED AIRWORTHINESS
PYLON HARDPOINT KIT
AA-10120
Revision A
LIST OF FIGURES
List of Figures Title
Page
FIGURE 1. PYLON HARDPOINT (RIGHT SIDE HARDPOINT, LEFT SIDE
THRU-HOLE SHOWN) ....................................................................................... 10
FIGURE 2. 407-232-135 DECAL PYLON HARDPOINT COORDINATION
REQUIREMENT ................................................................................................. 10
FIGURE 3 (SHEET 1 OF 5). REFERENCE PYLON HARDPOINT INSTALLATION .... 27
FIGURE 3 (SHEET 2 OF 5). REFERENCE PYLON HARDPOINT INSTALLATION .... 28
FIGURE 3 (SHEET 3 OF 5). REFERENCE PYLON HARDPOINT INSTALLATION .... 29
FIGURE 3 (SHEET 4 OF 5). REFERENCE PYLON HARDPOINT INSTALLATION .... 30
FIGURE 3 (SHEET 5 OF 5). REFERENCE PYLON HARDPOINT INSTALLATION .... 31
FIGURE 4 (SHEET 1 OF 5). REFERENCE PYLON HARDPOINT SCHEMATIC AND
WIRING .............................................................................................................. 32
FIGURE 4 (SHEET 2 OF 5). REFERENCE PYLON HARDPOINT SCHEMATIC AND
WIRING .............................................................................................................. 33
FIGURE 4 (SHEET 3 OF 5). REFERENCE PYLON HARDPOINT SCHEMATIC AND
WIRING .............................................................................................................. 34
FIGURE 4 (SHEET 4 OF 5). REFERENCE PYLON HARDPOINT SCHEMATIC AND
WIRING .............................................................................................................. 35
FIGURE 4 (SHEET 5 OF 5). REFERENCE PYLON HARDPOINT SCHEMATIC AND
WIRING .............................................................................................................. 36
AERONAUTICAL ACCESSORIES
September 12, 2012
Page 8 of 38
BHT 407
1.0
INSTRUCTIONS FOR CONTINUED AIRWORTHINESS
PYLON HARDPOINT KIT
AA-10120
Revision A
INTRODUCTION
This Instruction for Continued Airworthiness has been created to provide
information to inspect, maintain and replace the AERONAUTICAL
ACCESSORIES 407-854-003 PYLON HARDPOINT INSTALLATION KIT
(Pylon Hardpoints Kit) as installed on Bell Helicopter Textron model 407
helicopters installed in accordance with STC SR09540RC.
407-854-003 Pylon Hardpoints Kit consist of 407-854-001 (L/H) Pylon Hardpoint
Installation Kit; 407-854-002 (R/H) Pylon Hardpoint Installation Kit; and
407-855-001 Pylon Hardpoint Wiring Kit.
1.1
DISTRIBUTION
These instructions are provided for use with aircraft equipped with Aeronautical
Accessories Pylon Hardpoint Kits. Any and all airworthiness or flight safety
revisions will be immediately made available to affected aircraft operators and
owners.
1.2
REVISION
A Log of Revision section is 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
2.1
SYSTEM OVERVIEW
See Figure 1.
The Aeronautical Accessories Pylon Hardpoints Kit provides structural mounting
provisions located on the fuselage floor at the corners where the aft passenger
seat pan and outboard fuselage structure meet. Hardpoints are installed for each
side of the cabin to allow for installation of (two) removable external pylons.
(External pylon installation is a separate installation, not covered under this
STC.)
Pylon Plugs, which conform to the OEM fuselage contour, are provided as part of
the Hardpoints Kit to be inserted into the fuselage thru-hole when an external
pylon is not installed.
The External Hardpoint Kit electrical provisions permit electrical power and signal
delivery to Hardpoint mounted equipment. The electrical provisions include a
pilot collective control head switch, cable assemblies, and circuit breaker. An
externally accessible, aft fuselage fairing mounted electrical connector is installed
to permit hook-up of mounted equipment.
AERONAUTICAL ACCESSORIES
September 12, 2012
Page 9 of 38
BHT 407
INSTRUCTIONS FOR CONTINUED AIRWORTHINESS
PYLON HARDPOINT KIT
AA-10120
Revision A
Installation of Aeronautical Accessories 407-270-003 Passenger Sliding Doors
Kit is a co-requisite for the Pylon Hardpoints Kit installation as it modifies the
cabin door to accommodate the Pylon thru-hole (and external pylon arms).
FIGURE 1. PYLON HARDPOINT (RIGHT SIDE HARDPOINT, LEFT SIDE THRU-HOLE SHOWN)
This STC includes a limitation, shown in a placard (see Figure 2) mounted to the
Pylon Hardpoint Fittings requiring installers to coordinate with Bell Helicopter
prior to installing any equipment to the Hardpoint to ensure that Bell Helicopter
evaluates the effect, if any, on the aircraft due to specific equipment installations.
FIGURE 2. 407-232-135 DECAL PYLON HARDPOINT COORDINATION REQUIREMENT
AERONAUTICAL ACCESSORIES
September 12, 2012
Page 10 of 38
BHT 407
3.0
INSTRUCTIONS FOR CONTINUED AIRWORTHINESS
PYLON HARDPOINT KIT
AA-10120
Revision A
TROUBLESHOOTING
For troubleshooting information, refer to Table 1.
TABLE 1. TROUBLESHOOTING
Problem
Vibration in Pylon Hardpoint
components
Probable Cause
Loose/missing attachment
hardware
4.0
MAINTENANCE INSTRUCTIONS
4.1
ANNUAL INSPECTION
Remedy
Tighten/replace hardware
The Hardpoint shall receive an Annual visual inspection consisting of the
following items. Ensure the damage and repair limits in Table 2 are not
exceeded.
1. Visually inspect the 407-232-135 Decal installed on the Pylon Fittings for
condition and legibility.
2. Visually inspect aluminum and steel components for cracks, nicks or
scratches, dents, and indications of corrosion.
NOTE
The indications of corrosion are 1) corrosion deposits (a
white or gray powder on aluminum or rust colored deposits
on steel), 2) pits in aluminum or steel surfaces, 3) blisters,
bulging or flaking of protective coatings.
3. Visually inspect attachment hardware for security and tightness.
4. Visually inspect attachment hardware for signs of fretting or working.
5. Visually inspect Pylon Hardpoint wiring for signs of fraying or cracking.
6. Utilize the Annual Inspection Record provided in Appendix A to document
inspection completion.
4.2
CONDITIONAL INSPECTIONS
A conditional inspection does not occur at a specified time. It is caused by
known or suspected unusual events, malfunctions, or defects. The Pylon
Hardpoint shall receive a conditional inspection in cases of known or suspected
rotor strikes, hard landings, or lightning strikes.
The Pylon Hardpoint shall also receive a conditional inspection prior to
reinstallation of Pylon Fitting(s).
1. Perform Annual Inspection detailed in Section 4.1.
AERONAUTICAL ACCESSORIES
September 12, 2012
Page 11 of 38
BHT 407
4.3
INSTRUCTIONS FOR CONTINUED AIRWORTHINESS
PYLON HARDPOINT KIT
AA-10120
Revision A
REPAIR
Repair scratches, dents, nicks, or corrosion to components listed in Table 2 as
follows:
NOTE
General repair practices shall be in accordance with advisory
circular AC 43.13-1B, Bell Helicopter Structural Repair
Manual BHT-ALL-SRM, and Bell Helicopter Electrical
Standard Practices Manual BHT-ELEC-SPM.
1. Lightly polish the affected area using Scotch-Brite or No. 400 to 600 abrasive
paper or cloth. Ensure the limits presented in Table 2 are not exceeded.
Take care to remove as little of the component original protective coatings as
possible.
2. After corrosion removal or damage repair: Clean repaired area with isopropyl
alcohol and apply a protective chemical film, Alodine, to bare aluminum areas
per MIL-DTL-5541; apply two coats of epoxy polyamide primer to repaired
area; paint to match original finish, as applicable.
NOTE
If cracks are present, replace part. Crack repairs are not
authorized.
Replace frayed/cracked wiring as required. Refer to Figure 4 for reference wiring
installation information.
TABLE 2. DAMAGE AND REPAIR LIMITS
Component
Pylon Fitting
Cover Assembly
Doubler Assembly
Wiring
Maximum Allowable Damage And Repair Limits
(Damage and corrosion may be repaired as noted in
Section 4.3 Repair, if it does not exceed these limits.)
Scratches / Nicks / Dents and
Corrosion
Depth: Up to 10% of original part
thickness
Area: Up to 20% of part surface
area
Cracks
Fraying
None
N/A
N/A
None
None
AERONAUTICAL ACCESSORIES
September 12, 2012
Page 12 of 38
BHT 407
5.0
INSTRUCTIONS FOR CONTINUED AIRWORTHINESS
PYLON HARDPOINT KIT
AA-10120
Revision A
PYLON HARDPOINT KIT REMOVAL / INSTALLATION INFORMATION
