TECHNICAL BULLETIN NO.

212-76-12

BELL DATE4-27-76
DATE2-13-78 HELICOPTER COMPANY

SUBJECT: INSPECTION AND REPAIR OF MAIN BEAM CAP

EXTRUSIONS P/N 212-030-190-5 AND -7
REASON: To provide main beam repair instruc-
tions
HELICOPTERS AFFECTED: Model 212 Helicopters S/N 30501 through
30789.
Model 212 S/N 30790 and subsequent will
conform with this Bulletin prior to de-
livery.

WEIGHT CHANGE: Negligible

ACCOMPLISHMENT: PART I - INSPECTION: Recommend at next
100 hour and each 100 hour in-
spection thereafter.
PART II- REPAIR PROCEDURES: If crack is
detected, recommend repairs be
accomplished at earliest con-
venience.
DESCRIPTION:

PART I - INSPECTION
1. Gain access through cargo hook opening (hell hole). Clean
area around the fuel vent line hole with Methyl Ethyl Ketone
and remove finish from beam cap. Carefully inspect each
beam cap for hairline cracks using a bright light. Inspect
the inboard side of the left and right handmainbeams
around the fuel vent line that goes through the cap extrusion
at station 131.00, waterline 21.50 and butt line 14.00 (See
Figure 1).

2. According to field reports, the cracks originate at the first

Hi-Shear rivet hole above waterline 22.00 at station 129.00.
Cracks have been located running from this fastener hole
forward to the radius of the cap extrusion upper leg at sta-
tion 129.00, and aft and downto the fuel vent line hole at
station 131.00.

AN APPROPRIATE ENTRY SHOULD BE MADE IN THE AIRCRAFT LOG BOOK UPON ACCOMPLISHMENT
IF OWNERSHIP OF AIRCRAFT HAS CHANGED PLEASE FORWARD TO NEW OWNER
 .B. No. 212-76-12
Page 2 of 15

3. Inspect area after every 100 hours of operation. If a

crack or cracks are found, the main beam is to be repaired
in accordance with PART II. The repair kits for the main
beam can be procured from your usual Bell Helicopter Tex-
tron Spare Parts source. Orders must include which main
beam kit is required, i.e., left or right side and ship-
to address.

PART II - REPAIR
KIT P/N 212-704-103-1 AND -3 L/H
AND
KIT P/N 212-704-103-1 AND -5 R/H

1. Refer to appropriate Overhaul and Maintenance Manuals.

Drain fuel cells. Remove upholstery, seats, and sound-
proof insulation blankets from area of cabin on both sides
at station 129.00, and aft to the aft cabin wall station
166.00, on left and right hand sides. Remove cargo hook
from fitting on lower surface of lift beam, if installed.

2. Remove screws from cabin floor right and left panels P/N
205-031-257-67 and 205-031-257-68 and remove panels from
aircraft. Retain hardware and panels for reuse.
3. Disconnect fuel lines from fuel cells under floor in
accordance with Maintenance and Overhaul Manual instruc-
tions. Untie the fuel cell bag retaining lacing and
remove from lacing hooks. Remove fuel cell from air-
craft. Disconnect hydraulic servo cyclic cylinders from
the support fittings P/N 212-030-286-1 L/H and -2 R/H.
Remove support fittings. Retain fittings and bolts for
reuse.

4. Attach a lifting hoist to the main rotor mast retaining

nut. Raise hoist to relieve load on structure. Place
jacks under the two aft jack points. Raise jacks
against the fittings with sufficient pressure to prevent
downward movement, without lifting the aircraft.
 T. B. No. 212-76-12
Page 3 of 15

5. Remove Hi-Shear rivets retaining the vertical splice

angle P/N 205-030-710-7 left hand and 205-030-710-8
right hand inboard sides, at station 129.00, butt line
14.00 extending from lower main beam cap to approxi-
mately 6.5 inches above the floor level, W.L. 22.00
(See Figures 3, 4 & 5). Remove fasteners from hori-
zontal stiffeners P/N 205-030-708-73 L/H and -74 R/H
to free splice angles. Cut the collars off the Hi-
Shear rivets with a chisel and with a punch carefully
push rivets out of splice and vertical attachments.
Remove bolt, washer, and nut from splice angle at lower
end.

b. Carefully separate the vertical splice angle P/N 205-

030-710-7 and -8 from the sealant and structure with a
putty knife. Remove splice angle from aircraft and
retain.