CAUTION
Removal of equipment installed to the Pylon Hardpoint
is required prior to Pylon Hardpoint removal from
aircraft; ensure Pylon Hardpoint wiring is disconnected
from any power source prior to start of Pylon Hardpoint
removal/installation.
NOTE
Pylon Hardpoint wiring is routed along existing aircraft wire
runs where possible. Refer to Figure 4 for reference wiring
connector and installation information.
NOTE
Doubler Assemblies and Inserts installed during Pylon
Hardpoint installation are considered permanent aircraft
modifications.
Should Doubler Assemblies or Inserts
removal be required, contact Aeronautical Accessories Bell
Helicopter Piney Flats Technical Support for assistance.
NOTE
The Pylon Hardpoint shall receive a conditional inspection
prior to reinstallation of the Pylon Fitting.
5.1
REMOVAL / INSTALLATION – MECHANICAL
5.1.1 Pylon Fitting Removal
See Figure 3.
NOTE
Removal of pylon fittings requires removal of fuel cell foam
and fuel cells. Reference 407 Maintenance Manual for
instructions.
NOTE
Pylon Fitting removal from aircraft is identical for
407-852-121 (L/H) and 407-852-122 (R/H) Pylon Fittings.
1. If installed, remove and retain 407-274-125 Pylon Plug.
2. Remove and retain the (14) NAS6204-2 Bolts and NAS1149C0416R
Washers, remove and discard the (7) 30-295-6W Nuts and 100-159-6-4
Pins, remove and retain the (9) MS27039-1-11 Screws securing the
Pylon Fitting to the seat pan.
3. Remove and retain the (15) NAS6204-3 Bolts, (6) NAS6204-5 Bolts and
(21) NAS1140C0416R Washers securing the Pylon Fitting to the cabin
floor. Note installation locations of the NAS6204-3 and NAS6204-5 Bolts
for proper Pylon Fitting reinstallation.
4. Carefully remove Pylon Fitting from aircraft. Removal complete.
AERONAUTICAL ACCESSORIES
September 12, 2012
Page 13 of 38
BHT 407
INSTRUCTIONS FOR CONTINUED AIRWORTHINESS
PYLON HARDPOINT KIT
AA-10120
Revision A
5.1.2 Pylon Fitting Installation
See Figure 3.
NOTE
Pylon Fitting installation to aircraft is identical for
407-852-121 (L/H) and 407-852-122 (R/H) Pylon Fittings.
NOTE
Pylon Fitting installation requires installer to obtain (7) new
30-295-6W Nuts and 100-159-6-4 Pins.
NOTE
The instructions below are applicable to installation of a
Pylon Fitting being re-installed to its previously installed
location. For assistance with installation of a replacement
Pylon Fitting, contact Aeronautical Accessories, Bell
Helicopter Piney Flats Technical Support.
1. Place the Pylon Fitting at its previously installed location.
2. Use the retained (14) NAS6204-2 Bolts and NAS1149C0416R Washers,
(9) MS27039-1-11 Screws, and (7) new 30-295-6W Nuts and
100-159-6-4 Pins to secure the Pylon Fitting to the seat pan.
3. Use the retained (15) NAS6204-3 Bolts, (6) NAS6204-5 Bolts and (21)
NAS1140C0416R Washers to secure the Pylon Fitting to the cabin floor.
4. Pylon Fitting installation complete. If desired, install 407-274-125 Pylon
Plug.
5.1.3 Cover Assembly Removal
See Figure 3.
NOTE
Cover Assembly removal from aircraft is identical for
407-853-113 (L/H) and 407-853-114 (R/H) Cover
Assemblies.
1. Remove and retain from the outboard side of the Cover Assembly the (4)
MS27039-0809 Screws and NAS1149DN832J Washers securing the
Cover Assembly to the 407-853-115 Bracket Assembly.
2. Remove and retain from the inboard side of the Cover Assembly the (4)
MS27039-1-09 Screws and NAS1149D0332J Washers securing the
Cover Assembly to the aircraft.
3. Cover Assembly removal from aircraft complete.
4. If required, remove and retain the (4) MS27039-1-09 Screws and
NAS1149D0332J Washers securing the 407-853-115 Bracket Assembly
to the aircraft. 407-853-115 Bracket Assembly removal complete.
AERONAUTICAL ACCESSORIES
September 12, 2012
Page 14 of 38
BHT 407
INSTRUCTIONS FOR CONTINUED AIRWORTHINESS
PYLON HARDPOINT KIT
AA-10120
Revision A
5.1.4 Cover Assembly Installation
See Figure 3.
NOTE
Cover Assembly installation to aircraft is identical for
407-853-113 (L/H) and 407-853-114 (R/H) Cover
Assemblies.
1. If required, use the retained (4) MS27039-1-09 Screws and
NAS1149D0332J Washers to secure the 407-853-115 Bracket Assembly
to the aircraft.
2. Secure the outboard side of the Cover Assembly to the 407-853-115
Bracket Assembly using the retained (4) MS27039-0809 Screws and
NAS1149DN832J Washers.
3. Secure the inboard side of the Cover Assembly to the aircraft using the
retained (4) MS27039-1-09 Screws and NAS1149D0332J Washers.
4. Cover Assembly installation complete.
5.2
REMOVAL / INSTALLATION – ELECTRICAL
NOTE
Pylon Hardpoint wiring is routed along existing aircraft wire
runs where possible. Refer to Figure 4 for reference wiring
connector and installation information.
CAUTION
Ensure Pylon Hardpoint wiring is disconnected from any
power source prior to start of removal/installation.
5.2.1 Fuselage Disconnects Removal / Installation
See Figures 3 and 4.
5.2.1.1
L/H Fuselage Disconnects Removal
1. Remove 407-853-113 Cover Assembly per section 5.1.3.
2. Remove and retain (4) NAS1801-04-7 Screws, NAS620-4L Washers, and
M85049/95-10A-A Retainer securing the D38999/20WA98SN
Connector/319H064XO09 Backshell to the aircraft (407-853-109 Doubler
Assembly).
3. Remove and retain (4) NAS1801-06-8 Screws, NAS620-6L Washers, and
M85049/95-25A-A Retainer securing the T3W-1725-92SN
Connector/319H064XO25 Backshell to the aircraft (407-853-109 Doubler
Assembly).
4. If required, remove and retain the (4) NAS1801-06-8 Screws, NAS620-6L
Washers, and M85049/95-25A-A Retainer securing the D38999/22JW
Dummy Receptacle to the aircraft (407-853-109 Doubler Assembly)
interior and D38999/33W25R Dust Cap to aircraft exterior.
AERONAUTICAL ACCESSORIES
September 12, 2012
Page 15 of 38
BHT 407
INSTRUCTIONS FOR CONTINUED AIRWORTHINESS
PYLON HARDPOINT KIT
AA-10120
Revision A
5. L/H Fuselage Disconnects removal from fuselage complete; disconnect
Connectors from associated Pylon Hardpoint wiring if replacing Connectors
or wiring. Reinstall Cover Assembly per section 5.1.4 if desired.
5.2.1.2
L/H Fuselage Disconnects Installation
NOTE
If wiring is disconnected from Connector(s), attach
associated Pylon Hardpoint wiring to Connector per Figure 3
prior to Disconnect installation.
1. Remove 407-853-113 Cover Assembly per section 5.1.3.
2. If required, use the retained (4) NAS1801-06-8 Screws and NAS620-6L
Washers, and M85049/95-25A-A Retainer to secure the D38999/22JW
Dummy Receptacle to the aircraft (407-853-109 Doubler Assembly)
interior and D38999/33W25R Dust Cap to aircraft exterior.
3. Use the retained (4) NAS1801-06-8 Screws and NAS620-6L Washers,
and M85049/95-25A-A Retainer to secure the T3W-1725-92SN
Connector/319H064XO25 Backshell to the aircraft (407-853-109 Doubler
Assembly).
4. Use the retained (4) NAS1801-04-7 Screws and NAS620-4L Washers
and M85049/95-10A-A Retainer to secure the D38999/20WA98SN
Connector/319H064XO09 Backshell to the aircraft (407-853-109 Doubler
Assembly).
5. L/H Fuselage Disconnect installation complete. Reinstall Cover
Assembly per section 5.1.4.
5.2.1.3
R/H Fuselage Disconnect Removal
1. Remove 407-853-114 Cover Assembly per section 5.1.3.
2. Remove and retain (4) NAS1801-04-6 Screws and NAS620-4L Washers,
and M85049/95-10A-A Retainer securing the D38999/20WA98SN
Connector/319H064XO09 Backshell to the aircraft (407-853-110 Doubler
Assembly).
3. Remove and retain (4) NAS1801-06-7 Screws and NAS620-6L Washers,
and M85049/95-25A-A Retainer securing the D38999/20WJ4SN
Connector/319H064XO25 Backshell to the aircraft (407-853-110 Doubler
Assembly).
4. Remove and retain the (4) NAS1801-06-8 Screws and NAS620-6L
Washers, and M85049/95-25A-A Retainer securing the T3W-1725-92SN
Connector/ 319H064XO25 Backshell to the aircraft (407-853-110 Doubler
Assembly).
5. R/H Fuselage Disconnect removal from fuselage complete; disconnect
Connector from associated Pylon Hardpoint wiring if replacing Connector
or wiring. Reinstall Cover Assembly per section 5.1.4 if desired.
AERONAUTICAL ACCESSORIES
September 12, 2012
Page 16 of 38
BHT 407
INSTRUCTIONS FOR CONTINUED AIRWORTHINESS
PYLON HARDPOINT KIT
5.2.1.4
AA-10120
Revision A
R/H Fuselage Disconnect Installation
NOTE
If wiring is disconnected from Connector(s), attach
associated Pylon Hardpoint wiring to Connector per Figure 3
prior to Disconnect installation.
1. Remove 407-853-114 Cover Assembly per section 5.1.3.
2. Use the retained (4) NAS1801-04-7 Screws and NAS620-4L Washers,
and M85049/95-10A-A Retainer to secure the D38999/20WA98SN
Connector/319H064XO09 Backshell to the aircraft (407-853-110 Doubler
Assembly).
3. Use the retained (4) NAS1801-06-8 Screws and NAS620-6L Washers,
and M85049/95-25A-A Retainer to secure the D38999/20WJ4SN
Connector/319H064XO25 Backshell to the aircraft (407-853-110 Doubler
Assembly).
4. Use the retained (4) NAS1801-06-8 Screws and NAS620-6L Washers,
and M85049/95-25A-A Retainer to secure the T3W-1725-92SN
Connector/319H064XO25 Backshell to the aircraft (407-853-110 Doubler
Assembly).
5. R/H Fuselage Disconnect installation complete. Reinstall Cover
Assembly per section 5.1.4.
5.2.2
Instrument Panel Mounted Pylon Hardpoint Switch Removal
See Figure 4.
NOTE
Removal of instrument panel mounted switches is identical
for Switch 21S1 and Switch 21S2.
1. Locate the MS24524-23 Switch and MS25224-1 Guard to be removed on
the instrument panel; remove and retain the associated attachment
hardware securing the Switch to the panel.
2. Disconnect Pylon wiring from the Switch. Removal complete.
5.2.3
Instrument Panel Mounted Pylon Hardpoint Switch Installation
See Figure 4.
NOTE
Installation of instrument panel mounted switches is identical
for Switch 21S1 and Switch 21S2.
1. Connect Pylon wiring to the MS24524-23 Switch.
2. Use the retained attachment hardware to secure the Switch and MS25224-1
Guard to the instrument panel. Installation complete.
AERONAUTICAL ACCESSORIES
September 12, 2012
Page 17 of 38
BHT 407
5.2.4
INSTRUCTIONS FOR CONTINUED AIRWORTHINESS
PYLON HARDPOINT KIT
AA-10120
Revision A
Pilot Collective Mounted Pylon Hardpoint Switch Removal
See Figure 4.
1. Remove and retain the (4) screws and washers securing the pilot
collective stick lit panel to the pilot collective stick switch box.
2. Remove and retain the associated attachment hardware securing the
MS25089-1G Switch to the collective head.
3. Disconnect Pylon wiring from the Switch. Removal complete.
5.2.5
Pilot Collective Mounted Pylon Hardpoint Switch Installation
See Figure 4.
1. Connect Pylon wiring to the MS25089-1G Switch.
2. Use the retained attachment hardware to secure the Switch to the collective
head.
3. Using the retained (4) screws and washers, secure the pilot collective stick lit
panel to the pilot collective stick switch box. Installation complete.
5.2.6
Pilot or Copilot Cyclic Mounted Pylon Hardpoint Switch Removal
See Figure 4.
NOTE
Removal of Pilot or Copilot cyclic mounted switch is
identical.
1. Remove cyclic stick grip per Bell model 407 maintenance manual.
2. Remove and retain the associated attachment hardware securing the
P2-110311 Switch to the cyclic.
3. Disconnect Pylon wiring from the Switch. Removal complete.
5.2.7
Pilot or Copilot Cyclic Mounted Pylon Hardpoint Switch Installation
See Figure 4.
NOTE
Installation of Pilot or Copilot cyclic mounted switches is
identical.
1. Connect Pylon wiring to the P2-110311 Switch.
2. Use the retained attachment hardware to secure the Switch to the cyclic.
Switch installation complete.
3. Install cyclic stick grip per Bell model 407 maintenance manual. Installation
complete.
AERONAUTICAL ACCESSORIES
September 12, 2012
Page 18 of 38
BHT 407
5.2.8
INSTRUCTIONS FOR CONTINUED AIRWORTHINESS
PYLON HARDPOINT KIT
AA-10120
Revision A
Pylon Hardpoint Circuit Breaker Removal
See Figure 4.
NOTE
Removal of Pylon Hardpoint 7.5A, 15A, and 25A circuit
breakers from the overhead circuit breaker panel is identical
for each circuit breaker.
1. Remove and retain the associated attachment hardware securing the
applicable Circuit Breaker to the overhead panel.
2. Disconnect Pylon wiring from the Circuit Breaker. Removal complete.
5.2.9
Pylon Hardpoint Circuit Breaker Installation
See Figure 4.
NOTE
Installation of Pylon Hardpoint 7.5A, 15A, and 25A circuit
breakers into the overhead circuit breaker panel is identical
for each circuit breaker.
1. Connect Pylon wiring to the applicable Circuit Breaker.
2. Using the retained associated attachment hardware, secure the Circuit
Breaker to the overhead panel. Installation complete.
5.2.10 Terminal Blocks Removal / Installation
See Figure 4.
NOTE
Terminal Blocks are mounted on 407-030-512-xxx panel
assembly.
5.2.10.1 Terminal Block 24WT1, 24WT2, 24WT3 Removal
See Figure 4.
NOTE
Terminal Block 24WT1, 24WT2, 24WT3 removal is identical.
1. Disconnect Pylon wiring from the Terminal Block.
2. Remove and retain the (2) MS35207-265 Screws, NAS1149D0332J
Washers, and MS21042L3 Nuts securing the Terminal Block
M81714/63-20F Module to the panel assembly. Removal complete.
5.2.10.2 Terminal Block 24WT1, 24WT1, 24WT3 Installation
See Figure 4.
NOTE
Terminal Block 24WT1, 24WT1, 24WT3 installation is
identical.
AERONAUTICAL ACCESSORIES
September 12, 2012
Page 19 of 38
BHT 407
INSTRUCTIONS FOR CONTINUED AIRWORTHINESS
PYLON HARDPOINT KIT
AA-10120
Revision A
1. Use the retained (2) MS35207-265 Screws, NAS1149D0332J Washers,
and MS21042L3 Nuts to secure the Terminal Block M81714/63-20F
Module to the panel assembly.
2. Connect Pylon wiring to the Terminal Block. Installation complete.
5.2.10.3 Terminal Block 24TB1 Removal
See Figure 4.
1. Disconnect Pylon wiring from the Terminal Block.
2. Remove and retain the (2) MS35207-265 Screws, NAS1149D0332J
Washers, and MS21042L3 Nuts securing the M81714/67-05 Rail and
Terminal Block M81714/60-20-01 Modules to the panel assembly.
Removal complete.
5.2.10.4 Terminal Block 24TB1 Installation
See Figure 4.
1. Use the retained (2) MS35207-265 Screws, NAS1149D0332J Washers,
and MS21042L3 Nuts to secure the M81714/67-05 Rail and Terminal
Block M81714/60-20-01 Modules to the panel assembly.
2. Connect Pylon wiring to the Terminal Block. Installation complete.
AERONAUTICAL ACCESSORIES
September 12, 2012
Page 20 of 38
BHT 407
6.0
INSTRUCTIONS FOR CONTINUED AIRWORTHINESS
PYLON HARDPOINT KIT
AA-10120
Revision A
PYLON HARDPOINT KIT RECOMMENDED OVERHAUL PERIODS
No component overhaul required for this type design change.
7.0
PYLON HARDPOINT KIT AIRWORTHINESS LIMITATIONS
There are no airworthiness limitations associated with this type design change.
8.0
WEIGHT AND BALANCE
8.1
PYLON HARDPOINT KIT
Kit Number
407-854-003
407-854-002
407-854-001
Weight
39.52 lbs
(17.93 Kg)
18.67 lbs
(8.47 Kg)
18.67 lbs
(8.47 Kg)
Station
118.7 in
(3010 mm)
119.2 in
(3028 mm)
119.2 in
(3028 mm)
Lateral Arm
0.0 in
(0 mm)
+18.9 in
(+480 mm)
-18.9 in
(-480 mm)
NOTE
Weight and balance data is for Pylon Hardpoint Kit only.
Installed weight and balance data for Hardpoint Wiring Kit
wiring is determined at installation.
AERONAUTICAL ACCESSORIES
September 12, 2012
Page 21 of 38
BHT 407
INSTRUCTIONS FOR CONTINUED AIRWORTHINESS
PYLON HARDPOINT KIT
9.0
AA-10120
Revision A
PARTS BREAKDOWN
Tables 3 and 4 contain Parts Breakdown data for the model 407 Pylon Hardpoint
Kit. Table 5 contains Parts Breakdown data for the model 407 Pylon Hardpoint
Wiring Kit.
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
0
1
2
3
4
Details
Nonprocurable part
Procurable part
Procure as detail parts only
Procurable as Next Higher Assembly
Local manufacture. Contact Aeronautical Accessories, Bell Helicopter Piney
Flats Product Support Engineering (PSE)
Part replacement requires a fixture or special equipment. Contact PSE
Non-stock procurable part
5
6
TABLE 3. PARTS BREAKDOWN,
407-854-003 PYLON HARDPOINT INSTALLATION KIT (W/ WIRING KIT)
Qty
Part Number
Description
1
1
1
1
1
1
1
2
2
4
2
4
8
16
407-854-001
407-854-002
407-855-001
407-853-109
407-853-110
407-853-113
407-853-114
407-853-142
D38999/22AW
D38999/22JW
D38999/33W9R
D38999/33W25R
NAS1398CFA3-5
NAS9301B-4-5
Pylon Hardpoint Installation Kit (L/H)
Pylon Hardpoint Installation Kit (R/H)
Pylon Hardpoint Wiring Kit
Doubler Assembly (L/H)
Doubler Assembly (R/H)
Cover Assembly (L/H)
Cover Assembly (R/H)
Doubler Assembly
Dummy Receptacle
Dummy Receptacle
Dust Cap
Dust Cap
Rivet
Rivet (ALT: CR3213-4-5)
AV
Code
1
1
1
1
1
1
1
1
1
1
1
1
1
1
AERONAUTICAL ACCESSORIES
September 12, 2012
Page 22 of 38
BHT 407
INSTRUCTIONS FOR CONTINUED AIRWORTHINESS