CAUTION
Do not stand in fuel cell cavity during
repair work, because the lower panel could
be damaged and possible misalignment and
deflection of the structure could occur.
Main beam should be held in place using
padded blocks under lower cap angle at
station 129.00. Should both left and
right main beam caps require repairs,
complete one side before starting the
other.
7. Drill out all rivets retaining the outboard splice
angle P/N 212-030-034-1 L/H and P/N 205-030-240-4 R/H
to the main beam cap angle, from station 107.5 to sta-
tion 155.00. Remove the Hi-Shear rivets by cutting off
the collars using a chisel or other suitable tool, or
Hi-Loc bolts by removing collars. Carefully drill out
the rivets retaining the fuel cell lacing hangers P/N
70-022-1 and nut plates P/N NAS697A3. Retain hangers,
washers, and nut plates for reuse. Remove bolts attach-
ing collective support P/N 212-030-458-1 and 212-030-
299-1 on the inboard side of the left or right hand main
beam (cargo hook opening) located at stations 134.00.
Remove angle P/N 205-030-708-98 of bulkhead P/N 205-030-
708 at station 129.00, butt line 14.00. Retain parts
for reinstallation.
1. B. No. 212-76-12
Page 4 of 15

Using a putty knife, carefully separate the outboard

splice angles from the fuel cell and main beam protec-
tive coating. Remove sealant. Remove the splice
angles from aircraft. Carefully locate and clamp new
splice assembly P/N 212-030-490-19 L/H or 212-030-490-
16 R/H to main beam cap angle in location of previously
removed splice angle, and accurately mark fastener holes.
Mark all fastener holes through the vertical leg of the
beam cap first. Remove splice assembly and drill holes
using a drill press. Locate splice assembly on main beam
again from the drilled holes. Clamp in position and mark
all holes through the horizontal leg of the beam cap.
Remove splice assembly and drill holes using a drill
press. (See Figures 3, 4, and 5 for further details).
Clean and deburr holes.
NOTE

Since it is imperative that a close tolerance

hole be provided for each fastener use an accurate
marking tool. The marking tool can be fabricat-
ed from a transfer or center punch reworked to
exactly fit the existing fastener holes in the
original parts. Center punch each hole for
accurate drill start. However, if elongated or
oversize holes are found, use oversize Hi-Loc
bolts provided in kit. Oversize Hi-Loc bolts
are 1/64 and 1/32 inch over basic diameter.
Use reamer to make close tolerance hole. (Refer
to Figure 2 for notes and rivet codes.)

a. Place beam repair splice plate P/N 212-030-490-25 and

filler P/N 212-030-490-23 in position on the inboard
side of beam aft of station 129.00 (see Figures 3 and
4 for details). Hold splice plate firmly in place and
back drill through existing fastener holes (omit 2 holes
under support fitting P/N 212-030-286-1 L/H and -2 R/H;
see Figures 3 and 4). Use cleco or other suitable fas-
teners as drilling progresses.
10. Place the 212-030-490-21 angle in position on upper,
outboard side of cap angle (see Figures 3 and 4 for loca-
tion and details), and beam panel P/N 212-030-169 L/H
and 212-030-179 R/H. Hold firmly to panel edge. Back
drill fastener holes. (Note: Do not drill nut plate
retaining rivet holes.)
 T. B. No. 212-76-12
Page 5 of 15

11. Remove all repair parts from the airframe structure and
clean metal chips and foreign material from area. Clean,
deburr, and coat all repair parts with zinc chromate
primer as required. Prior to installation, clean all
rework area with MEK.
12. Place new splice assembly P/N 212-030-490-19 L/H and -16
R/H in position on outboard side of main beam. Install
two fasteners, see Figures 3 and 4. Place beam splice
on inboard side of beam. Install nut plates for retain-
ing floor panel on lower, outboard leg of the splice
angle, using MS20426AD3 rivets. Rivets are installed
through cap angle and splice assembly and nut plates
(See Figures 3 and 4). Place angle P/N 212-030-490-21
in position on outboard upper side of cap angle and on
top of floor panel. Retain parts with Clecos or other
suitable fasteners. Place in position using Clecos.
Fasteners on inboard splice angle can interfer with
installation of fasteners being installed through out-
board splice and lower vertical leg of main beam cap
angle. Remove the Hi-Shear rivets at this location
and install Hi-Loc bolts P/N 100-076-5-3 and collars
P/N 30-055-5. Install parts with fasteners provided
in each kit. See Figures 3, 4, and 5 for fastener types
and location. If Hi-Shear flush rivets were removed at
forward end of splice, station 107.5 install Hi-Loc
bolts P/N 100-076-5-3 and collars P/N 30-055-5. If Hi-
Loc bolts were removed install Hi-Loc bolts P/N 100-047-
5-3 and collars P/N 30-015-5. Installation of vertical
splice angle 205-030-711 will require following in
sequence to install correctly, see Figure 5 for details.

13. On completion of installing all fasteners retaining the

repair parts, replace all fasteners removed from attach-
ment angles that had been removed or loosened to assist
in repairs. Replace all nut plates and fuel cell hangers
using MS20426AD3 rivets. Coat all fasteners with a
generous coating of Pro Seal 890 in the fuel cell
cavities.
14. Install hydraulic servo cyclic cylinder support fittings
using bolts and washers previously removed. Install the
fuel cell bag, connecting and torquing all fittings and
fuel line connections. Install fuel cell bag retaining
lacing and secure.
T. B. No. 212-76-12
Page 6 of 15

15. Install cabin floor panels P/N 205-031-257-67 L/H and

205-031-257-68 R/H sides, using previously removed hard-
ware. Refuel aircraft and inspect for leakage. Install
sound proof insulation and/or upholstery, seats and seat
belts previously removed.
16. Kit P/N 212-704-103-1 consists of the following parts:

QUANTITY PART NUMBER NOMENCLATURE

4 MS20426AD3-8 Rivet
4 MS20426AD3-5 Rivet
16 MS20470AD4-5 Rivet
4 MS20470AD4-6 Rivet
2 MS20470AD4-9 Rivet
57 30-015-6 Collar
10 100-048-6-4 Pin
42 100-048-6-5 Pin
12 100-048-6-6 Pin
9 100-048-6-7 Pin
4 100-048-6-8 Pin
6 100-048-6-9 Pin
2 100-048-6-10 Pin
6 AN960-10 Washer
42 AN960-10L Washer
2 MS20470AD4-7 Rivet
2 MS20470AD4-8 Rivet
6 MS21042L3 Nut
17. Kit P/N 212-704-103-3 consists of the following parts:

QUANTITY PART NUMBER NOMENCLATURE

1 212-704-103-11 Hardware Supplement
1 212-030-490-19 Splice Assembly
1 212-030-490-21 Angle
1 212-030-490-23 Filler
1 212-030-490-25 Plate
1 212-030-490-33 Shim "A"
63 AN525-10R8 Screw
27 AN525-10R10 Screw
16 AN525-10Rll Screw
2 AN960PD416 Washer
50 MS20426AD3-5 Rivet
32 MS20426AD3-6 Rivet
6 MS20426AD3-8 Rivet
7 MS20426AD5-5 Rivet
3 MS20426AD5-6 Rivet
2 AN4-10A Bolt "A"