PYLON HARDPOINT KIT
AA-10120
Revision A
TABLE 4. PARTS BREAKDOWN,
407-854-001 (L/H) / 407-854-002 (R/H) PYLON HARDPOINT INSTALLATION KIT
Qty
-001
Qty
-002
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
9
8
9
4
10
14
15
6
17
35
4
1
2
3
18
5
1
1
1
1
1
1
1
1
1
1
9
8
9
4
10
14
15
6
17
35
4
1
2
3
18
5
1
Part Number
407-232-135
407-852-121
407-852-122
407-853-101
407-853-102
407-853-103
407-853-104
407-853-105
407-853-106
407-853-107
407-853-108
407-853-111
407-853-112
407-853-115
407-853-124
407-853-125
407-853-126
407-853-143
206-032-120-105
206-032-120-106
ADBB120
A-A-59298 1.0
MS21075L3N
MS27039-1-09
MS27039-1-11
MS27039-0809
120-225C3R08
NAS6204-2
NAS6204-3
NAS6204-5
NAS1149D0332J
NAS1149C0416R
NAS1149DN832J
NAS1097AD5-5
NAS1097AD5-6
NAS1097AD5-7
NAS1399CFA3-5
NAS1739M5-3
NAS9301B-6-03
Description
Decal
Pylon Fitting (L/H)
Pylon Fitting (R/H)
Angle Assembly (L/H)
Angle Assembly (R/H)
Filler Assembly (L/H)
Filler Assembly (R/H)
Doubler Assembly (L/H)
Doubler Assembly (R/H)
Doubler Assembly (L/H)
Doubler Assembly (R/H)
Doubler Assembly (L/H)
Doubler Assembly (R/H)
Bracket Assembly
Plate
Splice
Splice
Spacer
Support (FWD L/H)
Support (FWD R/H)
Expandable Bolt
Tape
Nut Plate
Screw
Screw
Screw
Screw
Bolt
Bolt
Bolt
Washer
Washer
Washer
Rivet
Rivet
Rivet
Rivet
Rivet
Rivet (ALT: CR3213-6-3)
AV
Code
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
AERONAUTICAL ACCESSORIES
September 12, 2012
Page 23 of 38
BHT 407
INSTRUCTIONS FOR CONTINUED AIRWORTHINESS
PYLON HARDPOINT KIT
AA-10120
Revision A
TABLE 4. PARTS BREAKDOWN,
407-854-001 (L/H) / 407-854-002 (R/H) PYLON HARDPOINT INSTALLATION KIT
Qty
-001
Qty
-002
Part Number
30
18
1
7
14
7
6
4
2
1
14
10
8
18
6
3
7
2
2
7
1
1
1
1
1
1
1
1
1
1
30
18
1
7
14
7
6
4
2
1
14
10
8
18
6
3
7
2
2
7
1
1
1
1
1
1
1
1
1
1
NAS9301B-4-02
NAS9307M-4-2
NAS9307M-5-6
NAS9307M-6-4
NAS9307M-6-5
NAS9307M-6-6
NAS9308M-4-2
NAS9308M-4-3
NAS9308M-4-4
NAS9311M-5-6
80-007-08-4
80-007-15-3
80-007-17-3
80-007-17-4
80-007-19-4
110-220-T6-150
100-159-6-5
100-158-5-3
30-296-5W
30-295-6W
AMS-S-8802
870 B-2
099-050-121
099-050-271
099-859-002
HRH-36/OX-3/16-3.0
AA-10119
AA-10120
AA-10121
DWG 407-854
Description
Rivet (ALT: CR3213-4-2)
Rivet (ALT: CR3523-4-2)
Rivet (ALT: CR3523-5-6)
Rivet (ALT: CR3523-6-4)
Rivet (ALT: CR3523-6-5)
Rivet (ALT: CR3523-6-6)
Rivet (ALT: CR3522-4-2)
Rivet (ALT: CR3522-4-3)
Rivet (ALT: CR3522-4-4)
Rivet (ALT: CR3552-5-6)
Insert
Insert
Insert
Insert
Insert
Fastener
Pin
Pin
Collar
Collar
Sealant (1 pt)
Sealant
Adhesive
Edge Seal (8 oz)
Syringe
2
Honeycomb Core (1ft )
Installation Instructions
Instructions for Continued Airworthiness
Rotorcraft Flight Manual Supplement
Installation Drawing
AV
Code
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
AERONAUTICAL ACCESSORIES
September 12, 2012
Page 24 of 38
BHT 407
INSTRUCTIONS FOR CONTINUED AIRWORTHINESS
PYLON HARDPOINT KIT
AA-10120
Revision A
TABLE 5. PARTS BREAKDOWN,
407-855-001 PYLON HARDPOINT WIRING KIT
Qty
Part Number
Description
2
1
1
1
2
2
2
3
7
1
4
5
56 in
66 in
1
2
2
2
11
12 in
12 in
12 in
1
2
1
1
1
170 in
3
15
137
25
3
3
1
2
5
2
1
3
4
1
2
099-859-002
106-25002-00
319A064XO10
319A064XO14
319F064XO22
319F064XO24
319H064XO09
319H064XO25
36152
36160
36154
320619
5211001303S
5211001903S
5490
MS24509-A7 1/2
7270-1-25
MS25224-1
A10099
ATUM-16/4-0
ATUM-24/6-0
ATUM-32/8-0
BLACK 620.5
D38999/20WA98SN
D38999/20WJ4SN
D38999/22JW
D38999/33W25R
M23053/5-104-0
M39029/32-259
MS27488-16-2
MS27488-20-2
MS27488-22-2
M81714/60-20-01
M81714/63-20F
M81714/67-05
M81824/1-1
M81824/1-2
M85049/93-14
M85049/93-04
M85049/93-06
M85049/93-08
M85049/93-10
M85049/95-10A-A
Syringe 15cc
Grip Assembly
Backshell
Backshell
Backshell
Backshell
Backshell
Backshell
Ring Terminal
Ring Terminal
Ring Terminal
Ring Terminal
Expandandable Sleeving
Expandandable Sleeving
Teflon Tape
Circuit Breaker (Alt: 7270-1-7.5)
Circuit Breaker
Guard
Band
Insulated Tubing
Insulated Tubing
Insulated Tubing
Tape
Connector
Connector
Dummy Receptacle
Dust Cap
Heatshrink
Sockets
Sealing Plug
Sealing Plug
Sealing Plug
Module
Module
Rail
Splice
Splice
Shield Support Ring
Shield Support Ring
Shield Support Ring
Shield Support Ring
Shield Support Ring
Retainer
AV
Code
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
AERONAUTICAL ACCESSORIES
September 12, 2012
Page 25 of 38
BHT 407
INSTRUCTIONS FOR CONTINUED AIRWORTHINESS
PYLON HARDPOINT KIT
AA-10120
Revision A
TABLE 5. PARTS BREAKDOWN,
407-855-001 PYLON HARDPOINT WIRING KIT
Qty
Part Number
Description
4
1
8
1
2
1
1
2
1
1
1
8
8
16
8
8
16
2
2
M85049/95-25A-A
870 B-2
MS21042L3
MS24509-A15
MS24524-23
MS25089-1G
MS27473T24B4S
MS27473T22B55S
MS27473T24B61S
MS3476W10-6S
MS3476W14-5S
MS35207-265
NAS1801-04-6
NAS1801-06-8
NAS1149D0332J
NAS620-4L
NAS620-6L
P2-110311
T3W-1725-92SN
Retainer
Sealant
Nut
Circuit Breaker (Alt: 7270-1-15)
Switch
Switch
Connector
Connector
Connector
Connector
Connector
Screw
Screw
Screw
Washer
Washer
Washer
Switch
Connector
AV
Code
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
AERONAUTICAL ACCESSORIES
September 12, 2012
Page 26 of 38
BHT 407
INSTRUCTIONS FOR CONTINUED AIRWORTHINESS
PYLON HARDPOINT KIT
AA-10120
Revision A
NOTES:
1. INSTALLATION OF INSERTS:
A. DETERMINE POSITION OF INSERT AND MARK CENTER OF INSERT ON THE PANEL. DRILL Ø.193-.199 HOLE
THROUGH BOTH SKINS OF PANEL.
B. OPEN THE HOLE IN THE LOWER SKIN TO Ø.386-.392.
C. UNDERCUT THE CORE TO .25" MORE THAN THE LARGER HOLE.
D. DRILL TWO OPPOSED Ø.088-.093 INJECTION HOLES THROUGH THE LOWER SKIN .100 FROM EDGE OF LARGER
HOLE.
E. DEBURR HOLES AND REMOVE DEBRIS FROM CAVITY AND SURFACE OF PANEL
F. APPLY A THIN LAYER OF 099-050-121 ADHESIVE UNDERNEATH HEAD OF INSERT AND ON BOTTOM SURFACE OF
INSERT THAT WILL CONTACT UPPER SKIN. INSTALL INSERT INTO PANEL AND SECURE IN PLACE USING A BOLT
AND WASHER.
G. USING A 099-859-002 SYRINGE INJECT A SLOW STEADY FLOW OF 099-050-121 ADHESIVE THROUGH ONE HOLE.
CONTINUE INJECTING UNTIL A STEADY FLOW OF 099-050-121 ADHESIVE EMERGES OUT OF THE OPPOSITE
HOLE.
H. REMOVE EXCESS ADHESIVE AND ALLOW TO CURE24 HOURS AT ROOM TEMPERATURE BEFORE HANDLING.
FULL CURE IS ACHIEVED IN DAYS.
I. REMOVE BOLT AND SAND SURFACE OF INSERT AND ADJACENT AREA WITH FINE GRIT SCOTCHBRITE PAD.
BRUSH ALODINE BARE ALUMINUM PER MIL-DTL-5541 AND PRIME WITH EPOXY POLYAMIDE PER MIL-PRF-23377
TYPE I, CLASS C2. ALT PRIMER:MIL-P-23377.
2.
FOLLOW GENERAL SHOP PRACTICES IN ACCORDANCE WITH AC43.13
3.
SEAL FAYING SURFACES WITH AMS-S-8802 SEALANT
4.
ACCEPTABLE TO INCREASE FASTENER GRIP LENGTH UP TO 1 GRIP LENGTHS IF REQUIRED DUE TO
INSTALLATION OF SHIMS.
5.
A GAP GREATER THAN .030 AND LESS THAN .120 BETWEEN THE LOWER SHELL, AFT OF ST 121.44, AND THE
407-853-107/-108 DOUBLERS SHALL BE FILLED BY APPLYING A WET LAYUP OF SUFFICIENT LAYERS OF GLASS
FABRIC (APPROX. 1 PLY FOR EVERY .015-.020 OF GAP) TO THE DOUBLER. THE WET LAYUP SHALL BE
FABRICATED PER BPS 4478 USING GLASS FABRIC PER MIL-C-9084 CL 2, TY VIII OR TY VIIIA, WEAVE 1581 OR
WEAVE 181. HYSOL EA956 ADHESIVE SHALL BE USED TO BOND THE DOUBLERS AND THE WET LAYUP ON
LOCATION WHILE THE WET LAYUP IS STILL WET. FASTENER HOLE DIAMETER IN THE CURED WET LAYUP SHALL
BE MAINTAINED AS SPECIFIED FOR OUTER DOUBLER AND SKIN.
6.
SEAL ALL SURFACES TO STRUCTURE TO COMPLETELY SEAL SIDEBODY FAIRINGS AND CABIN WITH
MIL-PRF-81733 SEALANT.
7.
REMOVE PEEL PLY AND BOND PER BELL STANDARD PRACTICES MANUAL USING 099-050-121 ADHESIVE.
8.
FILLET SEAL EDGE OF DOUBLERS WITH 870 B-2 SEALANT.
9.
WHEN REMOVING INSERTS, FILL OPEN HOLES WITH 099-050-121 ADHESIVE
10.
WET INSTALL FASTENERS WITH MIL-PRF-81733 SEALANT
11.
APPLY AN OVERCOAT OF MIL-PRF-81733 SEALANT OVER CORE PLUG AND POTTING COMPOUND
12.
FILL CAVITY WITH HONEYCOMB CORE HRH-36/OX-3/16-3.0, 1" THICK. RECESS CORE .1 FROM EDGE AND FILL
CORE .2" AND BOND USING 099-050-121
13.
ACCEPTABLE TO SUBSTITUTE MONEL RIVETS WHERE ALUMINUM RIVETS ARE USED.
14.
PYLON FITTINGS SHALL BE RIGGED WITH ALIGNMENT TOOL TO ENSURE THE PYLON FITTINGS ARE ALIGNED
WITHIN +/- 1 DEGREE. SHIM ANY GAP BETWEEN THE CABIN FLOOR AND/OR THE FUEL CELL KICK PANEL AND
THE PYLON FITTINGS PER BELL STANDARD PRACTICES MANUAL USING INSTALLATION TOOL CLAMP
PRESSURE. THE FOLLOWING EXCEPTIONS ARE ONLY ALLOWED FOR THE INTERFACE BETWEEN THE AIRCRAFT
AND THE PYLON FITTING:

• MAX GAP SHALL NOT EXCEED .120"
• 099-051-121 ADHESIVE LIQUID SHIM THICKNESS SHALL NOT EXCEED .060"
• WHEN POSSIBLE, USE SOLID SHIM STOCK TO SHIM GAPS TO WITHIN .005". SHIM TO BE THE SAME

FOOTPRINT AS THE PYLON FITTING
• BOND SHIM TO DOUBLERS WITH ADHESIVE WITH 099-050-121
• APPLY RELEASE AGENT TO FAYING SURFACES OF PYLON FITTING TO PREVENT BONDING OF LIQUID
SHIMMING MATERIAL.
• ALLOW LIQUID SHIM TO CURE
15.
DELETED
16.
LOCATE DECAL AS SHOWN. AFTER DECAL INSTALLATION, APPLY TWO COATS OF 099-050-271 EDGE SEAL
AROUND PERIMETER OF DECAL
17.
IDENTIFY KIT IN ACCORDANCE WITH AA PS 88-05005 TO REQUIREMENTS
OF 14 CFR PART 45.15.
18.
TRIM AS REQUIRED TO PREVENT INTERFERENCE WITH EXISTING RIVET.
19.
REMOVE EXISTING RIVETS. COUNTERSINK DEPTH SHALL BE SUCH THAT THE 110-220-T6 FASTENER HEAD IS
.005-.010 ABOVE AIRCRAFT SURFACE. TRIM DRIVE SCREW SUCH THAT IT IS FLUSH WITH FASTENER HEAD.
20.
TRIM FOR PROPER FIT AND EDGE DISTANCE.
21.
TRIM SPACER TO LENGTH AS REQUIRED.
ST 111.47
FIGURE 3 (SHEET 1 OF 5). REFERENCE PYLON HARDPOINT INSTALLATION
AERONAUTICAL ACCESSORIES
September 12, 2012
Page 27 of 38
BHT 407
INSTRUCTIONS FOR CONTINUED AIRWORTHINESS
PYLON HARDPOINT KIT
AA-10120
Revision A
FIGURE 3 (SHEET 2 OF 5). REFERENCE PYLON HARDPOINT INSTALLATION
AERONAUTICAL ACCESSORIES
September 12, 2012
Page 28 of 38
BHT 407
INSTRUCTIONS FOR CONTINUED AIRWORTHINESS
PYLON HARDPOINT KIT
AA-10120
Revision A
FIGURE 3 (SHEET 3 OF 5). REFERENCE PYLON HARDPOINT INSTALLATION
AERONAUTICAL ACCESSORIES
September 12, 2012
Page 29 of 38
BHT 407
INSTRUCTIONS FOR CONTINUED AIRWORTHINESS
PYLON HARDPOINT KIT
AA-10120
Revision A
FIGURE 3 (SHEET 4 OF 5). REFERENCE PYLON HARDPOINT INSTALLATION
AERONAUTICAL ACCESSORIES
September 12, 2012
Page 30 of 38
BHT 407
INSTRUCTIONS FOR CONTINUED AIRWORTHINESS
PYLON HARDPOINT KIT
AA-10120
Revision A
FIGURE 3 (SHEET 5 OF 5). REFERENCE PYLON HARDPOINT INSTALLATION
AERONAUTICAL ACCESSORIES
September 12, 2012
Page 31 of 38
BHT 407
INSTRUCTIONS FOR CONTINUED AIRWORTHINESS
PYLON HARDPOINT KIT
AA-10120
Revision A
NOTES:
1
IDENTIFY KIT IN ACCORDANCE WITH AA PS 88-05005 TO REQUIREMENTS
OF 14 CFR PART 45.15.
2.
FOLLOW GENERAL SHOP PRACTICES PER AC43.13, BHT STANDARD
PRACTICES MANUAL (BHT-ALL-SPM), AND BHT ELECTRICAL STANDARD
PRACTICES MANUAL (BHT-ELEC-SPM) DURING INSTALLATION.
3.
ALL WIRE AND WIRE ROUTING TO BE IN ACCORDANCE WITH AC43.13-1B,
CHAPTER 11 AND COMPONENT MANUFACTURER'S RECOMMENDATIONS.
4
WIRE IS NOT PROVIDED WITH KIT. INSTALLER TO PROCURE WIRE
SPECIFIED IN TABLE I AND M22759/41-20-9 SHIELD GRND WIRE.
5
ALL UNSHIELDED WIRE TO BE PER SAE AS22759/41 AND ALL SHIELDED
WIRE TO BE PER NEMA WC27500. LENGTH OF WIRE TO BE DETERMINED
AT INSTALLATION. REFERENCE TABLE I FOR WIRE TYPES.
6
MARK ALL WIRES PER AC43.13-1B, CHAPTER 11, SECTION 16.
7
ASSEMBLE CONNECTOR AS FOLLOWS (REF: TYPICAL EMI CONNECTOR
CABLE, SHEET 3):
10
PREPARE ENTIRE SURFACE FOR ELECTRICAL BOND IN ACCORDANCE
WITH CHAPTER 8 OF THE BHT-ELEC-SPM.
11
ENSURE ELECTRICAL BOND OF 10 MILLIOHMS OR LESS PER AC43.13-1B,
CHAPTER 11, SECTION 15.
12
LABELS TO BE PROVIDED BY INSTALLER. MARK WITH REFERENCE
DESIGNATOR (EXAMPLE: 21J1)
MATERIAL: M23053/5-112-9 HEATSHRINK
13. ON SCHEMATIC:
EXISTING COMPONENTS SHOWN AS:
CONNECTOR INTEGRAL BRAIDSOCK SHOWN AS:
14
SEAL ELECTRICAL BOND IN ACCORDANCE WITH CHAPTER 8 OF
BHT-ELEC-SPM USING MIL-PRF-8516 TY II, CL 2, CATEGORY A SEALANT,
AND 099-859-002 SYRINGE.
15. IT IS PERMISSIBLE TO SOLDER WIRES IN LIEU OF USING M81824 SPLICES.
A.
B.
C.
D.
E.
F.
G.
H.
I.
J.
K.
L.
M.
N.
O.
P.
Q.
DETERMINE CONNECTOR MAIN POLARIZATION KEYWAY ORIENTATION
PER TABLE II (SHEET 3) AND DETAIL E. LOOSELY ASSEMBLE THE
BACKSHELL TO THE CONNECTOR, AND DETERMINE APPROPRIATE
SWING ARM ANGLE PER TABLE II AND DETAIL C . PLACE A WITNESS
MARK ON THE BACKSHELL ARM HINGE AT THE LOCATIONS IDENTIFIED
FOR REASSEMBLY AFTER MAINTENANCE OR MODIFICATION. PUSH
BACK THE BACKSHELL BRAID. DO NOT TIGHTEN SADDLE CLAMP
SCREWS.
INSERT WIRE BUNDLE INTO THE ADAPTER AND BOTTOM IT AGAINST
THE CONNECTOR. WHILE HOLDING THE CABLE, MARK THE LOCATION
WHERE THE M85049/93 SHIELD SUPPORT RING WILL BE LOCATED.
SHIELD BREAKOUTS MUST BE PLACED AT A MINIMUM OF 1.0" AND A
MAXIMUM OF 3.0" FROM THE END OF THE SHIELD SUPPORT RING, AS
SHOWN. TO THE MAXIMUM EXTENT POSSIBLE, THE SHIELD
BREAKOUTS MUST NOT OVERLAP ON ADJACENT WIRES AND SHOULD
BE SPREAD OVER THE ENTIRE RANGE ALLOWED.
CREATE BRAIDED LEAD SHIELD TERMINATIONS AS FOLLOWS:
REMOVE WIRE INSULATION TO BREAKOUT POINT. PUSH BACK THE
SHIELDING SO AS TO FORM A BULGE AT THIS POINT, INSERT AN AWL
OR OTHER POINTED TOOL BETWEEN THE STRANDS OF SHIELDING,
AND WORK AN OPEN CIRCULAR AREA INTO THE SHIELD. (NOTE:
MAXIMUM SHIELD STRAND BREAKAGE SHALL NOT EXCEED 10%. IF
MORE THAN 10% OF STRANDS ARE BROKEN, USE OF AN M83159/1
SHIELD TERMINATOR, NOT PROVIDED, IS ALLOWED.) BEND THE
CABLE, INSERT THE TOOL BETWEEN SHIELDING AND WIRE, AND PULL
CONDUCTOR THROUGH. PULL THE EMPTY PART OF SHIELD TAUT
AND INSTALL M23053/5-104-0 HEATSHRINK AS SHOWN IN DETAIL D.
PLACE 521100XX03S EXPANDABLE SLEEVING, ATUM-XX/X-0 INSULATED
TUBING, LABEL (TO BE PROVIDED BY INSTALLER), AND GLENAIR 319
SERIES BACKSHELL ONTO THE WIRE HARNESS.
INSTALL CONTACTS PER BHT-ELEC-SPM ON CABLE ASSEMBLY AND
TERMINATE TO THE CONNECTOR. THEN SLIDE THE BACKSHELL
FORWARD AND HAND-TIGHTEN TO THE CONNECTOR. PUSH THE
BRAID SOCK FORWARD OVER THE CONNECTOR.
AT THE LOCATION MARKED IN STEP B, WRAP 5490 TEFLON TAPE
AROUND THE WIRE BUNDLE TO ENSURE A SNUG FIT OF THE SHIELD
SUPPORT RING.
INSTALL SHIELD SUPPORT RING.
EVENLY SPACE THE SHIELD LEADS AROUND THE SHIELD SUPPORT
RING AND TEMPORARILY SECURE BEHIND THE RING USING LACING
TAPE OR A PLASTIC CABLE TIE.
PULL THE BRAID SOCK OVER THE SHIELD SUPPORT RING AND SHIELD
LEADS.
INSTALL THE A10099 BAND ONTO THE CENTER OF THE SHIELD
SUPPORT RING USING A40199 TIE-DEX II TOOL PER BAND-IT-IDEX, INC.
OPERATION INSTRUCTIONS (SEE NOTE 8).
TRIM THE BRAID SOCK AND SHIELD LEADS TO WITHIN .10" OF THE
A10099 BAND, REMOVING THE LACING TAPE OR PLASTIC CABLE TIE IN
THE PROCESS.
POSITION BACKSHELL TO THE ORIENTATION SPECIFIED IN DETAIL C
AND TORQUE TO THE CONNECTOR USING THE VALUE INDICATED ON
THE TYPICAL EMI CONNECTOR CABLE VIEW ON SHEET 3.
TURN THE CONNECTOR END OF THE 521100XX03S EXPANDABLE
SLEEVING INSIDE ITSELF BY 1" AND SLIDE UNDERNEATH THE
SADDLE CLAMP. IF NECESSARY, ADD A-A-59163 CLASS 1, TYPE I
(P/N: BLACK 620 .5) TAPE TO THE CABLE ASSEMBLY TO ENSURE THE
SADDLE CLAMP HOLDS THE CABLE ASSEMBLY SECURELY. TIGHTEN
SADDLE CLAMP SCREWS AS INDICATED.
TRIM THE OTHER END OF THE 521100XX03S EXPANDABLE SLEEVING
SO THAT IT EXTENDS PAST THE A10099 BAND BUT WILL NOT EXTEND
BEYOND THE ATUM-XX/X-0 HEATSHRINK TO BE APPLIED IN STEP P.
CENTER ATUM-XX/X-0 HEATSHRINK OVER THE SHIELD SUPPORT RING
AND APPLY HEAT TO SECURE IT TO THE CABLE ASSEMBLY.
SLIDE THE LABEL (TO BE PROVIDED BY INSTALLER) INTO THE AREA
BETWEEN THE BACKSHELL AND THE SHIELD SUPPORT RING AND
SHRINK INTO PLACE.
8
FOR BAND-IT IDEX INC. OPERATION INSTRUCTIONS, DOC # P08787,
REFER TO:
http://www.band-it-idex.com/en/Tools%20&%20Resources/Tool_Instructions/P08787.pdf
9.
FILL ALL UNWIRED CONNECTOR CONTACTS WITH APPROPRIATE SIZE
M27488 SEALING PLUGS.
16. ALL SOLDERING TO BE PER IPC-J-STD-001 CLASS 3.
17
TERMINATE WIRES AT AVAILABLE GROUND MODULE LOCATIONS IN NOSE
SECTION.
18
INSTALL CIRCUIT BREAKERS INTO AVAILABLE POSITIONS IN THE
OVERHEAD CIRCUIT BREAKER PANEL.
19
MARK CIRCUIT BREAKER PROVISION AS APPLICABLE AT INSTALLATION.
20 MARK PILOT COLLECTIVE HEAD LIT PANEL AS APPLICABLE AT
INSTALLATION.
21 INSTALLER RESPONSIBLE FOR SUPPLYING MODIFIED LIT PANEL
ASSEMBLY AND COVER. MS25089-1G SWITCH TO BE INSTALLED IN "FLOAT
KIT" SWITCH PROVISION.
22 MARK PILOT AND COPILOT CYCLIC STICK GRIPS AS APPLICABLE AT
INSTALLATION.
23
CUT TO LENGTH, AS NEEDED.
24 IF REQUIRED, TERMINAL BLOCKS MAY BE INSTALLED IN AN ALTERNATE
LOCATION TO ACCOMMODATE EXISTING EQUIPMENT.
25
AFTER DRILLING, DEBURR HOLES AND BRUSH ALODINE BARE ALUMINUM
PER MIL-DTL-5541.
26 MARK INSTRUMENT PANEL AND SWITCH GUARD AS APPLICABLE AT
INSTALLATION.
FIGURE 4 (SHEET 1 OF 5). REFERENCE PYLON HARDPOINT SCHEMATIC AND WIRING
AERONAUTICAL ACCESSORIES
September 12, 2012
Page 32 of 38
BHT 407
INSTRUCTIONS FOR CONTINUED AIRWORTHINESS
PYLON HARDPOINT KIT
AA-10120
Revision A
22J6
PILOT COLLECTIVE (REF)
21J2
21J4
PILOT CYCLIC (REF)
21A3P1
21A4P1
STOW CONNECTORS