(Continued)
 T. B. No. 212-76-12
Page 7 of 15

QUANTITY PART NUMBER NOMENCLATURE

(Continued)
6 MS20470AD3-10 Rivet
10 MS20470AD3-9 Rivet
1 MS20615-4M5 Rivet
14 MS20615-4M7 Rivet
39 MS21069L3 Nut Plate
1 MS21086L3 Nut Plate
1 MS21073L3 Nut Plate
16 AN960PD3L Washer
8 100-076-5-5 Pin
16 30-055-5 Collar
1 MS27980-7B Stud
1 NAS1738M4-5 Rivet
24 30-015-5 Collar
31 30-015-6 Collar
8 100-076-5-3 Pin
7 100-047-6-5 Pin
2 100-047-6-6 Pin
3 100-048-6-5 Pin
11 100-048-6-6 Pin
8 100-048-6-7 Pin
8 HL64PB-6-5 Pin
5 HL64PB-6-6 Pin
2 HL64PB-6-7 Pin
14 HL220-6-5 Pin
1 HL220-6-6 Pin
15 HL93-6 Collar
15 HL87W6 Collar
18. Kit P/N 212-704-103-5 consists of the following parts:
QUANTITY PART NUMBER NOMENCLATURE
1 212-704-103-11 Hardware Supplement
1 212-030-490-16 Splice Assembly
1 212-030-490-22 Angle
1 212-030-490-23 Filler
1 212-030-490-25 Plate
1 212-030-490-33 Shim "A"
52 AN525-10R8 Screw
16 AN525-10R10 Screw
16 AN525-10Rll Screw
2 AN4-10A Bolt "A"
(Continued)
T. B. No. 212-76-12
Page 8 of 15

QUANTITY PART NUMBER NOMENCLATURE

(Continued)
2 AN960PD416 Washer
28 MS20426AD3-5 Rivet
6 MS20426AD3-8 Rivet
5 MS20426AD5-5 Rivet
3 MS20426AD5-6 Rivet
4 MS20470AD3-9 Rivet
1 MS20615-4M5 Rivet
14 MS20615-4M7 Rivet
28 MS21069L3 Nut Plate
1 MS27980-7B Stud
1 NAS1738M4-5 Rivet
30 MS20426AD3-6 Rivet
10 AN960PD3L Washer
6 MS20470AD3-10 Rivet
8 100-076-5-5 Pin
16 30-055-5 Collar
24 30-015-5 Collar
25 30-015-6 Collar
8 100-076-5-3 Pin
4 100-047-6-6 Pin
4 100-048-6-5 Pin
11 100-048-6-6 Pin
8 100-048-6-7 Pin
8 HL64PB6-5 Pin
5 HL64PB-6-6 Pin
2 HL64PB-6-7 Pin
14 HL220-6-5 Pin
1 HL220-6-6 Pin
15 HL87W6 Collar
15 HL93-6 Collar

19. Hardware supplement P/N 212-704-103-11 consists of the following:

QUANTITY PART NUMBER NOMENCLATURE

3 MS27980-7B Stud
5 MS21069L3 Nut Plate
4 MS20426AD3-10 Rivet
10 MS20426AD3-5 Rivet
2 MS20426AD3-6 Rivet
4 MS20426AD3-8 Rivet
3 MS20426AD5-4 Rivet
4 MS20426AD5-5 Rivet
3 MS20615-4M3 Rivet
3 MS20615-4M5 Rivet

(Continued)
 T. B. No. 212-76-12
Page 9 of 15
QUANTITY PART NUMBER NOMENCLATURE
(Continued)
3 MS20615-4M6 Rivet
5 MS20615-4M7 Rivet
3 MS20470AD3-7 Rivet
4 MS20470AD3-9 Rivet
3 NAS1738M4-5 Rivet
10 AN525-10R10 Screw
5 AN525-10Rll Screw
10 AN525-10R8 Screw

NOTE
If both main beam cap angles have been repaired using
parts 212-030-445-1, 212-030-445-3 and 212-030-445-5,
and kits P/N 212-704-103-1, 212-704-103-3 and 212-704-
103-5 this bulletin is not effective.
T. B. No. 212-76-12
Page 10 of 15

zx

z r
 T. B. No. 212-76-12
Page 11 of 15

AA NAS1738M-4-5RIVET L 4 MS20615 4M7 RIVET

AAR 4 100-048-6-4PIN
NAS1738M-4-6RIVET 30-015-6COLLAR

AAR-4 NAS1738M-4-7RIVET 100-048-6-5PIN

30-015-6COLLAR

MS20426AD3-5(RIVET HEAD ON FAR SIDE) 100-048-6-5PIN (HEAD ON NEAR SIDE)

MS20426AD3-5(RIVET HEAD ON FAR SIDE) 30-015-6COLLAR

MS20426AD5-4(RIVET HEAD ON NEAR SIDE) 100-048-6-6PIN (HEAD ON FAR SIDE)

MS20426AD3-8(RIVET HEAD ON FAR SIDE) 30-015-6 COLLAR
30-015-6 COLLAR

MS20426AD5-5RIVET HEAD ON NEAR SIDE) 100048-6 PIN

MS20426AD5-6(RIVET HEAD ON NEAR SIDE)

MS20470AD3-7RIVET 100-048-6-9PIN
30-015-6COLLAR

- MS20470AD3-8 RIVET
30-015-6COLLAR
N 100-047-5-3 PIN (HEAD ON NEAR SIDE)
MS20470AD3-9 RIVET 30-015-3 COLLAR

MS20470AD3-10 RIVET 100-047-5-4(RIVET HEAD ON NEAR SIDE)

30-015-6COLLAR

MS20470AD3-11 RIVET 100-0474-6-5

(RIVET HEAD ON FAR SIDE)
30-015-6COLLAR

MS20470AD4-5 RIVET 100-047-6-6(PIN HEAD ON FAR SIDE)

30-015-6COLLAR
T. B. No. 212-76-12
Page 12 of 15

NOTES:

AFTER REINSTALLAING THE 205-030-710-7AND -8 FITTING,

DRILL A .1895 HOLE THRU. COORDINATING THE HOLE
.1915
IN THE EXISTING STRUCTURE AND THE 205-030-710-7AND -8.
INSTALL ATTACHMENT SHOWNIN 212-704-103-1KIT.

USE EXISTING HOLESINSTALL THE 205-030-710-7 AND 8

FITTING WITH ATTACHMENT SHOWNIN 212-704-103-1KIT

1895 HOLE LOCATE FROM EXISTING STRUCTURE

.1915

DRILL HOLES FROM EXISTING RIVET HOLES IN STRUCTURE

LOCATE AND BACK DRILL FROM EXISTING STRUCTURE

.2026
A .2036 HOLE THRU NEW STRUCTURE. IF THIS HOLE
CLEANS UP EXISTING HOLE USE THE HL 64
ATTACHMENT. IF THIS HOLE DOESNOT CLEAN UP,
DRILL A .2182 HOLE AND INSTALL A HL 220 ATTACHMENT.
.2192
.1895 HOLE LOCATE FROM EXISTING STRUCTURE
.1915

THESE ATTACHMENTS ARE FURNISHED TO PROVIDE PROPER

CLOSETOLERANCE IF HOLES ARE ELONGATED.
REFER TO NOTE 5.

1895 HOLE IN 212-030-490-19AND 16 SPUCE ASSY ONLY

.1915
INSTALL THESE TWO ATTACHMENTS FLUSH IN
EXISTING BEAM CAP BEFORE INSTALLING
212-030-490-25PLATE. DO NOT DRILL PLATE.
TO ALLOW INSTALLATION OF SPLICE FASTENERS, REMOVE
THESE EXISTING 8 FASTENERS. IF YOU REMOVE A HI SHEAR
RIVET & COLLAR, ENLARGE HOLE TO .1655 (DO NOT DISTURB
THE CSK) & INSTALL A 100-076-5-5PIN & 30055-5 COLLAR.
IF YOU REMOVE A HI LOCK PIN & COLLAR, USING EXISTING
HOLE & CSK WITH EXISTING PIN INSTALL A 30-015-5 COLLAR
BE SURE TO INSTALL THE 8 FASTENERS IN SPLICE AREA
THRU VERTICAL LEG OF CAP BEFORE INSTALLING THE
FASTENERS MENTIONED ABOVE.