4TB1

21A1P1
21A2P1
21A2P2
21A2P3
24TB1
24WT1
24WT2
24WT3


21S1
21S2
COPILOT CYCLIC (REF)

TO OVERHEAD CIRCUIT
BREAKER PANEL
21J3
21CB1
21CB2
21CB4
21CB5
34CB2

22J7
VIEW

(WIRE ROUTING AND
COMPONENT LOCATIONS)
ROUTE WIRE BUNDLE ALONG
OUTBOARD LH SIDE OF BROOM CLOSET

TO OVERHEAD CIRCUIT
BREAKER PANEL
SEE DETAIL

21A1P1
STOW CONNECTOR BEHIND
INSTRUMENT PANEL
STOW 2 FT MIN LENGTH OF CABLE
TERMINAL BLOCKS (REF)
21A2P1
21A2P2
21A2P3
STOW CONNECTORS
STOW 3 FT MIN LENGTHS OF CABLE




PILOT COLLECTIVE SWITCH (REF)
PILOT/COPILOT CYCLIC SWITCHES (REF)
21A3P1
21A4P1
STOW CONNECTORS
STOW 2 FT MIN LENGTHS OF CABLE
407-854-001 PYLON INSTALLATION KIT L/H (REF)
21J3
21J4
(OPP)
21J2
(OPP)
22J7
22J6
(OPP)
WIRE ROUTING AND COMPONENT LOCATIONS
FIGURE 4 (SHEET 2 OF 5). REFERENCE PYLON HARDPOINT SCHEMATIC AND WIRING
AERONAUTICAL ACCESSORIES
September 12, 2012
Page 33 of 38
BHT 407
INSTRUCTIONS FOR CONTINUED AIRWORTHINESS
PYLON HARDPOINT KIT
AA-10120
Revision A
21J4
10 11 14
D38999/20WA98SN CONNECTOR (REF)
319H064XO09 BACKSHELL (REF)
SEE TABLE II FOR ADDITIONAL COMPONENTS
407-853-109/(-110 OPP) DOUBLER ASSY (REF)
21J3
10 11 14
D38999/20WA98SN CONNECTOR (REF)
319H064XO09 BACKSHELL (REF)
SEE TABLE II FOR ADDITIONAL COMPONENTS
D38999/22JW DUMMY RECEPTACLE
NAS620-6L WASHER (4)
NAS1801-06-8 SCREW (4)
D38999/33W25R DUST CAP (FAR SIDE)
M85049/95-10A-A RETAINER
NAS620-4L WASHER (4)
NAS1801-04-7 SCREW (4)
10 11 14 22J7
T3W-1725-92SN CONNECTOR (REF)
319H064XO25 BACKSHELL (REF)
SEE TABLE II FOR ADDITIONAL COMPONENTS
M85049/95-10A-A RETAINER
NAS620-4L WASHER (4)
NAS1801-04-7 SCREW (4)
21J2
D38999/20WJ4SN CONNECTOR (REF)
319H064XO25 BACKSHELL (REF)
SEE TABLE II FOR ADDITIONAL COMPONENTS
407-853-121 PYLON FITTING (REF)
22J6
T3W-1725-92SN CONNECTOR (REF)
319H064XO25 BACKSHELL (REF)
SEE TABLE II FOR ADDITIONAL COMPONENTS
407-853-122 PYLON FITTING (REF)
RHS
407-853-110 DOUBLER ASSY (REF)
DETAIL
FWD
M85049/95-25A-A RETAINER
NAS620-6L WASHER (4)
NAS1801-06-8 SCREW (4)
DETAIL

TABLE II - CONNECTOR COMPONENTS, CLOCKING, AND ANGLES
(FUSELAGE DISCONNECT LH)
REFERENCE
DESIGNATOR
LHS
M85049/95-25A-A RETAINER
319 SERIES BACKSHELL (REF)

(FUSELAGE DISCONNECT RH)
FWD
BACKSHELL ARM (REF)
(PART OF 319 SERIES BACKSHELL)
CONNECTOR
BACKSHELL
CLOCKING -
SHIELD SUPPORT
RING
EXPANDABLE
SLEEVING
INSULATED
TUBING
BAND
DETAIL

SWING ARM ANGLE DETAIL

21A1P1
MS27473T24B4S
319H064XO25
M85049/93-08
5211001303S
ATUM-24/6-0
A10099
D
-90° POSITION
21A2P1
MS27473T22B55S
319F064XO22
M85049/93-08
5211001303S
ATUM-24/6-0
A10099
D
-90° POSITION
21A2P2
MS27473T24B61S
319F064XO24
M85049/93-10
5211001903S
ATUM-24/6-0
A10099
D
-90° POSITION
21A2P3
MS27473T22B55S
319F064XO22
M85049/93-08
5211001303S
ATUM-24/6-0
A10099
D
-90° POSITION
ATUM-16/4-0
A10099
A
STRAIGHT POSITION
ATUM-16/4-0
A10099
A
STRAIGHT POSITION
-45° POSITION
21A3P1
MS3476W10-6S
319A064XO10
M85049/93-04
5211001303S
21A4P1
MS3476W14-5S
319A064XO14
M85049/93-06
5211001303S
P/N
TORQUE
(IN-LBS)
D38999/20WJ4SN
319H064XO25
A10099
A
319A064XO10
35
21J3
D38999/20WA98SN
319H064XO09
M85049/93-06
5211001303S
ATUM-16/4-0
A10099
D
319A064XO14
319H064XO09
40
35
21J4
D38999/20WA98SN
319H064XO09
M85049/93-06
5211001303S
ATUM-16/4-0
A10099
A
-90° POSITION
22J6
T3W-1725-92SN
319H064XO25
M85049/93-08
5211001903S
ATUM-24/6-0
A10099
A
-90° POSITION
22J7
T3W-1725-92SN
319H064XO25
M85049/93-08
5211001903S
ATUM-24/6-0
A10099
D
-90° POSITION
319F064XO22
80
319F064XO24
80
319H064XO25
80
21J2
A-A-59163 CLASS 1, TYPE I (P/N: BLACK 620 .5) TAPE
6.0 ± .5
SADDLE SCREW (REF)
2 PLCS
TIGHTEN UNTIL THREAD PROTRUDES .0625 TO .250
WITNESS MARK
LOCATION (REF)
5490 TEFLON TAPE
M85049/93-10
5211001903S
ATUM-24/6-0
-90° POSITION
.10
(MAX DISTANCE FROM
EDGE OF A10099 BAND
TO BRAIDSOCK)
SCREW HEAD (REF)
-90° POSITION
M85049/93 SPLIT SHIELD
SUPPORT RING (REF)
8 A10099 BAND (REF)
M23053/5-104-0
HEATSHRINK (REF)
CABLE ASSY
(REF)
ATUM INSULATED TUBING (REF)
SCREW HEAD (REF)
BRAIDSOCK (REF)
SCREW HEAD (REF)
521100 EXPANDABLE
SLEEVING (REF)
SHIELD TERMINATION
BRAIDED LEAD (REF)
1.0
TYP
-45° POSITION
STRAIGHT POSITION
7 STEP N
LABEL 12
HATCH PATTERN LEGEND
FOR CONNECTORS:
BRAIDSOCK
(INTEGRAL WITH BACKSHELL)
WITNESS MARK
LOCATION (REF)

521100 EXPANDABLE
SLEEVING (REF)
BACKSHELL ARM SCREW (REF)
2 PLCS
TIGHTEN UNTIL SNUG
521100
EXPANDABLE SLEEVING
LABEL
90°
B
ATUM HEATSHRINK (REF)
M23053/5-104-0
HEATSHRINK
1.00
MIN
3.0 MAX
7
TYPICAL EMI CONNECTOR CABLE

BACKSHELL SWING ARM ANGLES
(REF: TABLE II)
180°
STRAIN RELIEF CLAMP (REF)
(PART OF 319 SERIES BACKSHELL)
ATUM INSULATED TUBING
DETAIL
C
1.5

DETAIL

(VIEW LOOKING AT CROSS SECTION OF SHIELD
TERMINATIONS NEAR SHIELD SUPPORT RING)
(VIEW ENLARGED 2X)
45°
D
SCREW HEAD
(REF)
A
DETAIL

CONNECTOR MAIN POLARIZATION
KEYWAY CLOCKING ORIENTATION
5490 TEFLON TAPE
FIGURE 4 (SHEET 3 OF 5). REFERENCE PYLON HARDPOINT SCHEMATIC AND WIRING
AERONAUTICAL ACCESSORIES
September 12, 2012
Page 34 of 38
BHT 407
INSTRUCTIONS FOR CONTINUED AIRWORTHINESS
PYLON HARDPOINT KIT
AA-10120
Revision A
21A2P3
MS27473T24B4S CONNECTOR
319H064XO24 BACKSHELL
M85049/93-14 SUPPORT RING
A185A20
A196A20
21A3P1
MS3476W10-6S CONNECTOR
319A064XO10 BACKSHELL
M85049/93-04 SHIELD SUPPORT RING
22J6
21J2
A185A20
A192A20
B
A
A196A20
A192A20
A191A20
LOC: STOW IN BROOM
CLOSET AREA OF CABIN
21A1P1
FF
M
U
T
ORN
BLU A149A20
WHT
A195A16
21CB1
Z
Y
JJ
AA
L
28VDC BUS
7270-1-25 CIRCUIT BREAKER
320619 RING TERMINAL (2) MS24509-A15 CIRCUIT BREAKER
A137B20
A137C20
A137D20
C
J
H
R
B
Q
D
Z
S
R
W
GG
Y
X
T
A
B
K
G
M
U
S
KK
P
N
LL
HH
V
W
X
EE
BB
CC
DD
SH 4
A104B20
B
ZN 7A
A184A20
A183A20N
A197A20N
A194A16N
21A4P1
WHT
A193A16 BLU
C
B
D38999/20WJ4SN CONNECTOR
319H064XO25 BACKSHELL
M85049/93-10 SHIELD SUPPORT RING
T3W-1725-92SN CONNECTOR
319H064XO25 BACKSHELL
M85049/93-08 SHIELD
SUPPORT RING
A
Z
A
CC
AA
8
78
79
80
81
87
88
89
9
6
J113A20N
J106A20
101
7
96
A160A22N
A150A22N
A159A22N
F SH 4 ZN 3A
G SH 5 ZN 5D
LOC: FUSLG DISC RH
A197A20N
A183A20N
A184A20
LOC: STOW IN BROOM
CLOSET AREA OF CABIN
A129A20
4TB2
LA
24TB1
A129B20
A129D20
LH
A129E20
LK
A129F20
LC
A129C20
LOC: AFT FUSLG
STA 155.00
LD
17
M81824/1-2 SPLICE
M81714/60-20-1 MODULE
LOC: NOSE
24TB1
A108B20
K SH 4 ZN 3B
(17)
LOC: STOW BEHIND INSTRUMENT PANEL
1ST DETENT
M81824/1-2 SPLICE
8TB3
KG
(1)
2ND DETENT
(2)
H
J
A208A20
A137C20
E SH 4 ZN 6D
A190C20
D
KF
4TB1
MF
MJ
MM
LOC: PILOT
SEAT PAN
STA 155.00
A206A20
KB
KG
KD
KE
KC
M81714/63-20F MODULE
M81714/60-20-1 MODULE
LOC: AFT FUSLG
STA 155.00
SH 4 ZN 5A J
SH 4 ZN 7D A
24WT3
B
D
LOC: AFT FUSLG STA 155.00
L71A22
A210A22
A131A22
A209A22
+
X1
A1
A2
A3
B1
B2
B3
LOC: NOSE
STA 28.00
RHEOSTAT
ON
M81714/63-20F MODULE
M81824/1-1 SPLICE
1ST DETENT
(1)
A207A20
A137B20
2ND DETENT
(2)
A190A20
A190B20
A344A22
M81824/1-2 SPLICE
(17)
D SH 4 ZN 6D
LOC: PLT CYCLIC
SH 4 ZN 2B J
8R7
L71A22
REF: BHT-407-MM-12, FIGURE 98-23
LOC: NOSE
STA 28.00
B SH 4 ZN 4D
M81824/1-1 SPLICE
MS25089-1G SWITCH
T3W-1725-92SN CONNECTOR
319H064XO25 BACKSHELL
M85049/93-08 SUPPORT RING
OFF
2
1
A108B20
P2-110311 SWITCH
8K4
8XK4
CLOCK LIGHTING RELAY (REF)
X2
REF:
BHT-407-MM-12
FIG. 98-23
A104C20
A130A20
SH 4 ZN 6B K
GG
HH
M
L
DD
22J7
62
96
101
7
78
79
80
81
87
88
89
8
6
9
LOC: FUSLG DISC LH
A344C22
A122A22N
A121A22N
A124A22N
A114A22
A115A22
A116A22
A117A22
A118A22
A119A22
A120A22
A123A22
J111A20
K
J
M
L
J
A
D
F
H
G
E
C
MS27473T24B61S CONNECTOR
319F064XO24 BACKSHELL
M85049/93-10 SHIELD SUPPORT RING
G
E
H
C
J
H
X
B
W
D
Y
S
R
W
GG
Y
X
T
NN
JJ
I
G
AA
U
S
KK
P
N
T
CC
A
Z
A
B
V
K
L
M
N
P
M
A205A20N
A204A20N
V
E
LOC: STOW IN HATBIN
24WT2
A122A22N
A121A22N
A124A22N
A125A20N
D
C
F
Z
A175A20
A174A20
A173A20
A136A20
A135A20
A172A20
A171A20
A170A20
A169A20
A168A20
A167A20
A138A20
A166A20
A165A20
A164A20
A180A20
A179A20
A148A20
A178A20
A147A20
A177A20
A176A20
A146A20
A145A20
A144A20
A143A20
A113A20
A182A20
A181A20
A112A20
A162A20
A161A20
A163A20
A344A22
A129B20
A129D20
A129E20
A129F20
A129C20
A108J20
A108H20
A108G20
A108E20
A108C20
A137D20
LOC: COPLT CYCLIC
LOC: NOSE
STA 25.00
A104B20
SS
KJ
KH
2303J3
M81714/60-20-1 MODULE
A198A20N
A188A20N
A187A20N
A186A20N
A200A20N
A199A20N
A184A20
LOC: STOW IN HATBIN
LOC: NOSE STA 23.00
LF
P2-110311 SWITCH
Y
D
E
F
C
F
V
X
21A2P2
A180A20
A179A20
A148A20
A178A20
A147A20
A177A20
A176A20
A146A20
A145A20
A144A20
A143A20
A113A20
A182A20
A181A20
A112A20
A162A20
A161A20
WTXX
X
X
X
X
V
A151A22
A152A22
A153A22
A154A22
A155A22
A156A22
A157A22
A158A22
A189A20N
LOC: AFT FUSLG
STA 155.00
A175A20
A174A20
A173A20
A136A20
A135A20
A172A20
A171A20
A170A20
A169A20
A168A20
A167A20
A138A20
A166A20
A165A20
A164A20
A175A20
A174A20
A173A20
A136A20
A135A20
A172A20
A171A20
A170A20
A169A20
A168A20
A167A20
A138A20
A166A20
A165A20
A164A20
A180A20
A179A20
A148A20
A178A20
A147A20
A177A20
A176A20
A146A20
A145A20
A144A20
A143A20
A113A20
A182A20
A181A20
A112A20
A162A20
A161A20
A129A16
A142A20N
A141A20N
A140A20N
A139A20N
A108B16
A132A22
A131A22
A130A20
MS27473T22B55S CONNECTOR
319F064XO22 BACKSHELL
M85049/93-08 SHIELD SUPPORT RING
M81714/63-20F MODULE
24WT1
A
M
L
K
J
F
G
H
E
D
C
B
LOC: FUSLG DISC RH
36160 RING TERMINAL
D SH 4 ZN 5B
E SH 4 ZN 5B
M81824/1-2 SPLICE
F
G
E
H
15
LOC: CB PANEL
320619 RING TERMINAL (1)
MS3476W14-5S CONNECTOR
25
28VDC BUS
319A064XO14 BACKSHELL
LOC: CB PANEL
M85049/93-06 SHIELD SUPPORT RING
A137A20
WHT
A193A16 BLU
34CB2
21CB2
25
28VDC BUS
LOC: CB PANEL
A133B16
A133A16
A134B16
A134A16
SEE ZONE 2B A
D
C
F
BB
S
T
Y
X
W
DD
FF
LL
ORN
A149A20 BLU
WHT
A191A20
7270-1-25 CIRCUIT BREAKER
320619 RING TERMINAL (2)
U
K
A185A20
A196A20
21A2P1
A201A20N
A202A20N
A203A20N
A128A20N
A127A20N
A126A20N
J
H
G
HH
GG
D
A125A20N
A114A22
A115A22
A116A22
A117A22
A118A22
A119A22
A120A22
A123A22
Z
V
M
K
MS27473T22B55S CONNECTOR
319F064XO22 BACKSHELL
M85049/93-08 SHIELD SUPPORT RING
LOC: AFT FUSLG STA 155.00
C SH 5 ZN 5C
J112A20N
SH 4 ZN 3D F
J113A20N
24WT3
R
P
N
G
V
LOC: STOW IN HATBIN
H
F
ON
LOC: PILOT
COLLECTIVE
-001 PYLON HARDPOINT WIRING KIT SCHEMATIC
FIGURE 4 (SHEET 4 OF 5). REFERENCE PYLON HARDPOINT SCHEMATIC AND WIRING
AERONAUTICAL ACCESSORIES
September 12, 2012
Page 35 of 38
BHT 407
INSTRUCTIONS FOR CONTINUED AIRWORTHINESS
PYLON HARDPOINT KIT
AA-10120
Revision A
WTXX
WTB150
21J4
J101A20
21S2
SH 4 ZN 3D G
C
WHT
J104A20 BLU
A
B
D38999/20WA98SN CONNECTOR
319H064XO09 BACKSHELL
M85049/93-06 SHIELD SUPPORT RING
206-001-818-XXX SWITCHBOX ASSY (REF)
J103A20N
1
2
3
4
5
6
MS24524-23 SWITCH
26 MS25224-1 GUARD
J106A20
WHT
J104A20 BLU
J105A20N
LOC: FUSLG DISC RH
J102A20
LDG
LTS
LOC: INSTR PNL
7.5
J102B20
F
W
D
28VDC BUS
OFF
LOC: CB PANEL
36154 RING TERMINAL
SHIELD GRND WIRE (REF)
21S1
21J3
SH 4 ZN 3A C
J111A20
C
WHT
J108A20 BLU
A
B
D38999/20WA98SN CONNECTOR
319H064XO09 BACKSHELL
M85049/93-06 SHIELD SUPPORT RING