REMOVE THESE EXISTING 8 FASTENERS. IF YOU REMOVE A

Hi SHEAR & COLLAR ENLARGE HOLE TO :1655 (DO NOT DISTURB
THE CSK) & INSTALL A 100-076-5-3PIN & 30-055-5 COLLAR IF
YOU REMOVE A HI LOCK PIN & COLLAR USING EXISTING HOLE
& CSK WITH EXISTING PIN INSTALL A 30-015-5 COLLAR
11. USE DRILL SIZE FOR RIVETS AS SHOWN BELOW:

NAS1738M-4 NO. 27 DRILL .146 HOLE

142
MS20426AD3 NO. 40 DRILL 097 HOLE
.102
MS20426AD4 NO. 20 DRILL .161 HOLE
MS206154M NO. 30 DRILL .128 HOLE
.133

Figure2. 212 Main (Street 2 of 2)

 W.L
22.00

B.L. 14.00_
 T. B. No. 212-76-12
Page 13 of 15

2 HOLES DONOT DRILL

BUCK FLUSHIN BEANCAP BEFORE

REMOVE EXISTING SCREW PLACES

USE EXISTING LOCATIONSUSE

EXISTING LOCATION
ANDREPLACE AS SHOWN MOLE
REMOVE EXISTING SCREWSAND

SCREW
AN525.10 200 ANS525.10
REMOVE EXISTING SCREW MS21069L3 NUTPLATE 16 REQD
USE EXISTING NUTPLATE REMOVE EXISTING SCREWSAND
FLUSH IN BEAM CAP ONLY
USE EXISTING LOCATION
REMOVE EXISTING SCREWS REMOVE AND REPLACE

3 Figure
 MS20470AO10-3 RIVET. 2 RED
212-704 AN943L WASHER. 2 REQD

212-010-490-22
ANGLE
212-030-490-25 PLATE

USE EXISTING LOCATIONS

05-030-710(REF) HOLE (12 REQD)

REMOVE EXSTING SCREWS AND
NUTPLATES - SCREW.
ANS25-10R10 REPLACE
12 AS SHOWN
REQD
MS2 NUTPLATE. 12 REQD
 T. B. No. 212-76-12
Page 14 of 15

NOT0

SECTION
B-B
ANS525-10RI0 SCREW
REMOVE EXISTING SCREW
USE EXISTING NUTPLATE 205-032-726(REF)

, REMOVE EXISTING SCREWS FLUSH IN BEAN

STA USE EXISTING NUTPLATES REMOVE EXISTING RIVET AND STUD

ANS2S. 0RS SCREW. 39 RE0O Sl2710.T7STUOANO A I LNi , -

t1~~~ REMOVE EXISTING SCREWS

USE EXISTING NUTPLATES
USE EXISTING. LOCATIONS
REMOVE EXISTING RIVETS
/

USE EXISTING LOCATIONS

-249 HOLE.2ROO

USE EXISTING DOME NUT AND CAP NUT SEE VIEW D- D

FLUSH IN BEAM CAP STA
130.00
Figure4. 212
 T. B. No. 212-76-12
Page 15 of 15
INSTALL THESE VERTICAL INSTALL THESE VERTICAL
ATTACHMENTS BELOW ATTACHMENTS BELOW
(8 PLACES) - FIRST * (6 PLACES. EXCLUDING
6 NUTPLATE) - SECOND *
BL
REMOVE EXISTING RIVETS 14.00
AND REPLACE AS SHOW

REMOVE EXISTING RIVETS AN960PD10L UNDER NUT

,f- . . .- INSTALL
CAP
NUT
LAST

REMOVE EXISTING RIVETS

& WASHERS
AND REPLACE AS SHOWN
100-048-6-6PIN 18 PLACES
AN960PD10 UNDER HEAD
AN960PD1 L UNDER NUT
PIN HEAD OUT 'BD

212-030-261(REF)
100-048-6-7PIN
AN960PD10 UNDER HEAD
AN960PD10LUNDER NUT 212-030-490
MS21042L3 NUT
PIN HEAD OUT'BD SHIM

10 PLACES

STA
REMOVE AND REPLACE 130.00
USE EXISTING HARDWARE

* ASTERISK DENOTES IMPORTANT

LOOKING INBD LH SHOWN INSTALLATION SEQUENCETHAT
RH OPP FOR 212 MUST BE FOLLOWED

NOTE:
REFER TO FIGURE 2 FOR ALL
FLAG NOTES AND RIVET CODES.

Figure 5. 212 MainBeam Repair - Left Hand Side Looking Inboard