DISENG
J107A20N
1
2
MS24524-23 SWITCH
26 MS25224-1 GUARD
407-375-038-XXX PANEL LIT-PILOTS COLLECTIVE STICK (REF)
206-001-815-XXX COVER - SWITCH BOX, COLLECTIVE STICK (REF) 21
BOTH
7270-1-7.5 CIRCUIT BREAKER
36152 RING TERMINAL (3)
21CB5
36154 RING TERMINAL
SHIELD GRND WIRE (REF)
START
WHT
J108A20 BLU
3
4
5
6
J109A20N
20
WTB150
J101B20
LOC: FUSLG DISC LH
WTXX
VIEW
LOC: INSTR PNL
36154 RING TERMINAL
SHIELD GRND WIRE (REF)
7.5
J101A20

(VIEW OF PILOT COLLECTIVE
SWITCH BOX)
7270-1-7.5 CIRCUIT BREAKER
36152 RING TERMINAL (3)
28VDC BUS
LOC: CB PANEL
REMOVE:
100-050B562 PLUG (REF)
INSTALL:
MS25089-1G SWITCH
36154 RING TERMINAL
SHIELD GRND WIRE (REF)
-001 PYLON HARDPOINT WIRING KIT SCHEMATIC (CONT'D)
100-050B500 PLUG (REF)
MS35207-265 SCREW
2 PLCS
VIEW
M81714/63-20F MODULE (REF)
3 PLCS

(PILOT COLLECTIVE SWITCH
INSTALLATION)
407-030-512-XXX PANEL ASSEMBLY (REF)
25 MATCH DRILL STRUCTURE TO FLANGE
Ø.199
.193 2 PLCS
NAS1149D0332J WASHER
2 PLCS
EXISTING PILOT GRIP (REF)
REPLACE COPILOT GRIP WITH
106-25002-00 GRIP ASSEMBLY
MS21042L3 NUT
2 PLCS
M81714/60-20-01 MODULE (REF)
2 PLCS
MS35207-265 SCREW
2 PLCS
24WT1 24WT2 AND 24WT3
407-075-012-XXX PANEL ASSEMBLY - OVERHEAD (REF)
P2-110311 SWITCH
M81714/67-05 RAIL
7.5
7.5
25
25
15
407-030-512-XXX PANEL ASSEMBLY (REF)
22
7270-1-15 CIRCUIT BREAKER (REF)
18 19 7270-1-7.5 CIRCUIT BREAKER (REF)
2 PLCS
25 MATCH DRILL STRUCTURE TO RAIL
Ø.199
.193 2 PLCS
DETAIL

18 19
7270-1-25 CIRCUIT BREAKER (REF) 18 19
2 PLCS
(LOOKING UP AT CIRCUIT
BREAKER PANEL)
NAS1149D0332J WASHER
2 PLCS
MS21042L3 NUT
2 PLCS
VIEW
24
VIEW

(PILOT/COPILOT CYCLIC STICK GRIP )
24TB1 BLOCKS K AND L

(TERMINAL MODULE AND GROUND MODULE
INSTALLATION, EXPLODED VIEW)
FIGURE 4 (SHEET 5 OF 5). REFERENCE PYLON HARDPOINT SCHEMATIC AND WIRING
AERONAUTICAL ACCESSORIES
September 12, 2012
Page 36 of 38
BHT 407
INSTRUCTIONS FOR CONTINUED AIRWORTHINESS
PYLON HARDPOINT KIT
AA-10120
Revision A
APPENDIX A – ANNUAL INSPECTION RECORD
AERONAUTICAL ACCESSORIES
September 12, 2012
Page 37 of 38
BHT 407
INSTRUCTIONS FOR CONTINUED AIRWORTHINESS
PYLON HARDPOINT KIT
AA-10120
Revision A
Pylon Hardpoint Kits Annual Inspection Record
Work Order Number:
_______________________
Registration Number: _______________________
Serial Number:
_______________________
Total Time:
_______________________
Date:
_______________________
Inspect Pylon Hardpoint Kits in accordance with Section 4.1 Annual Inspection.
1.
Visually inspect the 407-232-135 Decal installed on the Pylon Fittings
for condition and legibility.
2.
Visually inspect aluminum and steel components for cracks, nicks or
scratches, dents, and indications of corrosion.
NOTE
The indications of corrosion are 1)
corrosion deposits (a white or gray powder
on aluminum or rust colored deposits on
steel), 2) pits in aluminum or steel
surfaces, 3) blisters, bulging or flaking of
protective coatings.
3.
Visually inspect attachment hardware for security and tightness.
4.
Visually inspect attachment hardware for signs of fretting or working.
5.
Visually inspect Pylon Hardpoint wiring for signs of fraying or cracking.
Signature ________________________
A & P No. _________________________
Signature ________________________
Inspector _________________________
AERONAUTICAL ACCESSORIES
September 12, 2012
Page 38 of 38